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Operation and Safety Manual

1. pa vx RU 4 l H Figure 3 12 DVL Series Decal Installation Chart See Table 3 5 for Specification 3 28 J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Table 3 5 DVL Series Decal Installation Chart See Figure 3 12 ANSI ANSI ANSI ANSI ANSI CSA us CE CE CE CE CE CE LAT BRZ J PN CHI FRE AUS GER FRE SPA ITA DUT SWE 1 1700584 1700584 1700584 1700584 1700584 1700584 17
2. 6 2 J LG Lift 3121135 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other harmful chemicals known to the State of California WASH HANDS AFTER HANDLING Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa
3. POINT amp GO The J oystick can be moved in any direction off center Drive Power is applied proportionally the fur ther the J oystick is moved off center 3 16 J LG Lift 2 4 PRESS and RELEASE the Drive Function Button The flashing LED indicates the function is active The function remains active 3 to 4 seconds While the Drive Function is active PRESS and HOLD the enable button on top the joy stick Move the joystick in the desired direction of travel TO STOP the machine return the joystick back to center 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Adjusting Maximum Drive Speed Control NOTE When the platform is elevated the maximum drive speed is cut back to 1 4th the speed when the plat form is fully lowered The Ground Control Module LCD screen will display a turtle when in this mode see Machine LCD Status Display in this section of the manual Maximum Drive Speed Indicator lt amp Indicates current Maximum Drive Speed Setting Slow to Fast 1 Each Press of this button will reduce the Maximum Drive Speed allowed LESS LEDs Lit 2 Each Press of this button will increase the Maximum Drive Speed allowed MORE LEDs Lit Elevating Lowering the Platform A WARNING IF THE TILT ALARM HAS BEEN ACTIVATED THE PLATFORM WILL NOT ELEVATE
4. 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Figure 3 2 Ground Control Station Machine Rear View 1 Machine Status LCD Display 5 Platform Up 9 Hydraulic Oil Reservoir 2 Main Power Selector Switch 6 Platform Down 10 Manual Descent Control Valve 3 Emergency Stop 7 Battery Charging Status Indicators 11 Master Power Disconnect Switch UL EE Only 4 Brake Release 8 Charger A C Input Receptacle 3121135 J LG Lift 3 5 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Machine Status LCD Display E nun h X 00000 0 At power up and during operation the LCD display on the Ground Control Module displays the current machine operating status The following illustration explains the symbol indications N mmm p X 00000 0 400 4 000000 400 LCD Display Symbols Battery Charge Indicator BCI Function Display or Function Disabled
5. 3 Caster Axles 2 Grease Fittings MPG Pressure Gun v 4 SwivelRaceways 2 FrontCasters MPG Pressure Gun 2 PerMast 5 Mast Chains Section CL BrushorSpray Inspect lubricate if dry orrusting Key to Lubricants MPG Multipurpose Grease HO Hydraulic Oil ISO Vg grade 32 46 GEAR OIL Good Quality Worm Gear Oil SAE 90 AGMA 5 EP Compounded CL Chain Lube Usea good quality chain lubricant Notes a Becertainto lubricate like items on each side ofthe machine b Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions suchas a high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly c Priorto checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failureto do so will resultin incorrectoil level reading on the hydraulic reservoir 5 4 J LG Lift 3121135 SECTION 6 INSPECTION AND REPAIR LOG SECTION 6 INSPECTION AND REPAIR LOG Machine Serial Number Table 6 1 Inspection and Repair Log Date Comments 3121135 J LG Lift 6 1 SECTION 6 INSPECTION AND REPAIR LOG Table 6 1 Inspection and Repair Log Date Comments
6. 3 23 Machine Tie DOWN a o s aah Gesu ed ed Gael edged 3 24 Crane Hook Accessory DVL 3 24 FOrk Lift Tick Transports 2 ry su RE dea eR Eda de E Pd Er goes ds 3 24 3 16 RUG CARRIER ACCESSORY DVSP 3 25 General as dn 3 25 ii J LG Lift 3121135 TABLE OF CONTENTS 3 25 Hanging a Rug using the Rug Carrier Accessory Arms 3 25 Removing a Rug using Rug Carrier Accessory 5 3 26 3 17 STOCK PICKER HANGER 55 3 27 PresStart Inspection cesse em ER Re ele ew eg ted Be ee td a 3 27 Loading and Transporting an Item using the 0 3 27 SECTION 4 EMERGENCY PROCEDURES 4 1 GENERAL INFORMATION i zik oa dete usaq Ree UR dda eq Dares DECR EU E eee 4 1 4 2 EMERGENCY OPERATION yiii sade eid dat tc PER tec en RE ede ed OR e MIR deca 4 1 Operator Unable to Control Machine 4 1 Platform Caught Overhead 4 1 4 3 INCIDENT NOTIFICATION ins zs ente Rer eee PER P
7. 3 8 3 5 DVL Series Decal Installation 3 29 3 6 DVSP Decal Installation 3 31 5 1 Lubrication Specifications 2 m mm 5 3 5 2 Lubrication Intervals for Various 5 4 6 1 Inspection and 0 6 1 iv J LG Lift 3121135 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A mainte nance program using the information provided in this manual and the Service and Maintenance Manual must also be established by a qualified person and must be fol lowed to ensure that the machine is safe to operate The owner user operator lessor lessee of the machine should not accept operating responsibility until this man ual has been read training is accomplished and opera tion of the machine has been completed under the supervision of an experienced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact J LG Industries Inc f LG A WARNING FAILURE TO COMPLY WITH
8. 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 20DVL 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 1705017 12 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 13 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 14 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 15 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 16 1703786 1704032 1704024 1705099 1704081 1704039 1705099 1705099 1705099 1705099 1705099 1705099 1705099 17 1702153 18 1703684 1703685 1703686 1703723 1703751 1703719 1703684 1703718 1703719 1703685 1703721 1703722 1705100 19 1705046 1705104 1705105 1705118 1705106 1705107 1705049 1705113 1705114 1705112 1705115 1705116 1705117 20 1703785 1704031 1704023 1704089 1704079 1704797 1703785 1704071 1704042 1704031 1704063 1704055 1705102 21 1703779 22 3252797 1702797 1702797 1702798 1702797 1702797 3252798 3252798 3252798 3252798 3252798 3252798 3252798 3121135 J LG Lift 3 29 SECTION 3 MACHINE
9. 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP 1705703 1705703 1705703 1705703 170570 170570 170570 170570 170570 170570 170570 170570 170570 170570 12 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 13 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 14 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 15 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 16 1703786 1704032 1704024 1705099 1704081 1704039 1705099 1705099 1705099 1705099 1705099 1705099 1705099 1705099 17 1702153 18 1703684 1703685 1703686 1703723 1703751 1703719 1703684 1703718 1703719 1703685 1703721 1703722 1705101 1705100 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP I5DVSP 15DVSP 15DVSP 1705047 1705108 1705109 1705127 1705110 1705111 1705050 1705121 1705122 1705120 1705123 1705124 1705126 1705125 20DVSP 1705702 19 20 1703785 1704031 1704023 1704089 1704079 1704797
10. 3121135 SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 5 1 INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine The maintenance portion of this section is intended as information to assist the machine operator to perform daily mainte nance tasks only and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available Specific to this Machine Service and Maintenance Manual GLOBAU tes ia ce a Fes Eger iru inr ra 3121136 Illustrated Parts Manual PUN aana a 3121137 a 3121839 5 2 GENERAL SPECIFICATIONS Machine Specifications SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP Gross Machine Weight Platform Empty 2 105 Ib 2 105 Ib 2 150 Ib 2 150 lb 955 kg 955 kg 975 kg 975kg Machine Height Platform Stowed 78in 198cm Maximum Ground Bearing Pressure per wheel 800 Ib 360 kg Maximum Operating Incline 1 5 Maximum Travel Grade Gradeability 20 Platform STOWED ONLY Maximum Travel Grade Side Slope 5 Platform STOWED ONLY Maximum Drive Speeds Operator Variable 0 5 2 mph 0 8 3 2 kph Machine Base Over
11. 1703785 1704071 1704042 1704031 1704063 1704055 1705103 1705102 21 1703779 22 3252797 1702797 1702797 1702797 1702797 1702797 3252798 3252798 3252798 3252798 3252798 3252798 3252798 3252798 23 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 24 1705140 1704804 1704981 1705134 1705135 1705133 1705136 1705137 1705139 1705138 25 1704366 1705141 1705142 1704777 1704910 1704804 1704980 1705146 1705147 1705494 1705148 1705149 1705151 1705150 26 1704469 1705153 1705154 1705164 1705155 1705156 1704469 1705158 1705159 1705157 1705160 1705161 1705163 1705162 3121135 J LG Lift 3 31 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION This page intentionally left blank 3 32 J LG Lift 3121135 SECTION 4 EMERGENCY PROCEDURES SECTION 4 EMERGENCY PROCEDURES 4 1 GENERAL INFORM ATION This section explains the steps to be taken in case of an emergency situation during operation 4 2 EMERGENCY OPERATION Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE 1 Other personnel should operate the machine from ground controls only as required 2 Only qualified p
12. 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 CO co oO A N 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 e 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP 15DVSP I5DVSP 15DVSP 15DVSP 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 1705018 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP 20DVSP
13. 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction 3121135 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes drop offs are present 7 Means to avoid the hazards of unprotected electrical conductors 8 Specific job requirements or machine application Training Supervision Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine Operator Responsibility The operator must be instructed that he she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site NOTE The Manufacturer or Distributor will provide qualified people for training assistance with the first unit s delivered and from that time forward as requested by the user or his her personnel J LG Lift 2 1 SECTION 2 PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND MAINTENANCE The following table covers the periodic machine inspec tions and maintenance recommended by J LG Industries Inc Consult local regulations for further requirements for aerial work platforms The frequency of inspections and maintenance must be increased as necessary when the machine i
