Operation and Safety Manual ANSI
Contents
1. c TQ Figure 3 4 Decal Installation ANSI CSA Specification See Table 3 1 3 6 JLG Lift 3121212 SECTION 3 MACHINE CONTROLS amp INDICATORS Table 3 1 15AMI Decal Installation Chart ANSI See Figure 3 4 Table 3 1 15AMI Decal Installation Chart ANSI See Figure 3 4 Item ANSI CSA JPN LAT CHI Item ANSI CSA JPN LAT CHI 1 19 1704244 1700584 2 1703625 20 1700584 3 1703681 21 1704386 4 1703779 1701509 101 3251243 120V 60HZ 5 1703781 1703814 3251242 240V 50HZ 6 1704259 1703817 102 1704190 1704190 7 1703784 1703844 1703836 1704277 103 1704236 1704209 1704206 1704210 8 1703785 1704086 1704029 1704077 9 1703786 1704082. 5 N Jo ojeg 55 SnolA8Jd jeues 5141 uo pepnjour eq JOU 5 syun 5 7 310 12 GbZ LO0 L XeJ 1699 987 212 1 vsn GIN umoysuabey eze d 222 seujsnpu Tr 8 yonpolg yueyL paljloads se oj 10 5 LS 19npouJd 991 0 pejejduioo 5 Jo diusieuwo zuan pejepdn 97r siu esn 5 1essa2au si 9J9uM 5191 sesn pue 1onpoud 54f yore Surejuleul syonpoud jo 1uaA41no 991 payepdn ou dea 51 4 Jo 104 OUM 0 jenuew si Aq 1 ay jo Jeseuound eui LON 1nq umo
3. 2 1 3121212 SECTION PARAGRAPH SUBJECT PAGE 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 sese 2 2 2 3 PRE START INSPECTION 2 4 2 4 FUNCTION 2 5 2 5 DAILY WALK AROUND INSPECTION 2 5 General u bt ey ott cec AR 2 5 SECTION 3 MACHINE CONTROLS amp INDICATORS 34 GENERAL oi senili Rex I RES 3 1 3 2 CONTROLS AND 3 1 Ground Control Station 3 1 Platform Control Station 3 4 3 8 5 3 6 SECTION 4 MACHINE OPERATION 4 4 DESCRIPTION e Eau ER Ran 4 1 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS 4 1 Capacities 1 iu eR Eck 4 1 4 3 BATTERY CHARGING amp MAINTENANCE 4 2 Battery Maintenance and Safety 4 2 Battery Charger Operation 4 3 Abnormal Cycle Indicator LED 4 4 JLG Lift i TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE 4 4 MACHINE SET UP AND OPERATION 4 5 Extra Power Pack DC Battery Charger amp Case 5 1 Floor Brake 4 5 Lifting Hook isis RI 5 2 Platform 4 6 Platform Auxiliary Power Lowering Device 5 2
4. Operation and Safety Manual Original Instructions Keep this manual with the machine at all times Model 15AMI ANSI P N 3121212 January 5 2010 BS NOTES SECTION FOREWORD 3121212 FOREWORD This manual is a very important tool Keep it with the machine at all times The purpose of this manual is to provide owners users operators lessors and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information JLG Lift a SECTION SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol It is used to alert you to the potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 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 WARNING INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND b JLG Lift A CAUTION INDI
5. 19npoJd OL uone10dj02 usoxuso uy dIHSH3NMO 30 H34JSNVHL air PROPOSITION 65 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 chemicals known to the State of California to cause cancer Wash hands after handling 9 An Oshkosh Corporation Company JLG Industries Inc 1 Drive McConnellsburg PA 17233 9533 USA cS 717 485 5161 717 485 6417 JLG Worldwide Locations 3121212 JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 61 2 65 810122 A JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil f 55 19 3295 0407 55 19 3295 1025 e JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 A JLG France SAS Z l de Baulieu 47400 Fauillet France FF 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany FFE 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark
6. Figure 3 1 Ground Control Station ER 1 Power On Off Key Switch 3 Manual Descent Control Valve a 2 Emergency Stop Button 4 Hydraulic Oil Reservoir NOTE a Position of manual descent control valve on machines prior to S N 0900019526 JLG Lift 3121212 SECTION 3 MACHINE CONTROLS amp INDICATORS 4 y alll LL Figure 3 2 Manual Descent Control Valve Location 3121212 Machines Built Since S N 0900019526 1 Manual Descent Control Valve 2 Cut Out at Rear of Base Frame JLG Lift HYDRAULIC RESERVOIR CIRCUIT BREAKER FUSE located inside ground control station housing The hydraulic reservoir is housed inside the ground con trol station the hydraulic oil level can be checked through an access hole in the side of the cover Maintain an oil level to the Fill to Line indicator on the side of the reser voir Check hyaraulic oil only when platform is completely low ered and after cycling platform up down a few times A 20 amp reset type circuit breaker is located on the cover of the electrical box on AMI AC Models On AMI DC Models a 5 Amp fuse is located inside the ground control station 3 3 SECTION 3 MACHINE CONTROLS amp INDICATORS Platform Control Station See Figure 3 3 1 EMERGENCY STOP SHUT OFF Button An EMERGENCY STOP RED button is pro
7. Mast Installation Mast sections properly secured no visible damage to mast sections no loose or missing JLG Lift parts slide pads properly secured Mast chains and cables properly secured lubricated and undamaged Sequencing cables properly secured and undamaged Sheaves and pins are properly secured have no visible damage no loose or missing parts and are lubricated Platform Controls Up Down and Function Enable but tons properly secured no loose or missing parts no vis ible damage Placards secure and legible emergency shut off button set for operation Control markings legi ble Operators manual enclosed in manual storage tube Guard Rail Installation All railings securely attached no visible damage no missing parts sliding entry bar in proper working order Platform gate slide bar working properly no visible sign of damage if so equipped Platform Assembly Secure to mast no loose or miss ing parts no visible damage Control and power cables no visible damage cables properly tensioned and seated in control cable sheaves control cable sheaves not damaged and rotate freely 3121212 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Daily Walk Around Inspection Items Wheels amp Casters Floor Brake Base Frame Battery Box Charger Motor Pump Reservoir Unit Manual Descent Control Valve Location Priorto s n 0900019526 6b Sinces n 0900019526 7
8. Ground Controls 8 Mastinstallation 9 Platform Controls 10 Guard Rail Installation 11 Platform Assembly meme ml Figure 2 1 Daily Walk Around Inspection 3121212 JLG Lift 2 7 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION LBS NOTES 2 8 JLG Lift 3121212 SECTION 3 MACHINE CONTROLS amp INDICATORS SECTION 3 MACHINE CONTROLS amp INDICATORS 3 1 GENERAL 3 2 CONTROLS AND INDICATORS Ground Control Station see Figure 3 1 SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER NOTE When the machine is shut down for overnight parking or MACHINE APPLICATION AND OPERATION CONFORMANCE WITH battery charging be sure the POWER ON OFF KEY GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITY SWITCH is positioned to OFF to prevent draining the bat OF THE USER AND HIS OPERATING PERSONNEL teries This section provides the necessary information needed to under 1 POWER ON OFF Key Switch stand control functions Included in this section are the operating characteristics and limitations and functions and purposes of con trols and indicators It is important that the user operator read and understand the proper procedures before operating the machine These procedures will aid in o
