JLG LiftPod FS60 Operation, Safety, Service And Maintenance Manual Download Page 81

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SECTION 6 - SERVICE AND MAINTENANCE

LIFTPOD by JLG

1001070465

6-9

6.5

REPLACEMENT KITS OVERVIEW

The following details the various replacement kits that can be

ordered from your Authorized JLG Service Center.

Figure 6-1. Replacement Kits

12.

15.

14.

13.

10.

16.

11.

17.

19.

21.

22. 23. 24. 25.

Go to Discount-Equipment.com

to order your parts

Summary of Contents for LiftPod FS60

Page 1: ...nd Maintenance Manual English Keep this manual with the machine at all times LIFTPOD by JLG LiftPod Models FS80 FS60 P N 1001070465 24 October 2011 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 3: ...This page intentionally left blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 4: ...operators lessors and lessees with the precautions and operat ing procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc JLG reserves the right to make specification changes without prior notification G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 5: ...S INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES 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 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 po...

Page 6: ...SONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT NOTICE JLG INDUSTRIES INC SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORDS OF THIS MACHINE CONTACT JLG INDUSTRIES INC TO INSURE THAT THE OWNER RECORDS ARE UPDATED AND ACCURATE For Accident reporting Product safety publica tions Current owner updates Questions regarding product safety Standards and regulati...

Page 7: ...ue of Manual 24 July 2009 Revised 14 August 2009 Revised 28 August 2009 Revised 18 December 2009 Revised 4 April 2011 Revised 12 April 2011 Revised 10 May 2011 Revised 24 October 2011 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 8: ...e Start Inspection 2 4 2 3 DAILY WALK AROUND INSPECTION 2 4 Walk Around Inspection Components 2 5 Tool Tray Pre Start Inspection 2 9 2 4 FUNCTION CHECK 2 10 Function Check Items 2 10 SECTION 3 MACHINE OPERATION 3 1 GENERAL 3 1 3 2 MACHINE DESCRIPTION 3 1 Detailed Description 3 2 Platform Configuration 3 3 Mast Carriage Components 3 4 3 3 MACHINE OPERATION 3 4 General 3 4 Getting Started 3 5 Assemb...

Page 9: ...ed 5 10 Optional Powerpack Electrical Specifications 5 11 Platform Data 5 12 Interchangeable Modules 5 13 Machine Component Weights 5 14 Serial Number Locations 5 14 5 4 SUPPLEMENTAL INFORMATION 5 14 SECTION 6 SERVICE AND MAINTENANCE 6 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 6 1 General 6 1 Maintenance Safety 6 2 6 2 MACHINE PREPARATION INSPECTION AND MAINTENANCE 6 3 General 6 3 Preparation ...

Page 10: ...h shown engaged 2 8 2 8 Location of manual descent crank 2 8 2 9 Tool tray installation 2 9 3 1 Main components 3 1 3 2 Base frame component description FS80 3 2 3 3 Base frame component description FS60 3 3 3 4 Platform component description 3 3 3 5 Mast carriage component description 3 4 3 6 Carriage mast to base mounting 3 6 3 7 Castor lock 3 6 3 8 Detail view of level bubble 3 6 3 9 Attaching ...

Page 11: ...lation CE FS80 5 6 5 4 Carriage Mast Decal Installation CE FS60 5 7 5 5 Platform Decal Installation CE 5 8 5 6 Powerpack Decal Installation CE 5 9 6 1 Replacement Kits 6 9 6 2 Replacement Kits for 30FS Base 6 10 6 3 Drum view through inspection window 6 14 6 4 Rope alignment through carriage 6 15 6 5 Loose rope being re tensioned 6 15 LIST OF TABLES 1 1 Minimum Approach Distances M A D 1 5 2 1 Ins...

Page 12: ...and understand the manufacturer s operating instruction s and user s safety rules or have them explained 2 Understand all labels warnings and instructions dis played on the machine or have them explained 3 Ensure all occupants of the machine wear appropriate personal protection equipment PPE for the conditions including the environment in which the machine will be operated If there are any questio...

Page 13: ... 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 trail ers railway cars floating vessels scaffolds or other equip ment unless approved in writing by JLG This machine can be operated in temperatures of 0 C to 40 C 32 F to 104 F Consu...

Page 14: ...wn the machine and contact JLG 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 Oper ate controls with slow and even pressure Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform except in an emergency Do not carry materials dire...