14. Capacity 20DVL 350 Ib 160kg 15DVL 15DVSP 500 Ib 230 kg Model Max Capacity 20DVL 35016 160kg 15DVL 500 Ib 230kg 1 Sliding Side Entry Gate 3 Lanyard Attach Point 2 Platform Control Console Left side of mast 1 Gullwing Entry Gate 4 Extension Slide Lock Handle 2 Entry Gate Latch 5 Platform Control Console 3 Lanyard Attach Point on mast 6 Sliding Extendible Section MOLDED PLATFORM OPTION SHOWN w MATERIAL TRAY EXTENDIBLE PLATFORM SLIDING BAR ENTRY CE ONLY Model Platform amp Tray Material Tray Combined Max Capacity Max Capacity 20DVL 350 Ib 160kg 100 Ib 45kg 15DVL 15DVSP 500 Ib 230kg 150 Ib 70kg Model Max Capacity 20DVL 350 Ib 160kg 15DVL 15DVSP 500 Ib 230 kg 4 Platform Control Console 2 Entry Gate Latch 1 Swing Up Side Entry Gate 3 Lanyard Attach Point on mast 1 Sliding Bar Entry Gate 4 Platform Control Console 2 Lanyard Attach Point on mast 5 Sliding Extendible Section 3 Extension Slide Lock Handle 3121135 J LG Lift SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION StockPicking Platform Operation The stockpicking platform is available in two 2 versions Fixed s
15. General is seas repa bal Pees bed aa Trip and Fall Hazard ud aco e ea Electrocution Tipping Hazard Crushing And Collision 14 TOWING LIFTING AND SECTION 2 PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING Operator 0 Training Supervision Operator lt 51 2 2 PREPARATION INSPECTION AND 2 3 5 5 2 4 DAILY WALK AROUND INSPECTION 2 5 FUNCTION CHECK SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 1 GENERALE spe Ex eb Xe a ee wale 3 2 MACHINE DESCRIPTION ree peek pe a usa 3 3 MACHINE Getting Started coss RR SER CHR RR ns 3 4 BATTERY CHARGING Battery Low Voltage Warning Indicators To Charge lt Battery Charging Status Indicators 3 5 GROUND CON
16. Station must be set for either Ground Control Mode or Platform Control Mode Both Emergency Stop Switches one on the Ground Control Station the other on the Platform Control Con sole must be in the RESET position If equipped the On Off Key Switch on the Platform Console must be set to the ON position 3 2 J LG Lift 3 4 BATTERY CHARGING DVL and DVSP machines are equipped with an AC volt age input DC voltage output battery charger The charger automatically terminates charging when the batteries reach full capacity NOTE The machine s platform drive function is disabled when the battery charger is plugged into an AC receptacle I na Figure 3 1 Battery Charger Location 1 Battery Charger M S 120 lt lt EE S be 2 ss DIL Battery Charger Front Panel 1 120V 5 Amp Breaker 3 240V 5 Amp Breaker 2 AC Input Voltage Selector 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Battery Low Voltage Warning Indicators The Platform Control Console and Ground Control Station indicate battery low voltage at three 3 Warning Levels Table 3 2 Battery Low Voltage Warning Indicators Control Modu IMPORTANT The 3 Levels of Battery Low Voltage Warning indication will only activate on Ground Control Modules with version 29 orlater Ground e software imp
17. for location and PSL instructions NOTE SLEEP MODE During operation if no control func tions have been activated for 10 minutes default programmable setting the ground control module will power the machine down to conserve battery power Cycle power back on using either the main power selector switch key or the emergency stop power down button either on the platform controller or on the ground control station 3 11 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Platform On Off Key Switch Atthe Platform Control Console Setthe On Off Key Switch to the ON position 2 to operate machine 1 OFF Position 2 ON Position Set the ON OFF Key Switch to the OFF position to power machine down NOTE NOTE If necessary when machine is not in use remove key from platform key switch to disable machine from unauthorized use During operation the operator in the platform can prevent unauthorized control of the machine from the Ground Control Station by either switching the On Off Key to the OFF position or activating the Emergency Stop Button on the platform control con sole Platform Emergency Stop Shut Down Button NOTE The Platform and Ground Control Station Emer gency Stop Shut Down Buttons must both be in the RESET position to operate machine POWER OFF PUSH IN TO ENGAGE Emergency Stop POWER ON TURN CLOCKWISE and RELEASE to RESE
18. position Place pin in the carry position hole locking the hanger arm in place 3 Load the object onto the hanger arm and use the hanger arm strap to secure the object during transport IMPORTANT DVSP MACHINE S EQUIPPED WITH THE OBSTRUCTION SENSING SYSTEM OSS OPTION OBJ ECTS PLACED ON THE HANGER ACCESSORY AND EXTENDING BELOW THE BASE OF THE PLAT FORM MAY CAUSE AN OSS DETECTION SOUNDING THE HORN 3121135 AND PREVENTING THE PLATFORM FROM LOWERING IF NECES SARY REPOSITION THE OBJ ECT OUT OF THE OSS DETECTION ZONE 4 Be aware of clearance above below and around the object when driving and lifting orlowering the platform Stock Picker Hanger Carry Position 1 Mounting Bracket 2 Hanger Arm Carry Position 3 Capacity Decal a Notes a Maximum load capacity of hanger is 100 Ib 45kg 4 Lock Pin Carry Position 5 Hanger Arm Strap Stock Picker Hanger Stowed Position 1 Hanger Arm Stowed Position 3 Hanger Arm Carry Position 2 Lock Pin Stowed Position J LG Lift 3 27 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION
19. 2 NOTE If equipped with optional Programmable Security Lock PSL see Section 3 10 for additional instruc tions Main Power Selector Switch 92 Set the Main Power Selector Switch to Ground Control Mode at the Ground Control Station Emergency Stop Shut Down Button POWER OFF PUSH IN To Engage Emergency Stop POWER ON TURN CLOCKWISE and RELEASE To Reset Emergency Stop POWER ON Lever is pointing straight out towards left side of machine POWER OFF Lever is TURNED COUNTERCLOCK WISE towards decal 3 4 J LG Lift Brake Release Button NOTE The brakes only DISENGAGE electrically when the joystick control is moved off center during driving or are manually DISENGAGED electrically using the the Brake Release Button If the machine s batteries are completely depleted of electrical charge the brakes cannot be released manually PUSH and RELEASE TO DISENGAGE Brakes PUSH and RELEASE AGAIN TO ENGAGE Brakes A CAUTION DO NOT MANUALLY DISENGAGE THE BRAKES UNLESS MACHINE IS SETTING ON A LEVEL SURFACE OR MACHINE IS FULLY RESTRAINED Platform Up PUSH IN TO ELEVATE Platform RELEASE TO STOP ELEVATING Platform Down PUSH IN TO LOWER Platform RELEASE TO STOP LOWERING Manual Descent Control Valve A PUSH IN TO LOWER Platform RELEASE TO STOP Platform Descent
20. 3 6 PSL Switch amp Ground Control Station Locations AtRearofMachine 3 18 3 7 PSL Switch Controls amp 5 2 3 18 3 8 OSS Transducer Sensor Array 3 22 3 9 OSS Pre Start Inspection of Operation 3 23 3 10 Crane Hook 71 1 2 lt 345 3 24 3 11 Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations 3 24 3 12 DVL Series Decal Installation Chart See Table 3 5 for Specification 3 28 3 13 DVSP Decal Installation Chart See Table 3 6 for Specification 3 30 3121135 J LG Lift iii TABLE OF CONTENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distance 5 1 3 2 1 Inspection and Maintenance 2 2 3 1 DVL And DVSP Machine Operating Specifications 3 1 3 2 Battery Low Voltage Warning 1 0 5 3 3 3 3 LCD Display Operating 5 3 7 3 4 DVL DVSP Ground Control Station Level Programmable Settings and Factory Presets
21. 3 9 PARKING MAGHINE ua RR RD RCM RUSO UR raat tea Bika 3 17 3 10 PROGAMMABLE SECURITY LOCK PSL DVL DVSP 3 18 PSL Box and Ground Control Locations 3 18 Machine Power Up using 3 18 Machin Power ce te RE a eae RERO RR 3 18 Changing the Operators 3 18 3 11 PLATFORM CONFIGURATIONS RR RR RR NC CRI RC CN Oe 3 19 StockPicking Platform Operation 3 20 3 12 FALL PROTECTION LANYARD 3 21 3 13 QUICK CHANGE PLATFORM 3 21 2 ea oe et ee e Disp pons 3 21 Installations 3 21 3 14 OBSTRUCTION SENSING SYSTEM 5 3 22 System Description o iue Re RA ag UR RU ro n Re RD a 3 22 Operations ud Lu e ere 3 22 OSS 1 5 3 22 3 15 TRANSPORTING LIFTING AND TIE DOWN PROCEDURES 3 23 General anean edt tuus oce tan er st ede ee ed a DO detur 3 23 TRUCK Transports 2s Nes eot las E w Ca oes a u Dans
22. ALSO IF THE TILT ALARM HAS BEEN ACTI VATED WHEN THE PLATFORM IS ELEVATED THE DRIVE FUNC TION WILL BE DISABLED UNTIL THE PLATFORM IS COMPLETELY LOWERED NOTE For DVSP Models equipped with the optional Obstruction Sensing System see Section 3 14 for additional platform operation instructions 3121135 1 Drive the machine to the area where overhead work is to be performed and position the machine into it s approximate work position 2 PRESS and RELEASE the Platform Function Button The flashing LED indicates the function is active and will remain active 3 to 4 seconds 1 e 3 While the Platform Function is active PRESS and HOLD the Enable Button on top the J oy stick 4 Push the Joystick FORWARD from center TO ELEVATE the Platform TO STOP platform movement return the joystick back to center Pull the Joystick BACK from center TO LOWER the Plat form 5 If necessary reposition drive lift using platform con troller joystick to bring work object within reach 3 9 PARKING MACHINE 1 Drive machine to a well protected and well ventilated area 2 Ensure the platform is fully lowered turn the main power selector switch to the OFF position centered NOTE If required charge batteries in preparation for next work day JLG Lift 3 17 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 10 PROGAM M ABLE SECURITY LOCK PSL DVL DVSP OPT
23. CONTROLS INDICATORS AND OPERATION J Figure 3 13 DVSP Decal Installation Chart See Table 3 6 for Specification 3 30 J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Table 3 6 DVSP Decal Installation Chart See Figure 3 13 ANSI ANSI ANSI ANSI ANSI CSA EU CE CE CE CE CE CE CE LAT BRZ JPN CHI FRE AUS GER FRE SPA ITA DUT SWE FIN 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1702631 1702631 1702631 1702631 1702631 1702631