9. The battery fluid level should be approximately 1 8 8mm below vent tubes See Figure 4 1 4 2 JLG Lift aa Figure 4 1 1 Battery Filler Cap 2 Vent Tube Battery Fluid Level 3 Fluid Level 4 Cell Plates 3121212 SECTION 4 MACHINE OPERATION Battery Charger Operation See Figure 4 2 amp Figure 4 3 NOTICE ALWAYS CHECK THE VOLTAGE SELECT SWITCH ON THE FACE OF THE BATTERY CHARGER BEFORE OPERATION IF NOT SET TO THE PROPER AC POWER INPUT VOLTAGE THE CHARGER MAY BE DAM AGED 1 Turn the ground control key switch to the OFF position 2 Set the AC voltage switch on the face of the charger for the local AC line voltage 3 Plug the battery charger AC power cable stowed inside the battery charger carrier beside charger into a prop erly grounded receptacle Use a suitable extension cord if necessary 4 The charger runs through a self diagnostic check The LED s on the face of the charger flash in the following sequence a First all five 5 LED s flash three 3 times b Next each LED lights in sequence c Finally all five 5 LED s flash three 3 times again Figure 4 2 Battery Box and Charger Assembly 1 Battery Box Charger Assembly 3 Charger AC Power Cord 2 DC Battery Char
10. depressions holes dropoffs 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 devel oped 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 peo ple for training assistance with the first unit s delivered and from that time forward as requested by the user or his her personnel 2 1 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult local regulations for further requirements for aerial work platforms The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environ ment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED TH
11. information can be used to determine maintenance intervals and other for other informational purposes when recorded over a specific period of time Figure 5 1 HourMeter Location Option 1 HourMeter 3121212 JLG Lift 5 3 SECTION 5 OPTIONAL EQUIPMENT 5 2 EXTENDIBLE PLATFORM OPERATION The optional extendible platform is designed to increase operator reach over the front of the machine this allows the operator access to work areas which may otherwise be unreachable from the standard platform The following procedures describe proper use of the Extendible Platform Mounting to Mast The Extendible Platform mounts using the same quick mount hardware as the standard platform see Section 4 Quick Change Platform in this manual for procedures to mount and remove the platform on the mast Once the platform is mounted re check that all mounting pins on upper and lower platform mast mounts two 2 pins on upper mount and two 2 pins on lower mount are installed and secure Entering Exiting Platform Refer to Figure 5 2 The Extendible Platform is equpped with a swing up gullwing gate for entrance into the platform A WARNING THE TOTAL WEIGHT CAPACITY FOR THE EXTENDIBLE PLATFORM ASSEM BLY IS 300 LB 135 KG ANSI CE 5 4 JLG Lift To ENTER the platform 1 Raise the swing up gate by grasping the front mid rail with one hand and pull up on the gate lock pin
12. 3 MACHINE CONTROLS amp INDICATORS Table 3 2 15AMI Decal Installation CE All Languages 3121212 See Figure 3 5 Item EE All Languages 1 1700584 2 1701509 3 Not Available 4 1702928 5 1703625 6 1703681 7 1703814 8 1703817 9 1704277 10 1704406 11 1705801 12 1705802 13 1705803 14 1705804 15 1705805 16 1705831 17 Not Available JLG Lift See Figure 3 5 Item All Languages 18 3820006 101 1704190 102 1704236 Table 3 2 15AMI Decal Installation CE Languages 3 9 SECTION 3 MACHINE CONTROLS amp INDICATORS LBS NOTES 3 10 JLG Lift 3121212 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION This machine is a manually propelled machine with a work plat form mounted to an elevating aluminum mast mechanism The personnel lift s intended purpose is to provide personnel with their tools and supplies access to areas above ground level The primary operator control station is in the platform From this control station the operator can raise and lower the platform A ground control station is provided to lower the platform to the ground in an emergency if the operator in the platform is unable to do so or if a power failure should occur Vibrations emitted by these machines are not hazardous to an operator in the
13. Have Demonstrated That They Understand Safe And Proper Operation And Maintenance Of The Unit An Operator Must Not Accept Operating Responsibilities Until Adequate Training Has Been Given By Competent And Authorized Persons Before Operation Check Work Area For Overhead Electric Lines See Electrocution Hazard JLG Lift Before Operation Check Work Area For Machine Traffic Such As Forklifts Cranes And Other Construction Equip ment Set up Machine For Operation Only On A Smooth Firm Level Surface Ensure That Operators Of Other Overhead And Floor Level Machines Are Aware Of The Aerial Platforms Pres ence Disconnect Power To Overhead Cranes Barricade Floor Area If Necessary Precautions To Avoid Known Hazards In The Work Area Must Be Taken By The Operator And His Supervisor Before Starting The Work Do Not Operate This Machine Unless It Has Been Ser viced And Maintained According To The Manufacturers Specifications And Schedule Ensure Daily Inspection And Function Check Is Performed Prior To Placing Machine Into Operation Have Authorized Personnel Take Any Necessary Corrective Action Before Placing Machine Into Operation Never Disable Or Modify Any Safety Device Any Modifica tion Of The Machine Is A Safety Violation And Is A Viola tion Of Osha And Ansi Rules Do Not Operate Machine When Exposed To High Wind Rain Or Snow SECTION 1 SAFETY PRECAUTIONS 1 4 Never Operate Or Raise Platform
14. Hr Reserve Capacity 165 Min N A Cold Cranking Amps 625 Amps 09 F N A Weight 5410 24kg 78 Ib 35kg Battery Charger DC Models Input 120 240 Volts AC 50 60 Hz Voltage Selectable Output 12 Volt 10 Amps DC w Auto Charge Sensing Circuit JLG Lift 7 3 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Platform Data SPECIFICATION 15AMI Occupants Persons allowed in Platform 1 Platform Capacity All Platforms Except Extendible ANSI CE 350 Ib 160 kg Extendible Platform Capacity ANSI CE 300 Ib 135 kg Platform Height Mast Fully Extended Ground to Platform Floor 15ft 4 57 m Platform Working Height Average Size Person 21ft 6 4 m Platform Cycle Performance in seconds Lift Up 30 w max rated load Lift Down 22 28 JLG Lift 3121212 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Machine Component Weights SPECIFICATION 15AMI Platform Weight Standard Platform 5516 25 kg Quick Change Platforms Molded Platform 7016 32 kg DC Voltage Battery Pack Wet Cell 70 Ib 32 kg 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 3121212 JLG Lift 7 5 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7 3 OPERATOR MAINTENANCE Battery Ma
15. Occur Before Moving Machine On Floors Trucks And Other Sur faces Check Allowable Capacity Of Surfaces Two People Are Required On Slopes Up To 5 Degrees A Forklift Must Be Used When Moving Units On Slopes Greater Than 5 Degrees Always Travel Up Or Down A Slope With The Platform End Of The Machine Positioned Towards The Low Side Of The Slope The Operator And Assistant Must Walk Beside And Guide The Machine With The Handles On The Mast Crossbar Never Position The Unit Sideways On A Slope 3121212 SECTION 1 SAFETY PRECAUTIONS Use Handles Provided On Mast Crossbar To Move Machine Do Not Move Unit on Soft or Uneven Surfaces or Over Obstructions Bumps Debris Etc Use Caution And Check Clearances When Moving Machine In Restricted Or Close Quarters Always Use An Assistant When Moving Machine In Areas Where Vision Is Obstructed Keep Non operating Personnel At Least 6 Feet 1 8 M Away From Machine During Transporting Operations 3121212 JLG Lift 1 3 SECTION 1 SAFETY PRECAUTIONS Two People May Be Required on Slopes Up To Five Degrees Also Always Travel With Platform End On The Low Side of Slope 1 4 JLG Lift 3121212 SECTION 1 SAFETY PRECAUTIONS 3121212 1 3 PRE OPERATIONAL SAFETY Read Your Manual Read Your Manual Understand What You ve Read Then Begin Operations Allow Only Those Authorized And Qualified Personnel To Operate Machine Who