Page 15: ... Hazard Do not enter or leave the platform while elevated JLG recommends that the operator utilises a fall restraint system in the platform with a maximum 36 inch 91 4cm lanyard attached to the authorised lanyard anchorage point For further information regarding fall protection requirements on JLG products contact JLG Before operating the machine make sure all railings and gates are fastened in th...

Page 16: ...energized exposed or insulated parts according to the Minimum Approach Distance MAD as shown in Table 1 1 Allow for machine movement and electrical line swaying Maintain a clearance of at least 10 ft 3m between any part of the machine and its occupants their tools and their equipment from any electrical line or apparatus car Table 1 1 Minimum Approach Distances M A D VOLTAGE RANGE PHASE TO PHASE M...

Page 17: ...ing 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 DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping Hazards Only elevate the platform on a firm and level surface Check that the ...

Page 18: ...stribute loads evenly on platform floor and tool tray Keep the base of the machine a minimum of 0 6m 2 ft from holes bumps drop offs obstructions debris con cealed 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 unauthorised exten sions or attachments increasing...

Page 19: ... under a raised platform Position barricades on floor as necessary 1 4 MOVING LIFTING AND REPOSITIONING General Never allow personnel in platform while moving lifting or reposi tioning the machine This machine shall not be towed by a vehicle Ensure platform is fully retracted and completely empty of tools prior to disassembly lifting or hauling Remove powerpack and tool tray if fitted from platfor...

Page 20: ...ontrols in the platform and emergency controls 2 Decals instructions and warnings on the machine 3 Employer and government regulations 4 Correct assembly of the machine 5 Use of approved fall protection device 6 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 7 The safest means to operate the machine where over head obstructions othe...

Page 21: ...ce recommended by JLG Consult local regulations for any further requirements The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile envi ronment if the machine is used with increased frequency or if the machine is used in a severe manner G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 22: ...nualand applicableJLGLiftPod inspection form Annual Machine Inspection Every12 months Owner DealerorUser Qualified Mechanic Operation Safety Service Maintenance Manualand applicableJLGLiftPod inspection form 5Year Replacement Whenropeiswornornomorethan5yearsfrom firstuse Referto Figure2 4 forwear criteria Owner DealerorUser Authorized JLG Service Centre FactoryTraining NOTE Use thismanualtoperform...

Page 23: ...ction 3 4 7 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 2 4 for more specific instructions 2 3 DAILY WALK AROUND INSPECTION Begin the Walk Around Inspection at item one 1 as noted on the diagram Figure 2 1 Continue around machine checking each item in sequence for the c...

Page 24: ...lean and secure 3 Mast Assembly No cracks or corrosion especially around base and flange no excess wear kinks nicks or damage carriage running surfaces smooth and unob structed free of dust oil grease 4 Carriage Frame check for visible cracks check rollers for visible wear check carriage frame welds for visible cracks see Figure 2 2 5 Gearbox check for any oil leaks especially around bottom shaft ...

Page 25: ...raiding no longer visible 3 Sections of rope thinned down in diameter 8 Manual Descent Crank Ensure it is present and securely attached Figure 2 8 9 Powerpack and Control Console optional Ensure it is properly mounted and secured Button triggers and switches not obscured or damaged decals secure and legible emergency stop switch reset for operation con trol markings legible Battery is installed an...

Page 26: ...t page for Tool Tray Pre Start Inspec tion Procedure Figure 2 4 Examples of new acceptable and unacceptable ropes Figure 2 5 Ropes retained in mast cap Figure 2 6 Rope anchor points Check both ropes are retained in groove in cap Mast Mast Cap Check that each termination is engaged under its anchor point by viewing through the cover The two upper rope tails should be slack The lower rope loop shoul...

Page 27: ...ARATION AND INSPECTION 1001070465 LIFTPOD by JLG 2 8 Figure 2 7 Platform latch shown engaged Figure 2 8 Location of manual descent crank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 28: ...curely on the platform rail No cracks or bends in tray Both of the clips are securely attached to the platform rail Figure 2 9 Capacity decal is in place and legible Maximum Load The maximum permissible load on the tool tray is 15kg 33 lb evenly distributed Figure 2 9 Tool tray installation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 29: ...Items 1 Base Brake Step on base to ensure the swivel castor retracts properly 2 Adjustable Feet Check both rotate freely up and down check that rubber pads are installed and not excessively worn 3 Emergency Stop Button optional powerpack ensure all machine functions are disabled when the emergency stop button is activated pressed in then RESET the emergency stop button by twisting it in the direct...