24. Capacity PUMP MOTOR 32 7 lt OVER CURRENT LIFT UP Dis abled X 00000 0 432 432 Both PHP Bars UP Checkfor Object Blocking 3 2 E3mmmmp e 50 PHP 8885 2 RIVE and LiftUP Disabled Both the Leftand Right PHP X 00000 0 433 433 Aux 1 Platform Gate Close Platform Gate or 34 _ lt gt 2 AUX 1 INHIBIT lt gt 2 orNo MuR T the Platform aan X 000000 534 g Platform Enable switch switc during machine operation Aux 3t 1 Platform Enable DoNotPress on Platform 35 E ox lt gt 4 switch depressed during Enable switch during X 000000 35 4 35 Machine Power up Machine Power Up NOTE The fault conditions shown above are fault conditions which the Operator may be able to resolve Should a fault occur and be displayed on the LCD screen which cannot be corrected at the Operator s level the problem must be referred to a qualified mechanic A complete table of Fault Codes is listed in the TroubleShooting Section of the Service and Maintenance Manual 3121135 J LG Lift 3 7 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 6 GROUND CONTROL STATION PROGRAM MING General The DVL DVSP machine Ground Control Station allows on board programming of various component and control function personality settings Programming may be required under circumstances such as Optional equipment has been added to the machine in the field and a function must be enabled befor
25. ENABLE LEVER then move joystick in the direction of LIFT 3 OR LOWER 2 A WARNING THE GROUND CONTROL STATION CONTAINS A 1 5 DEGREE TILT ALARM IF THE TILT ALARM HAS BEEN ACTIVATED THE PLATFORM WILL NOT ELEVATE ALSO IF THE TILT ALARM HAS BEEN ACTIVATED WHEN THE PLATFORM IS ELEVATED THE DRIVE AND LIFT UP FUNCTIONS WILL BE DISABLED UNTIL THE PLATFORM IS COMPLETELY LOWERED THEN DRIVEN OFF THE TILT CONDITION Drive Speed Setting Controls NOTE When the platform is elevated the maximum drive speed is automatically cut back to 1 4th the speed when the platform is fully lowered The Ground Con trol Module LCD screen will display a turtle when in this mode See page 3 6 Ground Control LCD Status Display in this section of the manual Drive Speed Setting Selector Switch 1 Selector Switch on top of joystick Xe Each PRESS onthis side of theswitch will DECREASE maximum drive speed FEWER LEDs Litup onthe Drive Speed Indicator Each PRESS on this side of the switch will INCREASE maximum drive speed MORE LEDs Lit up on the Drive Speed Indicator J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 8 PLATFORM CONTROL CONSOLE OPERATION MACHINES BEFORE SERIAL NUMBER 0130007616 Figure 3 5 Platform Control Console Machines Before Serial Number 0130007616 1 Battery Charge
26. Fault Code LEDs 4 Increase Max Drive Speed 7 Platform Function Enable 2 Max Drive Speed Setting LEDs 5 Horn 8 J oystick with Enable Button 3 Decrease Max Drive Speed 6 Drive Function Enable 9 Emergency Stop At Ground Control Station Emergency Stop Shut Down Button Pi Set the Main Power Selector POWER OFF Switch to Platform Control PUSH IN Mode at the Ground Control TO ENGAGE Station See Figure 3 2 Emergency Stop POWER ON TURN CLOCKWISE and RELEASE TO RESET Emergency Stop 3121135 J LG Lift 3 15 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Battery Charge Fault Code LED Indicator On normal power up and operation this series of LEDs visually indicates the amount of charge left in the batter ies GREEN LEDs lit indicate maximum charge RED LED s lit indicate minimum charge remaining The number of LEDs lit will change depending on the level of charge in the batteries If battery voltage falls below 16 8 volts a fault condition will occur and the machine will stop operating The batteries will need recharged NOTE LED Fault Code indications are in Table 3 3 LCD Display Operating Fault Conditions this section of the manual Driving Machine WARNING WHEN DRIVING WITH PLATFORM LOWERED DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP GRADE OF GREATER THAN TWENTY PER CENT 20 AS TIPPING COULD OCCUR
27. Indicators Hour Meter Display Fault Code Indicator Fault Text Message Display a Q RUN m Note a When an Fault Code is indicated the LCD screen will alternate between the text and symbol display modes 3 6 JLG Lift In the LCD Display Symbols illustration item 2 the Func tion Display or Function Disabled Indicators will vary as shown following DRIVE Disabled LIFT UP Disabled LIFT DOWN Disabled Both LIFT UP and LIFT DOWN Disabled Drive Speed Cut Back Turtle Mode Engaged When Platform is Elevated Battery Charger AC Plugged In M 3 gt LCD Display Fault Conditions Table 3 3 LCD Display Operating Fault Conditions show common LCD display Fault indications which may occur during operation and are usually caused by either an error in machine operation or a work area condition These fault conditions can usually be corrected by the operator and do not require a qualified mechanic to repair IMPORTANT AFTER A FAULT CONDITION IS CORRECTED THE MACHINE POWER MAY NEED TO BE RECYCLED TO RESET THE GROUND CONTROL STATION 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Table 3 3 LCD Display Operating Fault Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION CODE LED FAULT LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION LOOK FOR THIS Bra
28. Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
29. THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROP ERTY DAMAGE PERSONAL INJ URY OR DEATH 3121135 1 2 PRE OPERATION Operator Training And Knowledge Read and understand this manual before operating the machine Do not operate this machine until complete training is performed by authorized persons Only authorized and qualified personnel can operate the machine Read understand and obey all DANGERS WARN INGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by J LG All operating personnel must be familiar with the emer gency controls and emergency operation of the machine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all haz ards in the work area prior to machine operation Do not operate or raise the platform while on trucks trailers railway cars floating vessels scaffolds or other equipment unless approved in writing by J LG This machine can be operated in temperatures of 0 F to 104 F 20 C to 40 C Consult J LG for operation outside this range Machine Inspection Before machine operation perform inspections and functional checks Refer to Sec
30. control plac ards secure and legible emergency stop switch reset for operation Control markings legible 8 Ground Control Station Main Power Selector Switch operable placards secure and legible emer gency stop switch operates properly 9 Mast Assembly Mast sections slide pads mast chains sequencing cables platform control and power cables on side of mast power cables prop erly tensioned and seated in sheaves cable sheaves rotating freely J LG Lift 2 3 SECTION 2 PREPARATION AND INSPECTION Figure 2 1 Daily Walk Around Inspection for DVL DVSP Machines 1 Drive and Caster Wheels 4 Motor Pump Reservoir Unit 2 Base Frame 5 Batteries Open Cover Doors 3 Manual Descent Control Valve 6 Platform Assembly 2 4 J LG Lift 7 Platform Control Console 8 Ground Control Station 9 Mast Assembly 3121135 SECTION 2 PREPARATION AND INSPECTION 2 5 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 Section 3 for more specific operating instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMM
31. ea Rc vore a q 4 1 SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 5 1 INTRODUCTION 52556 c o P nec ea lote RR e c DR ROC 5 1 5 2 GENERAL 5 5 2 5 1 Machine Specifications 5 1 Electrical Specifications 5 2 Platform Datan a tee nC DOE RU RC e mero ak e pu Rd 5 2 Machine Component Weights _ 5 2 Serial Number 1 5 2 5 3 OPERATOR MAINTENANGE Sew OPE PER aes ERI DR PW Y nec 5 3 lubrication ss cens tet ben ro bic b cedet entem dps bn esate Due ire t ce cons 5 3 SECTION 6 INSPECTION AND REPAIR LOG LIST OF FIGURES FIGURE NO TITLE PAGE NO 2 1 Daily Walk Around Inspection for DVL DVSP 2 4 3 1 Battery Charger Eocation csse s rh eda meri RR RATS EROR Rn n dra 3 2 3 2 Ground Control Station Machine 3 5 3 3 Platform Control Console Machines Serial Number 0130007616 to Present 3 11 3 4 Platform Control Display Panel 3 12 3 5 Platform Control Console Machines Before Serial Number 0130007616 3 15
32. o b RR ER RU Rt 3 11 Platform On Off Key Switch 3 12 Platform Emergency Stop Shut Down 3 12 Platform Control Display Panel 3 12 Drive Lift Mode Selector Switch 3 13 ees den eot o peste ot as pe diet aaa 3 13 J oystick Function Enable Lever 3 13 Multifunction J oystick 3 13 Dive Modes sap ok DER Rau ja ead eee ida E Ted 3 14 Efe Mode x rss On AL Minoan cdm 3 14 Drive Speed Setting 5 3 14 3 8 PLATFORM CONTROL CONSOLE OPERATION MACHINES BEFORE SERIAL NUMBER 0130007616 3 15 AtGround Control Station 2 22 22 2222 3 15 Emergency Stop Shut Down Button 3 15 Battery Charge Fault Code LED Indicator 3 16 Briving Machilie zs a aun thawed Pe e ENDE ewok Sead WE Pise Emus be 3 16 Adjusting Maximum Drive Speed 3 17 Elevating Lowering the 3 17
33. object and allow the LED to stop flashing before testing next sensor 3121135 3 15 TRANSPORTING LIFTING AND TIE DOWN PROCEDURES General All DVL Series and DVSP Model Personnel Lifts may be transported to a work site using the following methods Driving the machine around on its base wheels if travel Surface area permits Loaded IN AN UPRIGHT POSITION ONLY onto a heavy duty vehicle with the payload capacity capable of supporting the full weight of the machine Check machine gross weights in the Operating Spec Chart at the beginning of this Section Moved with a fork lift truck using the fork lift pockets in the base frame Truck Transport A CAUTION DO NOT TRANSPORT THE MACHINE IN A HORIZONTAL POSI TION DUE TO LEAKAGE OF BATTERY ACID FROM THE BATTER IES OR HYDRAULIC FLUID FROM THE HYDRAULIC RESERVOIR The machine may be winched onto a tilted roll back truck bed see important note following which has been rolled back to ground level Disengage the brakes and always winch pull from the mast rear end of the machine using the rear tie down loop attached to the base frame IMPORTANT DO NOT ATTEMPT TO DRIVE MACHINE ONTO OFF OF OR PUSH MACHINE ONTO A TILTED ROLL BACK TRUCK BED THE DVL AND DVSP MACHINES POWER MODULE COULD SUS TAIN SERIOUS DAMAGE WHEN THE UNIT IS PUSHED OR TOWED AT SPEEDS GREATER THAN 2 MPH WHEN TOWING OR WINCHING THE MACHINE S BRAKES MUST BE DISENGAGED RE ENGAGE THE BRAKES ON
34. or Ground Control Mode 4 The machine will now operate normally Machine Power Down 1 At the Ground Control Station set the main power selector switch to the OFF position 2 Press the OFF button on the PSL keypad No LEDs on the PSL box will be lit Changing the Operator s Code The PSL Operators Code can be changed by a supervisor should the need occur A separate permanent Supervi sor s Code matched to the serial number of the PSL box is included on a sheet in the PSL user manual supplied with the machine 1 Enter the Supervisor s code on the key pad The PRO GRAM RED LED will be litif correct code is entered NOTE ON or OFF cannot be one of the four digits of the new Operator s code 2 Enter a new four 4 digit Operator s code on the key pad The ACCEPT AMBER LED will light up if the new Operator s code is accepted 3 Press the OFF button on the keypad to activate the new Operator s code NOTE The new Operators code will remain in the PSL even when power is removed from the equipment or until the Supervisor changes the Operator s code 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 11 PLATFORM CONFIGURATIONS STANDARD PLATFORM DVL EXTENDIBLE PLATFORM GULL WING ENTRY NON CE Model Max