16. Railings Positioned On Deck Never Position Ladders Steps Or Similar Items On Unit Do Not Extend Reach Limits Of This Machine With Addi To Provide Additional Reach For Any Purpose tional Equipment Such As Planks Boxes Etc 3121212 JLG Lift 1 9 SECTION 1 SAFETY PRECAUTIONS Do Not Use Ladders On Or Against Machine Do Not Per form Work That Will Subject Unit To A Horizontal Force Or Create A Rocking Motion Of The Platform Do Not Operate Machine From Platform Without The Plat form Gate In Place And Properly Closed This Is A Safety Violation Always Ensure That Power Tools Are Properly Stowed And Never Left Hanging By Their Cord From The Platform Work Area Avoid Accumulation Of Debris On Platform Work Area Keep Mud Oil Grease And Other Slippery Substances From Footwear And Platform Deck JLG Lift 1 5 MAINTENANCE SAFETY PRECAUTIONS A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND 15 A SAFETY VIOLATION Remove all rings watches and jewelry when performing any maintenance Do not wear long hair unrestrained or loose fitting cloth ing and neckties which are apt to become caught on or entangled in equipment Observe and obey all danger warning caution and other instructions on machine Keep standing surfaces and hand holds free of oil grease water etc Never work under an elevated platform unt
17. USA Toll Free 877 JLG SAFE 877 554 7233 Outside USA Phone 240 420 2661 E mail ProductSafety JLG com SECTION REVISION LOG Original Issue of Manual Manual Revised Manual Revised Manual Revised REVISION LOG July 6 2005 July 28 2006 December 1 2008 January 5 2010 JLG Lift 3121212 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE FOREWORD orosei oe bi ae BLEU Yu wid A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS cattails B Contacti gs neregana E GT e or e OE e perd C In USA eir UIDI RO a ER C Outside USA rubus bot boe C REVISION LOG D SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL tton Rods ia 1 1 1 2 1 2 Transport 1 2 1 3 PRE OPERATIONAL 1 5 1 4 OPERATING 1 6 Electrocution Hazard 1 7 1 5 MAINTENANCE SAFETY PRECAUTIONS 1 10 SECTION 2 USER RESPONSIBILITIES MACHINE PREPA RATION AND INSPECTION 21 PERSONNEL 2 1 Operator Training 2 1 Training 2 1 Operator Responsibility
18. rails with the two 2 platform upper mount pins and the two 2 lower platform mount pins The platform is now ready for operation 4 8 JLG Lift Figure 4 5 Quick Change Platform Mount 1 Platform Upper Mount 2 Platform Lower mount 3 Upper Mount Pins 4 Lower Mount Pins 3121212 SECTION 4 MACHINE OPERATION 4 6 STOWING MACHINE 1 Ensure that platform is fully lowered turn POWER ON OFF key switch on the Ground Control Station to the OFF position NOTICE WHEN MOVING MACHINE PLEASE FOLLOW ALL SAFETY PRECAU TIONS DESCRIBED IN SECTION 1 TRANSPORTING OF THIS MAN UAL ALSO SEE SECTION 4 TRANSPORTING LIFTING AND TIE DOWN FOR PROPER PROCEDURES FOR TRANSPORTING 2 Move machine to a well protected and well ventilated area If necessary cover the machine so it will be pro tected if in a hostile environment 3 Setthe floor brake when parking machine for an extended period of time 4 f necessary remove key from Ground Control Panel POWER ON OFF key switch to disable machine from unauthorized use NOTE If required DC machine batteries should be charged in preparation for next work day in accordance with Section 4 3 Battery Charging amp Maintenance 3121212 JLG Lift 4 7 TRANSPORTING LIFTING AND TIE DOWN General The AMI machine may be transported from worksite to worksite using any of the following methods Pus
19. top rail of the plat form allowing for convenient handling when replacing fluores cent tubes Extra Power Pack DC Battery Charger amp Case An extra power pack which includes the battery charger and molded case allows for extended use of an AM machine under high cycle conditions One power pack can be charging while the other is in use 5 1 SECTION 5 OPTIONAL EQUIPMENT Lifting Hook The optional lifting hook is mounted at the top rear of the first mast section The hook is used to lift the machine up or down to another level Platform Auxiliary Power Lowering Device The Platform Auxiliary Power Lowering device is a switch acti vated battery backed electrical circuit designed to provide power to the platform control box in the event of loss of the machines power supply This can be useful to the operator if the main battery on a DC model becomes depleted or the AC power supply of an AC model is interrupted while the platform is raised Also if the on off key switch on the ground control station is turned to the off position while the platform is still raised Laser Positioning Device The laser positioning device attaches to the platform railing and when powered on projects a laser dot on any surface above the machine This allows the operator to more accurately position the machine under a work area before raising the platform in position Locking Swivel Caster Wheels Machines equipped with this option allow th
20. work platform The equivalent continous A Weighted sound pressure level at the work platform is less than 70dB A 3121212 JLG Lift 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS Capacities The platform can be raised above the stowed position if The machine is positioned on a smooth firm surface on which the machine is capable of being leveled Load is within manufacturer s rated capacity All machine systems are functioning properly The machine is leveled and outriggers are properly installed as indicated by the outrigger interlock LED lights on the base frame 4 1 SECTION 4 MACHINE OPERATION 4 3 BATTERY CHARGING amp MAINTENANCE AMI Models are equipped with a 12 volt 10 amp output dual voltage 120 240V input battery charger The charger is micro processor controlled featuring an automatic charge sensing cir cuit which can determine cell voltage and regulate charger output and terminate charging as required Battery Maintenance and Safety see Figure 4 1 BATTERY ACID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING ALLOW NO OPEN FLAMES SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA ADD ONLY DISTILLED WATER TO BATTERIES WHEN ADD ING DISTILLED WATER TO THE BATTERIES A NON METAL LIC CONTAINER AND OR FUNNEL MUST BE USED
21. 1212 JLG Lift 2 3 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 3 PRE START INSPECTION The Pre Start Inspection should include each of the following 1 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel Decals and Placards Check all for cleanliness and legibility Make sure none of the decals and placards are missing Make sure all illegible decals and placards are cleaned or replaced Operators and Safety Manuals Make sure a copy of the Operator and Safety Manual EMI Safety Manual Domestic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container Walk Around Inspection Refer to Figure 2 1 on page 2 7 Battery Charge as required Fuel Combustion Engine Powered Machines Only Add the proper fuel as necessary Hydraulic Oil Check the hydraulic oil level Ensure hydraulic oil is added as required See Section 7 for hydraulic oil specifications JLG Lift 8 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 instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDIATELY REPORT THE PROBLEM TO THE PROPER MAIN T
22. 8 1704030 1704078 10 1701509 1704089 1704031 1704079 11 1703789 1704090 1704032 1704081 12 1703814 1704092 1704034 1704081 13 1703815 1704215 1704213 1704076 14 1703817 1704224 1704222 1704964 15 1704212 1704290 1704289 1704966 16 1704221 1704346 1704345 1704965 17 1707081 1707080 18 3820006 3121212 JLG Lift 3 7 SECTION 3 MACHINE CONTROLS amp INDICATORS 9 b p l4 3 E j amp j CSP 8 1 e mal OU 6 quU Uh T Figure 3 5 Decal Installation CE Specification 3 8 JLG Lift 3121212 SECTION