Page 30: ...iftPod is a battery powered portable personnel platform The platform is mounted to a mast and elevating carriage mecha nism The personnel lift s intended purpose is to provide person nel access to areas above level ground The platform must only be elevated on a firm level uniform surface The machine consists of seven parts 1 Base Frame FS80 base shown 2 Carriage Mast Assembly 3 Platform 4 Powerpac...

Page 31: ...ees of level from front and back only Prior to operation the adjustable feet are to be engaged to a point where the base is level as seen on the level bubble Figure 3 8 The base of the FS60 machine consists of two rotating castors and two adjustable feet Prior to operation the adjustable feet are to be engaged to a point where the base is level as seen on the bubble level Also the castor wheels mu...

Page 32: ...ests Mast Stump Level Bubble Retracting Castor Release Lever FRONT travel stops Step Plate Rotating castor Figure 3 4 Platform component description Platform Swing Gates Mounting Pin Authorized Lanyard Anchorage Point Platform Locator Platform Latch Mounting Pin Powerpack Mounts Powerpack Latch Mount Manual Storage Compartment other side G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e ...

Page 33: ... further rotation of the rope drum and engaging a carriage lock down latch onto the mast IN THE EVENT THAT THE CARRIAGE LATCHES TO THE MAST WHEN FULLY LOADED OR THE ROPE CONTINUES TO FEED OUT AFTER THE PLATFORM HAS REACHED THE REST POSITION THE MACHINE IS NOT WORKING PROPERLY AND MUST NOT BE USED UNTIL IT IS INSPECTED AND REPAIRED BY A QUALIFIED PERSON NOTE Do not attempt to lift the mast off the ...

Page 34: ...ure 3 1 DO NOT ATTEMPT TO ASSEMBLE OR USE A MAST ONTO A BASE FOR WHICH IT IS NOT INTENDED EACH MAST HAS A V SHAPED GROOVE ALONG ITS LENGTH WHICH WILL FIT WITHIN THE GROOVE ON A BASE STUMP FOR WHICH IT IS INTENDED ALWAYS ENSURE THE MAST IS FULLY INSERTED ONTO THE BASE STUMP PRIOR TO OPERATION 1 Position the base frame on a firm level uniform sup porting surface 2 Push down on the base frame s step ...

Page 35: ...ge mast to base mounting PUSH DOWN Adjustable Foot Adjustable Foot Figure 3 7 Castor lock Figure 3 8 Detail view of level bubble PUSH DOWN Locking Tab Level Bubble Rotating Knob adjusts foot height G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 36: ...re aligned with the holes in the carriage A then drop slowly down to seat properly Ensure the platform locator B is properly engaged in the bottom of the carriage frame Make sure the platform latch C is fully engaged CHECK Try to lift the platform out if it does not release then the platform has engaged properly Figure 3 9 Attaching the platform to the carriage Fully Engaged Figure 3 10 Platform a...

Page 37: ...s drill to the top of the drive shaft either using the supplied 7 16 11mm deep well drive socket located in manual pouch or by tightening the drill chuck directly to the hexagon on top of the driveshaft see Figure 3 11 CORDLESS DRILL LANYARD MUST BE INSTALLED BEFORE ELEVATING DO NOT DROP DRILL Figure 3 11 Cordless drill installation Driveshaft Drive Socket Lanyard Cordless Drill optional Manual Po...

Page 38: ...ck from the platform 9 Tool tray optional equipment Place on top rail of platform and fasten the two clips firmly around the rail see Figure 2 9 THE WEIGHT OF OBJECTS CARRIED IN A PLATFORM ACCESSORY ALONG WITH PERSONNEL AND EQUIPMENT PLACED IN THE PLATFORM MUST NOT EXCEED THE MAXIMUM RATED PLATFORM CAPACITY SEE TABLE 5 4 DO NOT PLACE ITEMS IN THE TOOL TRAY IN THE INDICATED AREA WHEN MAST IS BELOW ...

Page 39: ...Machine Reverse the above steps to disassemble the machine DO NOT ATTEMPT TO LIFT THE MAST OFF THE BASE UNLESS THE CAR RIAGE HAS BEEN FULLY LOWERED Figure 3 13 Tool tray load restriction NO LOAD AREA G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 40: ...ance will be limited at low temperatures The battery can be charged and discharged hundreds of times but will eventually wear out and need to be replaced A significantly reduced operat ing period after charging indicates that the battery must be replaced Battery Charge Status Lights The powerpack batteries indicates battery low voltage at three 3 warning levels Figure 3 14 Battery charging plug an...