35. 00584 1700584 1700584 1700584 1700584 1700584 1700584 2 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 3 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 4 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 5 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 6 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 7 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 10 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 15DVL 11 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 1705191 20DVL
36. CE MACHINE IS IN PLACE WITH TRUCK BED LEVEL AND READY FOR TIE DOWN TIE DOWN LOOPS ARE PROVIDED ON BOTH ENDS OF THE BASE FRAME TO SECURE MACHINE TO BED OF TRANSPORT VEHICLE J LG Lift 3 23 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Machine Tie Down With machine in position to be tied down and brakes engaged use the following guidelines for restraining the machine during transport IMPORTANT USE OF EXCESSIVE FORCE WHEN SECURING MACHINE DRIVE WHEEL LOAD CAN CAUSE DAMAGE TO THE MACHINES DRIVE WHEEL COMPONENTS 1 Secure machine with an adequate chain attached through the tie down loops located at the front and rear of machine See Figure 3 11 2 The chain should be securely tightened with a force of approximately 100 applied two feet from the pivot handle Crane Hook Accessory DVL Option NOTE Lifting devise must be capable of handling the gross weight of the machine see the Operating Specifica tions table at the beginning of this Section Figure 3 10 Crane Hook Accessory 1 Crane Hook Attachment 2 Back of Mast Fork Lift Truck Transport All DVL and DVSP Model Lifts are equipped with wide fork lift pockets running through the base frame See Figure 3 11 This allows the machine to be either trans
37. CKER PLATFORM OPEN RAIL CONFIGURATION DVSP 1 Platform Mid Gate enter rear of platform and close mid gate when driving with front rails open 2 Open Rail Configuration work area See previous Caution about fall protection requirements 3 Platform Control Console attached to fixed side rail in the rear of the platform 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 12 FALL PROTECTION LANYARD ATTACHMENT A CAUTION J LG INDUSTRIES INC RECOMMENDS THE OPERATOR IN THE PLATFORM WEAR A FULL BODY HARNESS WITH A LANYARD ATTACHED TO AN AUTHORIZED LANYARD ANCHORAGE POINT The main lanyard attach point for all DVL DVSP machines is located on the lower left side of the mast platform header just behind the operators platform A CAUTION AFTER ENTERING THE PLATFORM BEFORE BEGINNING OPER ATION ALWAYS CLOSE THE PLATFORM ENTRY GATE S 3121135 3 13 QUICK CHANGE PLATFORM MOUNTING DVL Model Lifts are equipped with quick change platform mounts which allow quick removal and installation of cur rently available quick change platforms NOTE DVSP Models require the installation of the Quick Change mount kit to use Quick Change Platforms 3 Lower Platform Mount 4 Lower Mount Pins 1 Upper Platform Mount 2 Upper Mount Attach Pins Platform Removal 1 Remove the platform control console from the platform and l
38. EDIATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION Perform a Function Check as follows 1 From the ground controls with no load in the plat form a Operate ground control functions platform lift up and lift down NOTE Ensure Pot Hole Protection device is fully engaged both bars down when the platform is elevated 3121135 b Ensure that all machine functions are disabled when the Emergency Stop Button is activated c Check Manual Descent Control valve is operat ing properly 2 From the platform control console a Ensure that the control console is properly mounted and secure b Raise and lower platform 2 ft to 3 ft 61m to 92 m several times Check for smooth elevation and lowering of platform c Operate all functions and check all limit and cut out switches d Ensure that all machine functions are disabled when the Emergency Stop Button is activated 3 With platform in the transport stowed position a Drive the machine on a grade not to exceed the rated grade ability and stop to ensure the brakes hold b Check the 1 5 degree tilt sensor alarm to ensure proper operation J LG Lift 2 5 SECTION 2 PREPARATION AND INSPECTION This page intentionally left blank 2 6 J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION SECTION 3 MACHINE CO
39. HINE CONTROLS INDICATORS AND OPERATION 3 7 PLATFORM CONTROL CONSOLE OPERATION MACHINES SERIAL NUMBER 0130007616 TO PRESENT 8 a On Off Key Switch See page 3 12 Emergency Stop Shut Down Button 6 qe EM 4 Bh 3 See page 3 12 3 Function Enable Lever on front of joystick See page 3 13 4 Multifunction J oystick Control See page 3 13 5 Drive Speed Setting Selector Switch See page 3 14 6 Platform Control Display Panel See page 3 12 7 Horn Button See page 3 13 8 Drive Lift Mode Selector Switch See page 3 13 Figure 3 3 Platform Control Console Machines Serial Number 0130007616 to Present General The following conditions must be met before the machine can be operated from the platform control console Ground Control Station Main Power Selector Switch must be setto PLATFORM CONTROL MODE Ground Control Station Emergency Stop Shut Down Button must be in the RESET position POWER ON NOTE See Section 3 5 on page 3 4 for Ground Control Station operation Platform Console On Off Key Switch must be set to the ON position Platform Console Emergency Stop Shut Down Button must be in the RESET position POWER ON 3121135 J LG Lift If equipped with the OPTIONAL PSL Programmable Security Lock it must be set to the ON position NOTE See Section 3 10 on page 3 18
40. ION The optional Programmable Security Lock switch can be programmed with a four 4 digit operators code to allow only those persons with the code to power up and oper ate the machine PSL Box and Ground Control Locations RA Figure 3 6 PSL Switch amp Ground Control Station Locations At Rear of Machine Z 1 PSL Switch Inside Right Cover a 2 Ground Control Station Note a Machines with bolt on fixed covers the PSL Switch is mounted on outside of right cover 2 4 1 2 Bs DEBE 05 80 17 7 8 9 5 9 GTI 4 N Figure 3 7 PSL Switch Controls amp Indicators 1 ON Green LED 4 Key Pad 2 ACCEPT Amber LED 5 OFF Switch 3 PROGRAM Red LED 6 ON Switch 3 18 J LG Lift Machine Power Up using the PSL NOTE When entering code on the key pad a short beep indicates a properly depressed key a long beep indi cates an error in depressing key If an error occurs you must restart the code entry process again 1 Enter the four digit code on the PSL key pad The ACCEPT AMBER LED indicator will be lit if the code is correct 2 Press the keypad ON button The ON GREEN LED indicator will light and power will be supplied to the Ground Control Station 3 At the ground control station turn the main power selector switch from OFF to either Platform Control Mode
41. Lift 1 4 TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unloading Refer to the Emergency Procedures Section of this manual for emergency towing procedures Ensure platform is fully retracted and completely empty of tools prior to towing lifting or hauling Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie down bars When lifting machine with a forklift position forks only at designated areas of the machine Lift with a forklift of adequate capacity Refer to the Machine Operation section of this manual for lifting information 3121135 SECTION 2 PREPARATION AND INSPECTION SECTION 2 PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is necessary that it be operated and maintained only by trained personnel Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical con trol must not operate this machine Operator Training Operator training must cover 1 Use and limitations of the controls in the platform and at the ground emergency controls and safety Systems 2 Control labels instructions and warnings on the machine 3 Rules of the employer and government regulations
42. NG INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJ URY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND A CAUTION INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJ URY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND IMPORTANT INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION THIS DECAL WILL HAVE A GREEN BACKGROUND J LG Lift 3121135 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS A WARNING THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHO RIZED J LG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT IMPORTANT J LG INDUSTRIES INC SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE CONTACT J LG INDUS TRIES INC TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE IMPORTANT JLG INDUSTRIES INC MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE J LG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJ URY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE J LG PRODUCT FOR Accident Reporting Product Safety Publications Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applica
43. NTROLS INDICATORS AND OPERATION Table 3 1 DVL And DVSP Machine Operating Specifications 15DVL 20DVL 15DVSP 20DVSP Maximum Occupants 1 Maximum Work Load Capacity 500 Ib 350b 500 Ib 400 b DVL Std Platform DVSP Stockpicker Platform 230 kg 160 kg 230 kg 180 kg Maximum Travel Grade Gradeability 20 Platform STOWED ONLY Maximum Travel Grade Side Slope 5 Platform STOWED ONLY Machine Height Platform Stowed 78 in 198cm Maximum Vertical Platform Height 15 ft 4 57 m 19 5 ft 5 94 m 15 ft 4 57 m 19 5 ft 5 94 m Maximum Wheel Load Per Wheel 800 Ib 360 kg Maximum Drive Speeds Operator Variable 0 5 2 mph 0 8 3 2 kph Max Platform Speeds w Max Load Plat 20sec 22 5 sec 20sec 22 5 sec form Up Platform Down 15 21sec 21 26 sec 15 21sec 21 26sec Gross Machine Weight 2 105 lb 2 105 Ib 2 150 lb 2 150 Ib Standard Equipment Platform Empty 955 kg 955 kg 975 kg 975kg 3121135 J LG Lift 3 1 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 1 GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES This secti