23. A MACHINE BY PUSHING SECURE ANY TOOLS OR OBJECTS WHICH MAY OTHERWISE FALL OFF AND CAUSE INJURY OR BE DAMAGED DURING TRANSPORT 4 10 JLG Lift Lifting If it becomes necessary to lift the machine use suitable lifting equipment capable of handling the weight of the machine see below NOTE Fork lifts cranes chains slings etc must be capable of handling the following weights Table 4 2 AMI Machine Gross Weights AM Model Gross Weight 15AMI AC 90010 408 kg 15AMI DC 97010 440 kg NOTE All AMI models are equipped with forklift pockets at the mast end of the frame for transporting the unit An optional crane hook is available Do not attempt to lift with a crane without the optional crane hook 3121212 SECTION 4 MACHINE OPERATION Transport Vehicle Tie Down See Figure 4 6 When placing the 15AMI machine onto a transport vehicle for transport to another worksite always tie machine securely to the transport vehicle using the tie down pockets provided on the machine There are four tie down pockets one on each corner of the machine There are also two cross strap saddles at the center on each side of the base frame Use corner tie down pockets and cross strap saddles as needed Tie down method shown is for illustrative purposes only Figure 4 6 15AMI Tie Down Pockets 1 Corner Tie Down Pockets 2 Cross Strap Saddles 3121212 JLG Lift 4 11 SECTION 4
24. ATIONS AND OPERATOR MAINTENANCE 7 4 SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006 42 EC and is only applicable to CE machines For electric powered machines the equivalent continuous A Weighted sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex Ill Part B Method 1 and 0 of the directive is 109 dB The vibration total value to which the hand arm system is sub jected does not exceed 2 5 m s2 The highest root mean square value of weighted acceleration to which the whole body is sub jected does not exceed 0 5 m s2 7 10 JLG Lift 3121212 SECTION 8 INSPECTION AND REPAIR LOG SECTION 8 INSPECTION AND REPAIR LOG Machine Serial Number Table 8 1 Inspection and Repair Log Date Comments 3121212 JLG Lift 8 1 SECTION 8 INSPECTION AND REPAIR LOG Machine Serial Number Table 8 1 Inspection and Repair Log Date Comments JLG Lift 3121212 eni amp Aou 5 uoneziueBJo ANOA ouA
25. CATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND 3121212 SECTION SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS A WARNING THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE TINS CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT NOTICE JLG INDUSTRIES INC SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE CONTACT JLG INDUSTRIES INC TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE NOTICE JLG INDUSTRIES INC MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT 3121212 JLG Lift For Accident Reporting Standards and Regulations Product Safety Publica Compliance Information tions Questions Regarding Spe Current Owner Updates cial Product Applications Questions Regarding Prod e Questions Regarding uct Modifications Product Safety Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 or Your Local JLG Office See addresses on manual rear cover In
26. E JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD UCT MODEL 2 2 JLG Lift 3121212 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Table 2 1 Inspection and Maintenance Table PRIMARY SERVICE piss EREGUENGY RESPONSIBILITY QUALIFICATION BE TERENCE Pre Start Before using each day or wheneverthere san User or Operator User or Operator Operator and Safety Manual Inspection Operator change Pre Delivery Before each sale lease or rental delivery Owner Dealer orUser Qualified JLG Service and Maintenance Inspection Mechanic Manual and applicable JLG See Note inspection form Frequent In service for 3 months or 150 hours whichever Owner Dealer orUser Qualified JLG Service and Maintenance Inspection comes first or Out of service for a period of more Mechanic Manual and applicable JLG than 3 months or Purchased used inspection form Annual Machine Annually later than 13 months fromthe Owner Dealer orUser Factory Certified Service and Maintenance Inspection of prior inspection Service Technician Manual and applicable JLG Recommended inspection form Preventative Atintervals as specified in the Service and Main Owner Dealer orUser Qualified JLG Service and Maintenance Maintenance tenance Manual Mechanic Manual NOTE Inspection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 312
27. ENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION 3121212 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 24 FUNCTION CHECK The function check of all systems should be performed in an area free of overhead and ground level obstructions Perform a function check as follows 1 Set up machine for operation according to instructions in Section 3 2 Enter platform raise and lower platform 2 ft to 3 ft 61m to 92 m several times Check for smooth eleva tion and lowering of platform 3 With platform completely lowered check hydraulic oil level in reservoir at ground control station Maintain an oil level to the Fill to Line indicator on the side of the reservoir NEVER USE HYDRAULIC BRAKE FLUID 3121212 JLG Lift 2 5 DAILY WALK AROUND INSPECTION It is the user operator s responsibility to inspect the machine before the start of each workday It is recommended that each user operator inspect the machine before operation even if the machine has already been put into service under another user operator This Daily Walk Around Inspection is the preferred method of inspection General Begin the Walk Around Inspection See Figure 2 1 at item 1 listed following Continue around machine checking each item in sequence for the conditions listed in the Walk Around Inspection Check list A WARNING TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL
28. ION AND REPAIR LOG 3121212 SECTION PARAGRAPH SUBJECT PAGE LIST OF FIGURES 2 1 Daily Walk Around Inspection 2 7 3 1 Ground Control Station 3 2 3 2 Manual Descent Control Valve Location Machines Built Since S N 0900019526 3 3 3 3 Platform Control 3 4 3 4 Decal Installation ANSI and CSA Specification 3 6 3 5 Decal Installation CE Specification 3 8 4 1 Battery Fluid Level 4 2 4 2 Battery Box and Charger Assembly 4 3 4 3 Dual Voltage Charger Front Panel 4 4 4 4 Setting amp Releasing Floor Brake 4 5 4 5 Quick Change Platform Mount 4 8 4 6 15AMI Tie Down 4 11 5 1 HourMeter Location 5 3 5 2 Extendible Platform 5 5 5 3 PSL Switch Location 5 6 5 4 PSL Switch Controls amp Indicators 5 6 JLG Lift TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE 1 1 2 1 3 1 4 1 4 2 7 1 8 1 LIST OF TABLES SECTION PARAGRAPH SUBJECT Minimum Approach Distance M A D 1 7 Inspection and Maintenance Table 2 8 15AMI Decal Installation Chart ANSI 3 7 15AMI Decal Installation CE All Languages 3 9 Maximum Platform Capacity 4 6 AMI Machine Gros
29. MACHINE OPERATION LBS NOTES JLG Lift 3121212 SECTION 5 OPTIONAL EQUIPMENT SECTION 5 OPTIONAL EQUIPMENT 5 1 OPTIONAL EQUIPMENT The following optional equipment is available for AMI models 22 x 25 Quick Change Platform The 25 long by 22 wide platform features a gull wing gate opening and is attached to the mast using the quick change mount 26 x 26 Quick Change Platform The 26 long by 26 wide platform features a side entry gate opening and is attached to the mast using the quick change mount 28 x 26 Quick Change Platform The 28 long by 22 wide platform features a gull wing gate opening and is attached to the mast using the quick change mount 25 x 26 Step in Molded Platform w Swing up Gate The 25 long by 26 wide Step in Molded Platform features a tough molded shell base and sides mounted to a welded steel 3121212 JLG Lift frame This step in platform features a swing up gate for easy entry 26 x 50 Quick Change ExtendiblePlatform See Section 5 2 Extendible Platform Operation The 26 long x 50 wide extendible platform features a gull wing gate and is attached to the mast using the quick change mount Tool Tray The tool tray is attached to the top rail of the platform allowing for quick access to hand tools or other small items placed in the tray Fluorescent Tube Caddy The fluorescent tube caddy is attached to the
30. MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR ING WALK AROUND INSPECTION NOTE Do not overlook visual inspection of chassis underside Checking this area often results in discovery of conditions which could cause extensive machine damage 2 5 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 1 Wheels and Casters Properly secured wheels and casters turn freely and are properly lubricated Check for any visible damage Floor Brake Properly secured to frame no visible damage cracks distortion etc and is functioning properly 9 Base Frame No visible damage components properly secured no loose wires dangling below base bubble level in place and functioning properly Battery Battery Charger Installation DC Machines 10 Proper battery electrolyte level cables secure no dam age or corrosion Motor Pump Reservoir Unit All properly secured no visible damage no evidence of hydraulic leaks Check 11 that hydraulic reservoir fluid level is filled to the Fill to Line mark on the side of the reservoir Manual Descent Control Valve Properly secured no loose or missing parts no visible damage Ground Controls Key switch operable no visible dam age placards secure and legible emergency stop Switch no visible damage and properly set for opera tion
31. N OF OSHA RULES 1 1 SECTION 1 SAFETY PRECAUTIONS 1 2 TRANSPORTING Before transporting the machine the user operator must be famil iar with the proper procedures for transporting the machine as well as the weight and size of the machine The user operator should be familiar with the surrounding work area and surface before transporting the machine The work area must be a smooth firm surface on which machine is capable of being leveled NOTE Remember that the key to safe and proper usage is com mon sense and its careful application A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION AND ON MACHINE MAY RESULT IN MACHINE DAMAGE PER SONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION Transport Safety Fully Lower And Completely Empty Platform Of Tools And Debris Before Moving Machine Never Allow Personnel In Platform While Moving Machine JLG Lift A WARNING FAILURE TO OBSERVE THE FOLLOWING TIPPING HAZARD INSTRUC TIONS COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CON TROL WHEN BEING MOVED WHICH COULD RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNED OR CRUSHED BY THE UNIT On A Level Surface Always Travel With The Platform End Leading The Way Watch For Obstructions Around Machine And Overhead When Moving Check Travel Path For Persons Holes Bumps Drop offs Obstructions Debris And Coverings Which May Conceal Holes And Other Hazards As Tipping Could
32. North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands 31 0 23 565 5665 31 0 23 557 2493 e JLG Polska UI Krolewska 00 060 Warsawa Poland FFE 48 0 914 320 245 48 0 914 358 200 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 444 0 141 773 1907 e Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34937724700 34 93 771 1762 JLG Sverige Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 www jlg com
33. Platform Operation 4 6 Laser Positioning Device 5 2 45 QUICK CHANGE PLATFORM 4 7 Locking Swivel Caster 5 5 2 Platform Removal 4 7 Programmable Security Lock 5 2 Platform 4 7 Descent 5 2 4 6 STOWING MACHINE 4 9 Descent Warning Strobe 5 2 DEDE ceca Ree DLE Hourim ter z 212 c Iss E LPPRERETM 5 3 T LIFTING AND Machine Cycle Counter 5 3 TAS POR IHG Dy PUSHING 5 2 EXTENDIBLE PLATFORM 5 4 It rne 4 10 Mounting to 94 Transport Vehicle Tie Down 4 11 Entering Exiting Platform 5 4 Extending Platform 5 4 SECTION 5 OPTIONAL EQUIPMENT Retracting Platform 5 5 51 OPTIONAL EQUIPMENT 5 1 5 3 PROGAMMABLE SECURITY LOCK PSL OPTION 5 6 NC TEE PSL Box Location 5 6 22 x 25 Quick Change Platform 5 1 EX 26 x 26 Quick Change Platform 5 1 Machine Power Up using the PSL 5 7 i TESE NEN T MERE Machine Power Down 5 7 28 x 26 Quic
34. TOR MAINTENANCE Table 7 2 Lubrication Intervals for Various Components INTERVAL HOURS NO TYPE ITEM COMPONENT LUBE METHOD 3 6 1 2 COMMENTS LUBE POINTS MONTHS MONTHS YEAR YEARS 150 Hrs 300 Hrs 600 Hrs 1200 Hrs 1 Hydraulic Oil Fill To Line HO Check Hyd Check Hydraulic Oil on Reservoir Oil Level EE E v every 10 hrs 5 Qt Reservoir HO Change Change Hydraulic Oil Hyd 01 every 1200 hrs 2 SwivelRaceways 2 FrontCasters MPG Pressure Gun 3 Mast Chains 2 Per Section CL Brush or Spray E v E Inspect lubricate if drying or rusting Applies Only to Mast Sections with Chains Key to Lubricants MPG Multipurpose Grease HO Hydraulic Oil CL Chain Lube Use a good quality chain lubricant Notes 1 Lubricate like items on each side of the machine 2 Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions such as a high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly 3 Lubricating intervals are calculated on 50 hours of machine operation a week 4 Priorto checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failure to do so will result in incorrect oil level reading on the hydraulic reservoir 3121212 JLG Lift 7 9 SECTION 7 GENERAL SPECIFIC
35. When Machine Is On A Truck Or Other Vehicle Approved Head Gear l e Hard Hat Etc Must Be Worn When Required By All Operating And Ground Personnel Read And Obey Danger Warnings Cautions And Operating Instructions On Machine And In This Manual Be Familiar With Location And Operation Of Ground Sta tion And Emergency Controls OPERATING SAFETY Do Not Operate Any Machine On Which Danger Warning Caution Or Instruction Placards Or Decals Are Missing Or Illegible Never Exceed Manufacturers Rated Platform Capacity Refer To Capacity Decal On Machine Operate Ac Units With An Extension Cord Wire Rated At A Minimum Of 15 Amps Do Not Enter Platform Until The Floor Brake Has Been Properly Adjusted And The Unit s Base Frame Is Level According To The Bubble Level Indicator On Base Frame Do Not Operate Machine On Soft Footing That Will Allow The Floor Brake To Settle Into Or Break Through Surface JLG Lift t Always Look in the Direction of Movement Watch for Overhead and Other Obstructions Never Operate A Malfunctioning Machine If A Malfunction Occurs Shut Down The Machine Remove It From Ser vice And Notify Proper Authorities When Applicable By Reason Of Local Regulations Or Job site employer Safety Rules Personnel In The Platform Shall At All Times Wear Approved Fall Protection Devices And Other Safety Gear As Required A Lanyard Attach ment Is Supplied On The Side Of The Machine
36. a properly depressed key a long beep indicates an error in depressing key If an error occurs you must restart the code entry process again Enter the four digit code on the PSL key pad The ACCEPT AMBER LED indicator will be lit if the code is correct Press the keypad ON button The ON GREEN LED indi cator will light and power will be supplied to the Ground Control Station At the ground control station turn the main power selec tor switch from OFF to ON The machine will now operate normally Machine Power Down 1 3121212 At the Ground Control Station set the main power selec tor switch to the OFF position 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 Supervisor 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 lit if correct code is entered NOTE The ON or OFF button cannot be one of the four digits of the 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 Operator s code will remain in the PSL even w