44. T Emergency Stop Platform Control Display Panel 1 Battery Charge Flash Code LEDS 2 Drive Mode Indicator Figure 3 4 Platform Control Display Panel 3 Lift Mode Indicator 4 Drive Speed Setting Indicator 1 Battery Charge Flash Code Indicator LEDS 0 normal power up and operation this series of ten 10 LEDs visually indicates the amount of charge remaining in the batteries The number of LEDs lit will change depending on the level of charge in the batteries NOTE All Three 3 GREEN LEDs lit up indicate maxi mum battery charge Four 4 YELLOW LEDs indicate a two thirds to one third battery charge remaining Three 3 RED LED s lit indicate minimum battery charge remaining The machine will continue to operate at this charge level but will begin to indicate low battery voltage warning indicators For more information on Battery Warning Level Indi cators See Battery Low Voltage Warning Indicators on page 3 3 This set of ten 10 LEDs will also indicate a flash fault code if operating problems are detected by the Ground Control Station NOTE J LG Lift LED Flash Fault Code indications that can be cor rected by the operator are shown on Table 3 3 on page 3 7 this section of the manual 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 2 Drive Mode Indicator When the Driv
45. TROL STATION OPERATION Main Power Selector Switch Emergency Stop Shut Down Button Master Disconnect Switch EE Option Only Brake Release Button Platform Dp is ieee d oa Ret Uem a any Platform DOWN ker or RE ao e ER ta Re Manual Descent Control Valve Machine Status LCD LCD Display 5 3121135 J LG Lift PAGE NO TABLE OF CONTENTS 3 6 GROUND CONTROL STATION 3 8 General ies ro Ra cte vc T Pe ay ga Bh cae odie aera 3 8 Programming 3 8 Operator Programming 3 8 Activating Programming Mode 3 9 Entering Password iu Aper RE VATERS NICE RC UC vad 3 9 Programming Mode Selection 3 9 Selecting Programmable Item to Adjust 3 10 Adjusting Programmable Setting _ 3 10 3 7 PLATFORM CONTROL CONSOLE OPERATION MACHINES SERIAL NUMBER 0130007616 TO 3 11 General sd eb pe tae d M ec i
46. all Width x Length 29 25 x 52in L 74cm x 132cm Maximum Wind S peed 0 mph Okph Machine rated for indoor use only a 45 Pound orce Maximum Hydraulic System Pressure 2600 PSI 1800 PSI 2600PSI 2800 PSI Recommended initial setting 180 Bars 124 Bars 180 Bars 193 Bars Hydraulic System Capacity 5qts U S 4 7L Hydraulic Reservoir Capacity 1 Gallon 3 78 L 3121135 JLG Lift 5 1 SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Electrical Specifications SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP System Voltage 24 Volts DC Battery Specifications Battery Type AGM VRLA Sealed Voltage 12 Volts DC Amp Hour AH Rating 100AmpHr 20 Battery Charger DC Models Input 120 240 Volts AC 50 60 Hz Voltage Selectable Output 24 volt 20 Amp Output with 2 Amp Finish Platform Data SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP Occupants Persons allowed in Platform 1 Maximum Work Load Capacity Standard 500 Ib 350 b _ _ 230 kg 160 kg Stockpicker 500 Ib 400 Ib 230 kg 180 kg Extendible 50010 35010 50010 35010 230 kg 160 kg 230 kg 160 kg Molded 500 Ib 35010 50016 35010 230 kg 160 kg 230 kg 160 kg Platform Height Mast Fully Extended 15 ft 19 5 ft 15 ft 19 5 ft Ground to Platform Floor 4 57 m 5 94 m 4 57 m 5 94 m P
47. ay aside 2 Remove both upper and lower mount attach pins securing the platform support rails to the mast mount ing channels 3 Swing and lift the platform out of the mounts and lay aside Platform Installation 1 Set platform in upper and lower mounts 2 Install attach pins in upper and lower mounts 3 Attach platform control console to platform rail A WARNING ENSURE ALL PINS AND FASTENERS ARE INSTALLED AND SECURE PRIOR TO OPERATION JLG Lift 3 21 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 14 OBSTRUCTION SENSING SYSTEM pvsp OPTION System Description The Obstruction Sensing System OSS is designed to detect the presence of obstructions within a predeter mined detection zone beneath the platform when lower ing the platform from an elevated position NOTE The OSS only operates normally when the Ground Control Module Power Selector Switch is set to PLATFORM CONTROL MODE When the Power Selector Switch is set to GROUND CONTROL MODE the OSS will detect an obstruc tion but will not stop platform downward movement or sound the horn However the OSS Control Mod ule LED will flash if a sensor detects the presence of an object Operation NOTE See Figure 3 9 for the location of the OSS Elec tronic module When the machine is powered on a RED LED located on the OSS electronics module will illuminate During plat form lowering if no obstructions have entered the detec tion z
48. dL Operation and Safety Manual Keep this manual with the machine at all times Model s DVL amp DVSP Series P N 3121135 September 27 2005 1509001 A REGISTERED COMPANY 015 JG 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 LG Industries Inc reserves the right to make specification changes without prior notification Contact LG Industries Inc for updated information Other Publications Available Service and Maintenance Manual eene 3121136 Illustrated Parts Manual 51 5 4 01 3121137 Illustrated Parts Manual CE seems 3121839 3121135 J LG Lift a SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the Safety Alert Symbol It is used to alert you to A DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE A RED BACKGROUND A WARNI
49. e Lift Mode Selector Switch is set to DRIVE MODE the round LED indicator on that portion of the display panel will light up indicating the DRIVE Mode active 3 Lift Mode Indicator When the Drive Lift Mode Selector Switch is set to LIFT MODE the round LED indicator on that portion of the display panel will light up indicating the LIFT Mode active 4 Drive Speed Setting Indicator The five 5 GREEN LEDs on the top of this indicator display the drive speed setting with the TURTLE on the left representing the MINIMUM speed setting and the RABBIT on the right representing the MAXIMUM speed setting Drive Lift Mode Selector Switch Drive Lift Mode Selector Switch 1 LIFT Mode 2 DRIVE Mode PUSH the rocker switch to selectmode of operation Whichever mode is selected the appropri ate LED indicator on the display panel below will light up showing which mode has been activated for joystick operation IMPORTANT Theselected mode will only remain active for 5 sec onds ifthe function asbl is notoperated 3121135 Horn Button E J oystick Function Enable Lever When the machineis powered on pressing this button willsound the Horn J oystick Function Enable Lever The Function Enable lever on the front of the joystick con trol mustbe engaged and held in during any joystick operation Multifunction J oystick Control The joy
50. e opera tion Customizing the machine to fit a specific application such as changing the LCD display language Programming Levels There is one 1 password protected programming level available to the Operator Level 3 Operator s Settings Level 3 Password 33271 Operator Programming Mode In the Operator Level Programming Mode the following items are shown on the main menu See Table 3 4 for Set ting Range and Default Factory Setting Tilt Sensor Program Tilt Sensor Allows viewing current tilt sensor individual X and Y di P rection degree reading rogram Allows programming of the items shown in Table 3 4 the following is a brief explanation of each program ming item NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Back To Main When selected will return to main level menu Set Language Selects the language that text on the LCD screen will be displayed Set Sleep Time Allows setting the length of time the machine will remain powered up without control input before powering itself down Set Polarity of Keypad Code Turns on or off the Programmable Security Lock switch circuit if equipped Enable Detection of Horn Open Circuit Enables horn electrical circuit to be turned
51. eck the fol lowing Carrier arm mounting is secure to the platform railing Positioning Rug Carrier Arms 3 Lift Arm Up Swing and Lock into Position 1 Carry Position 2 Stowed Position 8 After adequately attaching the rug to the display arm lower the platform stow the Rug Carrier Accessory arms 9 As required reposition and elevate the DVSP to com no missing or damaged fasteners pletely attach the rug The arm lock pins are in place and working properly Hanging a Rug using the Rug Carrier Accessory Arms The following is a description for use of the Rug Carrier accessory in hanging rugs on horizontal pivoting arm dis play racks 1 Selectthe intended location in the display for mounting the rug Open the display rack to provide adequate space for the DVSP lift and rug 2 With the Rug Carrier Accessory arms stowed drive the DVSP into position prior to loading the rug 3 Swing and lock Rug Carrier Accessory arms into the carry position 4 Load the rolled rug with the finished side facing the platform As required use an assistant to load the rug onto the Rug Carrier Accessory arms 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 mount Positioning Carpet Roll On Rug Carrier ing the rug onto the display arm 1 Center Carpet on Ar
52. ersonnel in the platform may use the platform controls DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 3 Cranes forklift trucks or other equipment can be used to remove the platform occupant and stabilize motion of the machine Platform Caught Overhead If the platform becomes jammed or snagged in overhead structures or equipment rescue the platform occupant prior to freeing the machine 3121135 4 3 INCIDENT NOTIFICATION J LG Industries Inc must be notified immediately of any incident involving a J LG product Even if no injury or prop erty damage is evident the factory should be contacted by telephone and provided with all necessary details J LG Phone U S A 877 LG SAFE 554 7233 8am till 4 45pm EST EURO 44 1 698 811005 AUSTRALIA 61 2 65 811111 E mail productsafety jlg com Failure to notify the manufacturer of an incidentinvolving a J LG Industries product within 48 hours of such an occur rence may void any warranty consideration on that partic ular machine IMPORTANT FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROL STATION THEN FROM THE PLATFORM CONTROL CONSOLE DO NOT LIFT ABOVE 10 FT 3 M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY J LG Lift 4 1 SECTION 4 EMERGENCY PROCEDURES This page intentionally left blank 4 2 J LG Lift