37. btaining optimum service life and safe operation A key operated power on off switch located on the ground control station panel controls power to all functions on the unit The machine will not operate without the key inserted and turned to the ON position When left unattended removing key will prevent unauthorized machine use 2 EMERGENCY STOP Button An emergency stop RED button is mounted on both the ground control station and the platform control panel When the button is depressed all machine functions will stop To reactivate power to the machine turn emergency stop button clockwise until button is reset 3121212 JLG Lift 3 1 SECTION 3 MACHINE CONTROLS amp INDICATORS 3 MANUAL DESCENT CONTROL VALVE Machines Built Prior to S N 0900019526 See Figure 3 1 This RED knurled knob located on the electric hydraulic pump motor unit on the ground control station panel provides for lowering of the platform in the event of an emergency or power failure Turning the valve knob to the left counterclockwise opens the valve turn ing the valve back to the right clockwise closes the valve Machines Built Since S N 0900019526 See Figure 3 2 The control knob is located in the recess under the base frame at the rear of the machine To open the valve lower the platform pull the RED knob on the control to close the valve stop platform lowering release the valve knob spring loaded 20 TA
38. c Oil ISO Vg grade 32 46 CL Chain Lube Use a good quality chain lubricant Hydraulic Oil HO BEES RARE SAE VISCOSITYGRADE 0 F to 2 180 189 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 JLG Industries recommends Mobilfluid 3121212 JLG Lift 424 hydraulic oil which has an SAE viscosity of 10W 30 and a vis cosity index of 152 For cold weather applications i e when temperatures remain con sistently below 20 F 7 C JLG recommends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types 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 JLG Industries for proper recommendations NOTE Refer to Lubrication Chart Table 7 2 on page 7 9 for cific lubrication locations on machine 7 7 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7 8 JLG Lift 3121212 SECTION 7 GENERAL SPECIFICATIONS AND OPERA
39. e operator to lock the front swivel caster wheels into position parallel with the base 5 2 JLG Lift frame when pushing the machine to a work area or during machine operation Programmable Security Lock See Section 5 3 Progammable Security Lock PSL Option The optional keyless 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 operate the machine Descent Alarm The descent alarm option will activate when the platform is being lowered from a raised position to alert ground personnel of platform movement The descent alarm can be combined with the descent warning strobe Descent Warning Strobe The warning strobe option will activate when the platform is being lowered from a raised position to alert ground personnel of platform movement The strobe is mounted to the base frame under the platform the strobe can be seen from any position in a 360 circle 3121212 SECTION 5 OPTIONAL EQUIPMENT Hourmeter See Figure 5 1 HourMeter Location Option The machine hourmeter accumulates pump operation time dur ing the platform LIFT UP cycle only The reading indicates hours and tenths of an hour Machine Cycle Counter Meter The Cycle Counter Meter is located on the front side of the Ground Control Station This meter tracks the number of cycles the mast travels up and down during macheine operation This
40. en and PLATFORM DOWN button bottom white but ton on control panel simultaneously Upon reaching AMI model is equipped with quick change platform mounts desired elevation level release PLATFORM DOWN and which will allow quick removal and installation of the currently FUNCTION ENABLE buttons available quick change platforms The following procedures describe platform removal and installation Platform Removal 1 Remove both lower mount pins securing the lower plat form support rail to the platform lower mount 2 Remove both upper mount pins securing the upper plat form support rail to the platform upper mount 3 Using either suitable lifting equipment capable of lifting the weight of the mounted platform or another person swing the lower platform support rail forward away from the mast to clear the platform lower mount then lift the upper platform support rail up and out of the platform upper mount Move the platform clear of the machine and carefully set the platform on its base out of the way Platform Installation 1 Using either two people or suitable lifting equipment capa ble of lifting the weight of the unmounted platform lift the platform and set the platforms upper support rail into the upper platform mount on the mast 3121212 JLG Lift 4 7 SECTION 4 MACHINE OPERATION 2 Swing the platform lower support rail into the lower plat form mount on the mast 3 Secure the platform support
41. face If AC powered machine connect machine to a grounded AC receptacle with a heavy duty extension cord equipped with an equipment grounding conductor Also the cord must be capable of handling the maximum amperage draw of the machine s electric pump motor If DC powered machine be sure battery box assembly is installed battery is charged and connected to the machine s DC input receptacle Set power on off key switch to the ON position at the ground control station Check both emergency stop switches one on platform control station and one on ground control station that they are in the reset position for operation Check if manual descent control valve is closed Set floor brake see steps following Floor Brake Operation 1 To Set Floor Brake Push Down till Pedal Locks in Place JLG Lift Figure 4 4 Setting amp Releasing Floor Brake 2 To Release Floor Brake Push Down on Release Rod At the front of the machine under the base frame engage and lock the floor brake down into position SECTION 4 MACHINE OPERATION A WARNING THE FRONT CASTER WHEELS SHOULD BE RELIEVED OF THE MACHINES WEIGHT ENOUGH SO THE MACHINE DOES NOT ROLL IN ANY DIRECTION IF THIS IS NOT THE CASE DO NOT ATTEMPT TO ELE VATE THE PLATFORM UNTIL THE FLOOR BRAKE IS OPERATING PROPERLY 2 To disengage the floor brake apply pressure to the release rod or lift up on the floor brake pedal Platform Loadi
42. ger 4 DC Battery to Machine Main 5 When ready to charge the CHARGER ON LED and the Power Connector INCOMPLETE CHARGE 25 LED on the front panel of 3121212 JLG Lift 4 3 SECTION 4 MACHINE OPERATION the charger will light up the charger will then begin to charge the batteries 6 When the battery cell voltage reaches 2 37 V cell the 80 CHARGE LED will light up The charger then continues to monitor the increase in charge until it sees no increase and then terminates the charging process 7 The CHARGE COMPLETE 10096 LED will light when the batteries are fully charged 8 Unplug the charger AC power cord and stow the cord Abnormal Cycle Indicator LED The ABNORMAL CYCLE indicator LED will light when The AC input to the charger was interrupted There is a dead cell or cells in the battery One or more of the battery connectors are loose or corroded Figure 4 3 Dual Voltage Charger Front Panel 96 of Charge in Progress 4 Circuit AC Circuit Breakers LED s Green 5 AC Voltage Selection Charger On LED Green Switch Abnormal Cycle LED Yellow 4 4 JLG Lift 3121212 SECTION 4 MACHINE OPERATION 4 4 MACHINE SET UP AND OPERATION The following sequence of set up procedures must be followed to safely operate this machine 1 NOTE 3121212 Position machine in work area Work area must be a smooth firm level sur