53. hanger accessory is intended for use in placing or retrieving stock items such as bicycles ladders etc on racks or shelves above ground level Use for any other purpose is not authorized by JLG The hanger accessory is a pivoting arm mounted to the DVSP platform rail The hanger accessory can be mounted to either side of the platform individually or two can be mounted one on each side of the platform Each individual hanger has a maximum load capacity of 100 Ib 45kg The hanger arm can be pivoted out of the way parallel with the platform side rails when not in use the stowed position The hanger arm is pinned into position at 90 degrees to the platform side rails when in use the carry position Pre Start Inspection Prior to use of the hanger accessory check the following Hanger arm mounting is secure to the platform railing no missing or damaged fasteners The hanger arm lock pin is in place and secure A CAUTION THE COMBINED WEIGHT OF PERSONNEL MATERIALS EQUIP MENT PLUS ANY LOAD ON THE HANGER ARM ACCESSORY MUST NOT EXCEED THE MAXIMUM LOAD CAPACITY OF THE PLATFORM Loading and Transporting an Item using the Hanger Accessory Use the following steps as a guide when loading and transporting an object with the hanger accessory arm 1 Keep the hanger arm in the stowed position when not in use 2 When ready to use pull the lock pin from the stowed position hole and swing the hanger arm into the carry
54. ide rail version Folding side rail version STOCKPICKER PLATFORM WITH FOLDING SIDE RAILS DVSP Model Max Capacity 15DVSP 500 Ib 230 kg 20DVSP 400 Ib 180 kg 1 Primary Entrance Exit Gate 4 Platform Control Console 2 Primary Entrance Latch 5 Mid Gate 3 Lanyard Attach Point 6 Gate Release Lock Pins on side of mast 7 Secondary Exit Gate A CAUTION THE STOCKPICKER PLATFORM ALLOWS THE MACHINE TO BE OPERATED IN AN OPEN RAIL CONFIGURATION SEE ILLUSTRA TION CE SPECIFICATION MACHINES THE OPERATOR MUST WEAR A FULL BODY HARNESS EQUIPPED WITH A LANYARD SHORT ENOUGH TO PREVENT A FALL FROM THE PLATFORM THE LANYARD MUST BE ATTACHED TO THE AUTHROIZED LANYARD POINT ALSO J LG RECOMMENDS THAT CE SPECIFICATION MACHINES EQUIPPED WITH THE STOCKPICKER PLATFORM ARE ONLY TO BE USED FOR STOCKPICKING APPLICATIONS 3 20 J LG Lift NON CE UNITS THE OPERATOR MUST WEAR A FULL BODY HARNESS WITH A LANYARD MAX 6 FT 1M ATTACHED TO THE AUTHORIZED LANYARD POINT OR A BODY BELT EQUIPPED WITH A LANYARD SHORT ENOUGH TO PREVENT A FALL FROM THE PLATFORM WHILE OPERATING THE MACHINE IN THE OPEN RAIL CONFIGU RATION ALWAYS OPERATE THE MACHINE FROM THE REAR OF THE PLATFORM WITH THE MID GATE CLOSED AND THE PLAT FORM CONTROL CONSOLE ATTACHED TO THE FIXED PORTION OF THE GUARDRAIL STOCKPI
55. iers are rated for the voltage of the line being guarded These barriers shall not be part of or attached to the machine The minimum safe approach distance shall be reduced to a distance within the designed work ing dimensions of the insulating barrier This determina tion shall be made by a qualified person in accordance with employer local or governmental requirements for work practices near energized equipment 3121135 Tipping Hazard The user should be familiar with the surface before driv ing Do not exceed the allowable sideslope and grade while driving x w Do not elevate platform or drive with platform elevated while on a slope or on an uneven or soft surface Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distrib ute loads evenly on platform floor Keep the chassis of the machine a minimum of 2 ft 0 6m from holes bumps drop offs obstructions debris concealed holes and other potential hazards at the ground level Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Do not increase the platform size with unauthorized deck extensions or attachments increasing the area exposed to wind will decrease stability f mast assembly or platform is caught so that one or more wheels are off the ground the operator must be removed before a
56. it on the ground station LCD display to clear the fault code To Charge Batteries Battery Charging Status Indicators 1 Park machine in a well ventilated area near an AC volt age electrical outlet 2 Check the AC voltage selector switch on front of the battery charger is set to correct local AC voltage NOTE The batteries on DVL DVSP machines require approximately five 5 hours to fully charge when drained to LOW BATTERY VOLTAGE warning on the Ground Control Module LCD display 3121135 3 Plug a heavy duty AC extension cord into the Charger AC Input Recepta cle on the center rear cover of the machine The battery charging status indicators are located just above the Charger AC input receptacle on the center cover section at the rear of the machine See Figure 3 2 When first plugged in the charger runs through a self diagnostic test lighting the LEDs in sequence then charg ing will begin wy gd impii 100 a 9 J LG Lift CHARGE COMPLETE 5 GREEN TOP LED ON P lt 100 Complete CHARGING 6 e AMBER MIDDLE LED ON Charge Incomplete MU CHARGING PROBLEM Q 100 Q RED BOTTOM LED ON S gt lt Consult Troubleshooting Section of the Service Manual 3 3 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 5 GROUND CONTROL STATION OPERATION See Figure 3
57. kes Released To Engage Brakes Press BRAKES RELEASED gt lt gt DRIVE Disabled Brake Release Button on X 00000 0 Ground Control Station Charger AC Plugged In Unplug Charger AC Power _ gt NONE DRIVE Disabled Cord X 00000 0 Obstruction SensorSystem Obstruction Under Platform gt m d 4 Platform Elevated orSensor Defective X 00000 0 LIFT DOWN Disabled Programmable Security Enter Code on PSL Keypad E LockPassword to Power Up Machine X 00000 0 LeftPHP Bar UP LowerPlatform and Check 02 j nn lt gt BAR UP gt Z Platform Elevated the Left Pot Hole Protection X 00000 0 02 DRIVEandLiftUP Disabled Bar T Right PHP Bar UP Lowerthe Platform and 03 2 mn eee lt gt BAR UP 5 Platform Elevated Check the RightPotHole X 00000 0 403 03 DRIVEandLiftUP Disabled Protection Bar Tilt Condition Lower the Platform and 4 TILTED 04 3 Platform Elevated Drive off the Tilt Condition X 00000 0 404 04 DRIVE and LiftUP Disabled Traction Module Allow Drive System Traction TRACTION 13 6 mmmm b 4 coo lt gt OverTemperature Moduleto Cool Before X 00000 0 413 13 DRIVE Disabled Operating Ground Control Module Allow Ground Control GROUND MODULE 4 17 7 gt lt IN FOLD BACK 4 Over Temperature Module to Cool Before X 00000 0 17 17 Machine Stopped Operating Pump MotorOverCurrent Platform Load Over
58. latform Cycle Performance LiftUp 20 sec 22 5sec 20 sec 22 5sec inseconds w max rated load LiftDown 15 21sec 21 265ec 15 21sec 21 265ec Machine Component Weights SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP Platform Weight Standard Platform 551b 25 kg Quick Change Platforms Molded Platform 701b 32 kg Battery per battery 65 710 29 8Kg Serial Number Locations For machine identification a serial number plate is affixed to the machine The plate is located on the back of the mast just above the mast support bracket 5 2 J LG Lift 3121135 SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 5 3 OPERATOR MAINTENANCE Lubrication Hydraulic Oil HO 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 Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system service J LG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 For cold weather applications i e when temperatures remain consistently below 20 F 7 C J LG recommends using Mobil DTE 13 hydraulic oil Aside from J LG recommendations it is not advisable to mix oils of different brands or t
59. lemented 8 2004 However machines with earlier versions of software must follow the same LED BAR indicator guidelines and battery charging cycles to maximize battery life INDICATOR LOCATION WARNING RESULT ACTION REQUIRED TO LEVEL PLATFORM CONTROLLED GROUND CONTROL LCD CLEAR FAULT LEVEL 1 3 LEDs BARS Flashing with Chargebatteries to a level of four _ E an audible beep 4 LEDs BARS or more before OOD ae Machine will Operate No operating LOU BATTERS Control Functions Locked Out LEVEL 2 2 LEDs BARS Flashing with Charge batteries for a minimum mau E an audible beep offour 4 continuous hours or n Platform Lift UP Function is eight 8 LEDs BARS lit before CHARGE BATTERS 7 Locked Out operating a 4 38 LEVEL 3 1 LED BAR Flashing with an Charge batteries for a minimum audible beep offour 4 continuous hours or II Drive and Platform Lift UP eight 8 LEDs BARS lit before CHARGE oo t Functions Locked Out operating a BATTERY 38 NOTE a To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 2 or 3 batteries must be charged until 8 bars are l
60. ms 3 Platform Front 7 Properly attach the rug to the display arm Never climb 2 Reston Arms Here a onto the platform rails for any reason Note a Maximum Capacity of Arms 150 Ib 68kg 3121135 J LG Lift 3 25 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Removing a Rug using Rug Carrier Accessory Arms This section describes the use of the Rug Carrier acces sory in removing a rug from a horizontal pivoting arm dis play rack 1 Select the intended location in the display for removal of the rug Open the display rack to provide adequate space for the DVSP lift and rug 2 With the Rug Carrier Accessory arms stowed drive the DVSP into position prior to loading the rug 3 Swing and lock the Rug Carrier Accessory arms into the carry position 4 Elevate the platform a few feet Start to roll the rug onto the Rug Carrier Accessory arms 4 Removing Rug From Display Arm 1 Roll Rug onto Rug Carrier while Elevating Platform 2 Rug Carrier in Carry Position 3 26 J LG Lift 5 Be certain the rug is centered over its length on the Rug Carrier Accessory 6 While elevating to the required height for removing the rug from the display arm continue to roll the rug until it is completely rolled up on the carrier arms 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
61. n Sensing System OSS Diagnostics until turned back off NO the machine will function normally but only the OSS Diagnostics screen will display until this setting is re set to the off NO posi tion Activating Programming Mode NOTE If machine does not power up check that both the Ground Control Station Emergency Stop Button and the Platform Control Console Emergency Stop Button are in the RESET position Also if machine is equipped with the PSL Program mable Security Lock option see Section 3 5 of this Operators Manual for additional machine power up steps Entering Password 1 The Brake Release button 1 moves the box from left to right to select which digit to change 2 Platform UP button 2 increases the numerical digit 3 Platform DOWN button 3 decreases the numerical digit 4 Change all five digits 4 to match password level then press the Brake Release button 1 again Programming Mode Selection With machine power OFF press and hold the Brake Release Button 1 on the Ground Control Station 2 While holding the Brake Release Button in power machine up by turning the Main Power Selector Switch 2 to either the Ground Control or Platform Control Mode 3 Release the Brake Release Button 1 after machine is powered up The LCD display should now display five zer
62. nsure that power tools are properly stowed and never left hanging by their cord from the platform work area Fully lower mast assembly and shut off all power before leaving machine When performing welding operations at elevation pre cautions must be taken to protect all machine compo nents from contact with weld splatter or molten metal Battery fluid is highly corrosive Avoid contact with skin and clothing at all times Charge batteries on in a well ventilated area 12 J LG Lift Trip and Fall Hazard J LG Industries Inc recommends that the operator in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point For further information regarding fall protection require ments on J LG products contact LG Industries Inc ih As Before operating the machine make sure all railing and gates are fastened in their proper position A Keep both feet firmly positioned on the platform floor at all times Never use ladders boxes steps planks or similar items on platform to provide additional reach Never use the mast assembly to enter or leave the plat form 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 atall times during entry and exi
63. on YES or off NO if machine is equipped with a horn Table 3 4 DVL DVSP Ground Control Station Level 3 Programmable Settings and Factory Presets Level 3 Operator Programmable Settings OnLCD Display YES HIGH T No X tow LEVEL PROGRAMMABLE ITEM fetes SETTING RANGE 3 Backto Main Return to Main Menu 3 Set Language 1 1 English 6 Italian 2 German 7 Swedish NOTE There are two production modules available at this A ma 1 a as time one for North South American and European 5 Spanish Languages and one for Asian Languages 5 1 English 3 Japanese 2 Chinese 3 SetSleepTime 5MINS 0 60MINS 3 Set Polarity of the Keypad Code LOW HIGH LOW 3 Enable Detection of Horn Open Circuit NO YES NO 3 Enable Detection of Beacon Open Circuit NO a YES NO 3 Forward Alarm Disable NO YES NO 3 OSS Diagnostics NO YES NO Notes a DVSP Models this feature is standard equipmentand presetto YES atfactory 3 8 J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Enable Detection of Beacon Open Circuit Enables mast base beacon strobe electrical circuits to be turned on YES or off NO if machine is equipped with either or both beacon strobes Forward Alarm Disable When turned on YES will disable the alarm when driving forward OSS Diagnostics When turned on YES will cause the controller LCD to continuously display the Obstructio
64. on provides the necessary information needed to understand control function and operation 3 2 MACHINE DESCRIPTION The JLG DVL and DVSP Model Lifts are electric self pro pelled machines with an aerial work platform mounted to an elevating aluminum mast mechanism The personnel lift s intended purpose is to provide personnel access to areas above ground level The DVSP model lift is intended for stock picking purposes in retail stores or warehouses The primary control station is located in the platform From the Platform Control Console the operator can drive the machine and raise or lower the platform The controls of the programmable Ground Control Station are to be used during machine power up machine main tenance or in case of emergency should the operator in the platform be unable to lower the platform Vibrations emitted by these machines are not hazardous to an operator working in the platform The continuous A Weighted sound pressure level at the work platform is less than 70db A NOTE Machines built to the UL EE electrical specification option include additional controls and design fea tures These controls are labeled as EE Only 3 3 MACHINE OPERATION Getting Started The following control conditions must be met before the machine can be operated from either the Ground or Plat form Controls The batteries contain enough voltage to operate the machine The Main Power Selector Switch on the Gound Control
65. one beneath the platform the platform will lower normally If an obstruction is detected within the detection zone beneath the platform the platform will Stop Lowering The RED LED on the electronics module will flash The horn will sound three short blasts If an obstruction is detected have the obstruction cleared by someone on the ground or carefully drive the lift until clear of the obstruction Reset the OSS by pressing the horn button on the platform control once and continue machine operation Should the OSS falsely detect an obstruction the system can be overridden by pressing and holding the horn button while operating the platform lowering controls A WARNING ALWAYS CHECK THE AREA UNDER THE PLATFORM IS CLEAR OF OBSTRUCTIONS BEFORE LOWERING THE PLATFORM 5 7 s 4 5 555 9 caf 0000 9 HLH 5 9 5 5 00000 C0000 00000 00000 00000 20222 56 2 00006 00000 2022221 66000 00000 0000 C ae 2 Figure 3 8 OSS Transducer Sensor Array Location 1 Transducer Arrays 1 through 6 2 Underside of DVSP Platform OSS Pre Start Inspec
66. os one with a box around Continue to next step Entering Password 3121135 RESET TIMERS L ZERO TILT SENSOR 1 Use Platform UP DOWN buttons 1 to move the selection box 2 up or down to select item to pro gram 2 Press the Brake Release button 3 to enter selected mode then move on to Selecting Programmable Item to Adjust J LG Lift 3 9 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Selecting Programmable Item to Adjust Adjusting Programmable Setting A eo 52 4 2 5 AINS 1 Use the Platform UP DOWN buttons 1 to scroll through the list of programmable items available to your programming level 2 Once a programmable item to be adjusted is selected press the Brake Release button 2 to enter that set tings adjustment mode J LG Lift 1 Adjust the programmable setting using the Platform UP DOWN buttons 1 see Table 3 4 for range of set tings for that item 2 Once parameter is set for the programmable item press the Brake Release button 2 this will enter the parameter and return you to the Programmable Set tings Menu TO EXIT Programming Mode after adjusting program mable settings power machine down with either the Main Power Selector Switch or Emergency Stop But ton 3121135 SECTION 3 MAC
67. ported around a work area or lifted onto a higher level using a standard fork lift truck NOTE Fork lift trucks must be capable of handling the gross weight of the machine see the Operating Specifications table at the beginning of this Section Figure 3 11 Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations 1 Rear Tie Down Loop 3 24 J LG Lift 2 Fork Lift Pockets 3 Front Tie Down Loop 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 16 RUG CARRIER ACCESSORY DVSP OPTION NOTE The Rug Carrier accessory is available only on the JLG DVSP model and is not authorized for use with any other JLG lift The Rug Carrier Accessory is intended for use in hanging and removal of rugs in hanging display racks only Use for any other pur pose is not authorized by JLG General The Rug Carrier Accessory consists of two pivoting arms mounted to the DVSP platform left side rails The pivoting arms are locked in the plane of the platform side rail when notin use the stowed position The arms are locked into position at approximately 90 degrees to the left side plat form side rails when in use the carry position The pivot ing arms position can be changed by lifting each arm to release the lock rotating the arm and lowering each arm back into a locked position Pre Start Inspection Prior to use of the Rug Carrier accessory ch
68. s used in a harsh or hostile environment if the machine is used with increased frequency or if the machine is used in a severe manner IMPORTANT JLG INDUSTRIES INC RECOGNIZES A QUALIFIED JLG MECHANIC AS A PERSON WHO HAS SUCCESSFULLY COM PLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPE CIFIC JLG PRODUCT MODEL Table 2 1 Inspection and Maintenance Table PRIMARY SERVICE FREQUENCY RESPONSIBILITY QUALIFICATION REFERENCE Pre Start Before using each day or User or Operator Useror Operator Operator and Safety Manual Inspection whenever there s an Operator change Pre Delivery Before each sale lease or rental delivery Owner Dealer orUser Qualified LG Service and Maintenance Inspection Mechanic Manualand applicable LG See Note inspection form Frequent Inservice for 3 months or 150 hours whichever Owner Dealer orUser Qualified LG Service and Maintenance Inspection comes first or Mechanic Manualand applicable LG Outofservice fora period of more than 3 months or inspection form Purchased used AnnualMachine Annually no later than 13 months fromthe date of Owner Dealer orUser Qualified LG Service and Maintenance Inspection priorinspection Mechanic Manualand applicable LG inspection form Preventative Atintervals as specified in the Service and Mainte Owner Dealer orUser Qualified LG Service and Maintenance Maintenance nance Manual Mechanic Manual NOTE In
69. spection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 2 2 J LG Lift 3121135 SECTION 2 PREPARATION AND INSPECTION 2 3 PRE START INSPECTION The Pre Start Inspection should include each of the follow ing 1 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel 2 Decals and Placards Check all for cleanliness and legibility Make sure no decals or placards are missing Make sure all illegible decals and placards are cleaned or replaced Reference Decal Installa tions in Section 3 3 Operators and Safety Manuals Make sure a copy ofthe Operator and Safety Manual EMI Safety Man ual Domestic only and ANSI Manual of Responsi bilities Domestic only is enclosed in the weather resistant storage container 4 Daily Walk Around Inspection See Section 2 4 5 Battery Charge as required 6 Hydraulic Oil Check the hydraulic oil level NOTE Check Service Manual for instructions and hydraulic oil specification before adding DO NOT OVERFILL FILL TO LINE on Hydraulic Reservoir indicates the proper level for hydraulic oil 7 Function Check Check machine controls for operation See Section 2 5 If optional equipment is installed on this machine refer to Section 3 for specific Pre Start Inspec