43. hen power is removed from the equipment or until the Supervisor changes the Operator s code JLG Lift 5 7 SECTION 5 OPTIONAL EQUIPMENT LBS NOTES JLG Lift 3121212 SECTION 6 EMERGENCY PROCEDURES SECTION 6 EMERGENCY PROCEDURES 6 1 This section explains the steps to be taken in case of an emer gency situation while operating the machine General Information 6 2 Emergency Operation Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE USE THE FOLLOWING INSTRUCTIONS AS A GUIDELINE 1 Other personnel should operate the machine from ground controls only as required 2 Only qualified personnel 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 3121212 JLG Lift Platform Caught Overhead If the platform becomes jammed or snagged in overhead struc tures or equipment rescue the platform occupant prior to freeing the machine Righting of Tipped Machine Before righting a tipped machine check machine for any damage which may prevent it from setting properly on its base wheels once in a vertical position i e base wheels damaged base frame distorted etc Use a crane forklift or othe
44. hing the machine around on its base wheels Transport with a forklift truck using the forklift pockets in the baseframe or to lift onto a transport vehicle Transporting by Pushing NOTICE CAREFULLY REVIEW ALL SAFETY PRECAUTIONS NOTED IN SECTION 1 TRANSPORTING BEFORE ATTEMPTING TO MOVE MACHINE The 15AMI machine s base frame is equipped with load bearing wheels mounted on a straight axle at the mast end of the machine and a pair of heavy duty swivel caster wheels mounted on the frame at the platform end of the machine It is important to closely follow the instructions mentioned in the fol lowing WARNING note to ensure safe transport of unit when pushing SECTION 4 MACHINE OPERATION A WARNING FAILURE TO HEED THE FOLLOWING INSTRUCTIONS COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING MOVED WHICH COULD RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNED OR CRUSHED BY UNIT WALK BEHIND THE UNIT TO PUSH AND STEER USING THE HANDLES ON THE MAST CROSSBAR ON A LEVEL SURFACE ALWAYS TRAVEL WITH THE PLAT FORM END LEADING THE WAY ON A SLOPE ALWAYS TRAVEL WITH THE PLATFORM END ON THE LOW SIDE OF THE SLOPE TWO PEOPLE ARE REQUIRED ON SLOPES UP TO 5 DEGREES A FORKLIFT MUST BE USED WHEN MOVING UNITS ON SLOPES GREATER THAN 5 DEGREES NEVER POSITION THE UNIT SIDEWAYS ON A SLOPE DO NOT MOVE UNIT ON SOFT OR UNEVEN SURFACES OR OVER OBSTRUCTIONS BUMPS DEBRIS ETC BEFORE MOVING
45. il platform has been safely restrained from any movement by blocking or overhead sling Before making adjustments lubricating or performing any other maintenance shut off all power controls Battery should always be disconnected during replace ment of electrical components Keep all support equipment and attachments stowed in their proper place Use only approved nonflammable cleaning solvents 3121212 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is neces sary that it be operated and maintained only by trained personnel Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control 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 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 3121212 JLG Lift 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles
46. intenance NOTE This information applies to wet cell batteries only Do not attempt to open a maintenance free sealed battery The battery fluid level should be approximately 1 8 3mm below vent tubes See Illustration Keep cable connections clean and free of corrosion A CAUTION BATTERY ACID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING ALLOW NO OPEN FLAMES SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA ADD ONLY DISTILLED WATER TO BATTERIES WHEN ADDING DIS TILLED WATER TO THE BATTERIES A NON METALLIC CONTAINER AND OR FUNNEL MUST BE USED 7 6 JLG Lift Battery Fluid Level 1 Battery Filler Cap3 Fluid Level 2 Vent Tube4 Cell Plates 3121212 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Lubrication Table 7 1 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 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 or MIL Spec MIL L 2105 HO Hydrauli
47. k Change Platform 5 1 Chanaina the O tors Cod 5 7 25 x 26 Step in Molded Platform anging the Operator s Code w Swing up 5 1 26 x 50 Quick Change ExtendiblePlatform SECTION SO EMERGENCY PROCEDURES aa pese bei DS utara te Eoi s dae hel 5 1 6 1 6 1 Fluorescent Tube 5 1 6 2 EMERGENCY OPERATION 6 1 ii JLG Lift 3121212 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE Operator Unable to Control Machine 6 1 Platform Caught 6 1 Righting of Tipped Machine 6 1 6 3 INCIDENT NOTIFICATION 6 2 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7 1 1 7 1 7 2 GENERAL SPECIFICATIONS 7 2 Machine Specifications 7 2 Electrical Specifications 7 8 Platform Data 7 4 Machine Component Weights 7 5 Serial Number Locations 7 5 7 8 OPERATOR 7 6 Battery Maintenance 7 6 Lubrication onn Rer a 7 7 7 4 SUPPLEMENTAL 7 10 SECTION 8 INSPECT
48. n Platform Is Being Raised Or Lowered Check Clearances Above On Sides And Bottom Of Plat form When Raising And Lowering Platform Death or Serious Injury Could Occur from a Tip Over Never Use The Mast To Gain Access To Or Leave Platform 1 8 JLG Lift 3121212 SECTION 1 SAFETY PRECAUTIONS Do Not Attach Overhanging Loads To The Platform Or Increase The Platform Size With Unauthorized Deck Extensions Or Attachments Do Not Tie Off Machine To Any Adjacent Structure Never Attach Wire Cable Or Any Similar Items To Platform Transfers Between A Structure And The Platform Expose Operators To Fall Potentials This Practice Should Be Dis couraged Wherever Possible Where Transfer Must Be Accomplished To Perform The Job Two Lanyards Will Be Used And The Platform Must Be Within 1 Foot 0 3 M Of The Adjacent Safe And Secure Structure One Lanyard Should Be Attached To The Platform The Other To The Structure The Safety Lanyard That Is Attached To The Platform Should Not Be Disconnected Until Such Time As The Transfer To The Structure Is Complete Do Not Allow Personnel To Tamper With Service Or Oper Falling from Platform could cause ate This Machine From The Ground With Personnel In Death or Serious Injury Platform Except In An Emergency No Horseplay Is Permitted In Platform During Platform Operation Keep All Body Parts Inside Plat When Working From Platform Both Feet Must Be Firmly form
49. ng The platform maximum rated load capacity is shown on a plac ard located on the platform control panel and is based upon the following criteria Maximum capacity for each model is as follows Table 4 1 Maximum Platform Capacity PLATFORM CAPACITY MODEL All Platforms Extendible Platform Except Extendible Option 15AMI AC DC 350 Ib 160 kg 30016 135 kg JLG Lift Platform Operation A WARNING DO NOT ATTEMPT TO RAISE THE PLATFORM UNLESS THE FLOOR BRAKE IS PROPERLY SET AND MACHINE IS ON A SMOOTH FIRM LEVEL SURFACE BEFORE AND WHILE RAISING THE PLATFORM CHECK CLEARANCES ABOVE AND AROUND PLATFORM AND MAST TO ENSURE ADEQUATE CLEARANCE OF SURROUNDING OBJECTS AND PERSONNEL 1 Enter platform and close the gate slide bar NOTE On platform control box the FUNCTION ENABLE green button must be depressed simultaneously with either the PLATFORM UP or PLATFORM DOWN button in order for these functions to work 2 To raise the platform up depress the FUNCTION ENABLE BUTTON green and PLATFORM UP button top white button on the platform control panel simultaneously Upon reaching desired elevation level release PLATFORM UP and FUNCTION ENABLE buttons A WARNING ENSURE AREA BENEATH PLATFORM IS FREE OF PERSONNEL AND OBSTRUCTIONS PRIOR TO LOWERING PLATFORM 3121212 SECTION 4 MACHINE OPERATION 3 To lower platform depress FUNCTION ENABLE BUTTON 4 5 QUICK CHANGE PLATFORM gre