70. stick will operate the following machine functions Drive Platform Lift Up and Down NOTE Use the Drive Lift Mode Selector Switch to select which function the joystick will operate The selected operating mode will only remain active for 5 seconds if the function is not operated Remember to press and hold the joystick function enable lever to operate any joystick functions A WARNING WHEN DRIVING WITH PLATFORM LOWERED DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP GRADE OF GREATER THAN FIFTEEN PER CENT 15 DRIVING WITH PLATFORM ELEVATED IS RESTRICTED TO A SMOOTH FIRM AND LEVEL SURFACE WITHIN 1 5 DEGREES OF LEVEL IN ANY DIRECTION J LG Lift 3 13 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Drive Mode Lift Mode ros 3 14 1 Activate the Drive Mode using the Drive Lift Mode Selector Switch Within 5 seconds of activa tion ENGAGE and HOLD the OYSTICK ENABLE LEVER then move the joy stickin the desired direction of travel Drive power is applied proportionally the further the joystick is moved off center 1 Activate the Lift Mode using the Drive Lift Mode Selector switch D 2 Platform LIFT DOWN Direction 3 Platform LIFT UP Direction Within 5 seconds of activa tion ENGAGE and HOLD the OYSTICK
71. t Platform to structure transfers at elevated positions are discouraged Where transfer is necessary enter exit through the gate only with the platform within 1 foot 0 3m of a safe and secure structure 100 tie off is also required in this situation utilizing two lanyards One lanyard must be attached to the platform with the second lanyard attached to the structure The lanyard connected to the platform must not be disconnected until such time the transfer to the structure is safe and complete 3121135 SECTION 1 SAFETY PRECAUTIONS Electrocution Hazard oO Table 1 1 Minimum Safe Approach Distance M S A D VOLTAGE RANGE MINIMUM SAFE APPROACH PHASE TO PHASE DISTANCE Feet 0 50KV 10 3 Over 50KV 200KV 15 5 Over 200KV to 350KV 20 6 Over 350KV to 500KV 25 8 Over 500KV to 750KV 35 11 Over 750KV to 1000KV 45 14 NOTE This Minimum Safe Approach Distance shall apply except where employer local or governmental regu lations are more stringent Maintain a clearance of at least 10 ft 3m between any part of the machine and its occupants their tools and their equipment from any electrical line or apparatus car rying up to 50 000 volts One foot 0 3m additional clear ance is required for every additional 30 000 volts or less The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact and if the barr
72. the platform 9 Remove the rug from the Rug Carrier Accessory If required use an assistant to unload the rug from the Rug Carrier Accessory Arms 10 Replace the Rug Hanger Accessory arms to the stowed position for normal operation A CAUTION THE RUG CARRIER ACCESSORY ARMS MUST BE LOCKED IN THE STOWED POSITION WHEN NOT IN USE EXTREME CAUTION MUST BE EXERCISED AT ALL TIMES WHILE THE RUG CARRIER ACCESSORY IS IN USE DRIVING RAISING AND LOWERING TO PREVENT OBSTACLES AND PERSONNEL FROM STRIKING THE LOAD WHEN DRIVING WITH A RUG WITHIN THE RUG CARRIER ACCES SORY THE RUG MUST BE PROPERLY SECURED TO PREVENT INADVERTENT MOTION OR MOVEMENT OF THE RUG AND MUST NOT EXCEED THE RATED CAPACITY OF THE RUG CARRIER ACCESSORY NEVER OVERLOAD THE RUG CARRIER ACCESSORY MAXIMUM CAPACITY OF THE RUG CARRIER ACCESSORY IS 150 LBS THE COMBINED WEIGHT OF PERSONNEL MATERIALS EQUIP MENT PLUS ANY LOAD ON THE RUG CARRIER ACCESSORY MUST NOT EXCEED THE MAXIMUM CAPACITY OF THE PLAT FORM NEVER USE A RUG CARRIER ACCESSORY THAT HAS DAMAGE OR LOOSE MOUNTINGS IMMEDIATELY REPORT ANY DAMAGE TO APPROPRIATE PERSONNEL DISCONTINUE USE OF THE RUG CARRIER ACCESSORY UNTIL ALL DISCREPANCIES HAVE BEEN CORRECTED 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 17 STOCK PICKER HANGER ACCESSORY NOTE The stock picker hanger accessory is available only on the JLG DVSP model and is not authorized for use with any other JLG lift This
73. tion See Figure 3 9 From ground controls raise platform approximately 5 6 The RED LED on the electronic module will be illuminated when power is applied If an obstruction such as a pad of paper is placed under any of the transducer sensor arrays the RED LED will flash and remain flashing while the obstruction is present and stop flashing 3 seconds after the obstruction is removed Check the operation of each transducer sensor array by placing an object individ ually under each sensor array within approximately 6 12 and checking if the RED LED starts to flash and stops flashing 3 seconds after the obstruction is removed Also inspect the transducer arrays and electronic module for physical damage loose wires loose mounting hardware etc 3 22 J LG Lift 3121135 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION Figure 3 9 OSS Pre Start Inspection of Operation 1 Electronic Module LED Indicator a 2 Detection Zone 3 Place a pad of paper or similar size object 6 to 12 in 15 to 30cm individually beneath each transducer to check detection Notes a TheLED Indicator will flash when an object is detected at each sensor Remove
74. tion 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual J LG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Ensure all safety devices are operating properly Modifi cation of these devices is a safety violation A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS SION FROM THE MANUFACTURER Do not operate any machine on which the safety or instruction 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 footwear and platform floor 1 3 OPERATION General Do not use the machine for any purpose other than positioning personnel their tools and equipment or for hand stock picking Never operate a machine that is not working properly If a malfunction occurs shut down the machine Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Operate controls with slow and even pressure Do not allow personnel to tamper with or operate the machine from the ground with personnel in the plat form except in an emergency Do notcarry materials directly on platform railing unless approved by J LG Always e
75. tion and Operation instructions 3121135 2 4 DAILY WALK AROUND INSPECTION Begin the Walk Around Inspection at item one 1 as noted on the diagram Continue around machine check each item in sequence for the conditions listed in the fol lowing check list A WARNING TO AVOID POSSIBLE INJ URY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED IMPORTANT DO NOT OVERLOOK VISUAL INSPECTION OF THE BASE FRAME UNDERSIDE CHECK THIS AREA FOR OBJECTS OR DEBRIS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE NOTE On all components make sure there are no loose or missing parts that they are securely fastened and that no visible damage leaks or excessive wear exists in addition to any other criteria mentioned 1 Drive and Caster Wheels Check for any debris stuck to or around wheels 2 Base Frame Check pothole protection system components check for loose wires or cables dan gling below the base 3 Manual Descent Control Valve See note above 4 Motor Pump Reservoir Unit No evidence of hydraulic leaks Hydraulic oil level should be filled level with the full line o Batteries Battery cables no corrosion 6 Platform Assembly and Gate Quick Change plat form mounting and mounting pins DVSP platform fasteners platform railings entry bar or gate in proper working order 7 Platform Control Console Platform
76. tions Questions Regarding Product Modifications CONTACT Product Safety and Reliability Department J LG Industries Inc 1JLG Drive McConnellsburg 17233 or Your Local J LG Office See addresses on back cover of manual In USA Toll Free 877 LG SAFE 871 554 7233 Outside USA 717 485 5161 E mail ProductSafety LG com 3121135 J LG Lift C REVISION LOG REVISION LOG October 1 2001 Original Issue of Manual November 19 2001 Manual Revised December 13 2001 Manual Revised February 22 2002 Manual Revised October 29 2002 Manual Revised J anuary 22 2003 Manual Revised February 18 2003 Manual Revised August 9 2004 Manual Revised May 6 2005 Manual Revised J uly 25 2005 Manual Revised September 27 2005 Manual Revised JLG Lift 3121135 TABLE OF CONTENTS TABLE OF CONTENTS SUBJ ECT SECTION PARAGRAPH EOREWORD e Peake Ae aD sa bnt SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS REVISION LOG gt etr oe lus e e e P erae i Song SECTION 1 SAFETY PRECAUTIONS ld GENERAL dh EXE PUER Se PR dte ED qa gua T2 BRE OPERATION tr C Operator Training And Workplace Inspection Machine 1 5 1 3 OPERATION yz yaaa u Meno HERR OC
77. ttempting to free the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine and remove personnel J LG Lift 1 3 SECTION 1 SAFETY PRECAUTIONS Crushing And Collision Hazard Personal protection equipment must be worn by all operating and ground personnel Check work area clearances above on sides and bot tom of platform while driving and lifting or lowering plat form D During operation keep all body parts inside platform railing Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 6 ft 1 8m away from machine during all driving operations Limit travel speed according to conditions of ground surface congestion visibility slope location of person nel and other factors causing hazards of collision or injury to personnel Be aware of stopping distances in all drive speeds Do not drive at high speeds in restricted or close quar ters or when driving in reverse Exercise extreme caution at all times to prevent obsta cles from striking or interfering with operating controls and persons in the platform Ensure that operators of other overhead and floor level machines 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 raised platform Position barricades on floor as neces sary 1 4 JLG
78. ypes as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact J LG Industries for proper recommendations Table 5 1 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping pointof 350 F Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum Extreme Pressure Gear Lube oil meeting API service classification GL 5 orMIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Usea good quality chain lubricant NOTE Refer to Lubrication Chart Table 5 2 for specific lubrication locations on machine 3121135 J LG Lift 5 3 SECTION 5 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 5 2 Lubrication Intervals for Various Components a INTERVAL ITEM CoMPONENT NO TYPE LUBE METHOD COMMENTS LUBE POINTS 3 6 1 2 MONTHS MONTHS YEAR YEARS Fill To Line on HO Check Hyd Oil Check fluid level every day c 1 Hydraulic Oil Reservoir Level v Change hydraulic oil every 2 5Qt Reservoir Hyd Oil years Drive Wheel Change only when serviced 2 Gear Box 2 Gear Boxes Gear Oil requires 6 oz 175 cc s to fill

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