50. r suitable lifting equip ment and carefully lift the machine to an upright postion FOLLOWING ANY INCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS DO NOT LIFT ABOVE 10 FEET 3 METERS UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 6 1 SECTION 6 EMERGENCY PROCEDURES 6 3 Incident Notification JLG Industries Inc must be notified immediately of any incident involving a JLG product Even if no injury or property damage is evident the factory should be contacted by telephone and pro vided with all necessary details JLG Phone USA 877 JLG SAFE 554 7233 8am till 4 45pm EST EURO 011 44 1 698 811005 AUSTRALIA 011 61 265 811111 Email USA productsafety jlg com Failure to notify the Manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine 6 2 JLG Lift 3121212 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7 1 INTRODUCTION This section of the manual provides additional necessary informa tion to the operator for proper operation and maintenance of this machine 3121212 The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only and does not replace the mo
51. re thorough Preventive Mainte nance and Inspection Schedule included in the Service and Main tenance Manual OTHER PUBLICATIONS AVAILABLE SPECIFIC TO THIS MACHINE Service And Maintenance Manual Illustrated Parts Manual ANS bien eH aed 3120752 3120753 3120872 3120873 JLG Lift 7 1 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7 2 GENERAL SPECIFICATIONS Machine Specifications SPECIFICATION 15AMI Gross Machine Weight Platform Empty DC 970 lb 440 kg Machine Height Platform Stowed AC 900 Ib 408 kg 78 25in 1 9 m Machine Base Overall Width x Length 29in W x47 in L 74 cmx 119 cm Maximum Wind Speed 0 mph Okph Machine rated for indoor use only Maximum Horizontal Manual Side Force Platform fully extended with Maximum load 45 Pound Force 200 Newtons Maximum Hydraulic System Pressure Pressure Relief Set at 1500 to 1700PSI 193 bar at Factory 7 2 JLG Lift 3121212 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Electrical Specifications 3121212 SPECIFICATION 15AMI System Voltage DC Models 12 Volts DC AC Models 100 120 240 Volts AC Battery Specifications applies to all DC models Battery Type WET DRY COMBO AGM VRLA Voltage 12 Volts DC Amp Hour AH Rating 105 AmpHr 20 Hr 100 AmpHr 20
52. release cable on the front of the platform assembly 2 Nextlift the gate high enough to enter the platform Step into the platform when completely inside platform lower the gate until it s closed and the gate lock pin is engaged and locked To EXIT platform 1 Repeat above steps and exit the platform Extending Platform Refer to Figure 5 2 1 Locate the two platform extend handles 1 one located each side of platform on the vertical rails at the back of the platform 2 2 Grasp each extend handle and pull the handle 1 up to a horizontal position releasing it from the spring clamp Face the mast 4 and pull the extend handles to extend the platform extension forward away from mast 5 3 Slide the platform extension forward until it s completely extended 5 and the extend handles line up with the spring clamps on the vertical rail at the opposite end of the platform 1 3121212 SECTION 5 OPTIONAL EQUIPMENT 4 Next fold the extend handles down until they lock into the spring clamps on the vertical rail 1 this will lock the platform extension in place Retracting Platform Refer to Figure 5 2 1 3121212 To retract the platform grasp the extend handles now located at the middle of the extended platform on the vertical rail 1 Pull up on each handle to a horizontal position to clear the handle spring clamps Retract the platform extension by standing on the rear mast platfo
53. rm section and pulling the extend handles 1 toward the mast 4 you may need to pull the han dles halfway then turn and push them the rest of the way to fully retract the platform extension When both extend handles line up with the handle spring clamps 2 on the vertical rail at the rear of the platform fold the handles 1 down locking them into the spring clamps 2 JLG Lift Figure 5 2 Extendible Platform 5 5 SECTION 5 OPTIONAL EQUIPMENT 5 3 Progammable Security Lock PSL Option 1 The optional keyless Programmable Security Lock switch be ns 3 programmed with a four 4 digit operators code to allow only those persons with the code to power up and operate the machine PSL Box Location Tele end D 2 h A 24 Figure 5 4 PSL Switch Controls amp Indicators Figure 5 3 PSL Switch Location 1 ON Green LED 4 Key Pad 2 ACCEPT Amber LED 5 OFF Button 1 PSL Switch 2 Back of Mast Assembly 3 PROGRAM Red LED 6 ON Button 5 6 JLG Lift 3121212 SECTION 5 OPTIONAL EQUIPMENT Machine Power Up using the PSL NOTE 4 When entering code on the keypad a short beep indi cates
54. s Mast 3121212 SECTION 1 SAFETY PRECAUTIONS Electrocution Hazard 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 carrying up to 50 000 volts One foot 0 3m additional clearance is required for every additional 30 000 volts or less 3121212 JLG Lift Table 1 1 Minimum Approach Distance M A D VOLTAGE RANGE MINIMUM APPROACH PHASE TO PHASE DISTANCE Feet m 0 50KV 10 3 Over 50KV to 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 Approach Distance shall apply except where employer local or governmental reg ulations are more stringent The minimum approach distance may be reduced if insulating bar riers are installed to prevent contact and if the barriers are rated for the voltage of the line being guarded These barriers shall not be part of or attached to the machine The minimum approach distance shall be reduced to a distance within the designed work ing dimensions of the insulating barrier This determination shall be made by a qualified person in accordance with employer local or governmental requirements for work practices near energized equipment SECTION 1 SAFETY PRECAUTIONS gt All Personnel Must Stand Clear Whe
55. s Weights 4 10 Lubrication 5 7 7 Lubrication Intervals for Various Components 7 9 Inspection and Repair Log 8 1 JLG Lift PAGE 3121212 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section prescribes the proper and safe practices for major areas of machine usage which have been divided into three basic categories Transporting Pre Operation and Operation In order to promote proper usage of the machine it is mandatory that a daily routine be established based on instruction given in this section A maintenance program must also be established by a qualified per son and must be followed to ensure that the machine is safe to operate 3121212 JLG Lift The user operator of the machine should not accept operating responsibility until this manual has been READ and UNDER STOOD and operating instructions of the machine under the supervision of an experienced and qualified operator has been completed If there is a question on application and or operation JLG Industries Product Safety and Reliability Department should be consulted A WARNING MODIFICATION OF THE MACHINE WITHOUT APPROVAL OF JLG INDUS TRIES INC OR CERTIFICATION BY A NATIONALLY RECOGNIZED TEST ING LAB TO BE IN CONFORMITY WITH APPLICABLE OSHA REGULATIONS AND TO BE AT LEAST AS SAFE AS BEFORE MODIFICA TION IS PROHIBITED AND IS A VIOLATIO
56. vided in order 1 to turn machine power on and off in the platform and also to turn off machine power in the event of an emergency ESSI Power is on when the switch is in the reset position turned completely clockwise out Power is off and all machine functions will stop when button is depressed a 3 2 FUNCTION ENABLE Button __ MAXIMUM CA This GREEN button must be depressed simultaneously 4 with either the UP or DOWN platform function buttons in order to operate the platform 3 PLATFORM UP Button When depressed simultaneously with ENABLE button Figure 3 3 Platform Control Station ises the platform to a higher level Det ee A da 1 Emergency Stop RED 3 Function Enable GREEN 4 PLATFORM DOWN Button 2 Platform UP WHITE 4 Platform DOWN WHITE When depressed simultaneously with ENABLE button low ers the platform to a lower level 3 4 JLG Lift 3121212 SECTION 3 MACHINE CONTROLS amp INDICATORS JS NOTES 3121212 JLG Lift 3 5 SECTION 3 MACHINE CONTROLS amp INDICATORS 3 3 DECAL INSTALLATIONS
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