Page 41: ...not fit the power outlet use an attachment plug adaptor of the proper configuration for the power outlet If the supply cord is damaged it must be replaced by a special cord or assembly available from the manufacturer or its service agent See Section 6 Unless the battery is being charged always remove the battery from the fast charger Figure 3 16 Removing the battery from the powerpack Pull and lif...

Page 42: ...ASHING RED Please reinsert battery If the red light continues to flash the battery or the charger may be faulty To troubleshoot whether the battery or the charger is at fault insert another battery If this battery charges the other battery is faulty and must not be used If the red light continues to flash the charger is faulty 3 5 Operation Cordless Drill 1 Drive Socket optional 2 Chuck 3 Torque C...

Page 43: ...Do not set to maximum torque setting USE ONLY CORDLESS DRILLS DISCONTINUE USE OF THE CORDLESS DRILL IF A FAULT IS DETECTED ENSURE CORDLESS DRILL IS IN DRILL MODE ON MEDUIM TO HIGH TORQUE SETTING BUT NOT MAX IMUM TORQUE SETTING TO AVOID INJURY Powerpack Control Console Optional Equipment 1 Enable Trigger 2 Battery Release Latch 3 Battery Trickle Charge Plug 4 Emergency Stop Button 5 Direction Selec...

Page 44: ...NE LIGHT COMES ON REPLACE WITH FULLY CHARGED BATTERY NOTICE IF THE POWERPACK DOES NOT ACTIVATE WITH A CHARGED BATTERY INSTALLED THE EMERGENCY BUTTON MAY NEED TO BE RESET TWIST IN DIRECTION OF ARROWS AND POP OUT Elevating Make sure the pre start inspection has been completed the machine is safe to use and the base is level Move the cordless drill s direction selector to the screw in clock wise dire...

Page 45: ...y resets itself when the motor has cooled down allowing normal operation to resume Depending on ambient temperature this can take 5 to 30 minutes Engaging the triggers to run the cooling fan will decrease the ther mal reset time The manual descent procedure Section 4 1 can be used to lower the platform if required Do not attempt to elevate with no load in the platform The platform has a total capa...

Page 46: ...selector to the DOWN position Hold the handle so the enable trigger is pressed and squeeze the speed trigger To stop at anytime simply release the speed trigger To exit the platform ensure the platform is all the way down until it touches down on the base This will engage the drive mecha nism s overdrive ratchet making a ratcheting sound This means the platform has reached its lowest position and ...

Page 47: ... the platform operator to lower the platform in the event that the cordless drill or powerpack batteries run out of sufficient charge to lower the platform Allow ground personnel to lower the platform in event that the platform operator becomes incapacitated For emergency operation please see Section 4 Emergency Pro cedures Figure 3 23 Emergency stop button operation Press down to activate Rotate ...

Page 48: ...d pushed around the floor using the wheels and castor Fully assembled tilted over Disassembled with each major component carried sepa rately Fully Assembled Maneuvering There are two ways to move the assembled machine PUSHED UPRIGHT The machine can be pushed around using the built in wheels and castor The floor is required to be smooth level clean and dry There can be no significant load on the ma...

Page 49: ...can be tilted over and maneuvered as shown in Figure 3 25 FULLY ASSEMBLED THROUGH DOORWAY The FS60 can be tilted back and pushed through a doorway as shown in Figure 3 26 NOTE Ensure powerpack and tool tray are securely attached and tool tray and platform are empty before moving Figure 3 25 Maneuvering when tilted back Figure 3 26 Maneuvering FS60 through doorway G o t o D i s c o u n t E q u i p ...

Page 50: ...ering The machine is designed to be used and assembled by a single operator To improve portability it is divided into a number of self contained sub assemblies see Figure 3 1 TAKE PRECAUTIONS TO AVOID MANUAL HANDLING INJURIES USE PROPER LIFTING TECHNIQUES BEND AT KNEES ONLY NEVER TWIST YOUR BACK WHEN HOLDING OR CARRYING A LOAD AND OR GET HELP ONLY CARRY ONE COMPONENT AT A TIME The mast carriage as...

Page 51: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 52: ...E MAY ACCUMU LATE ICE GREASE OR AIRBOURNE DEBRIS Vehicle Transport When transporting the machine by vehicle it should be disassem bled into its major components see Figure 3 1 and each compo nent secured separately Restrain each component of the machine securely during transport Ensure the swivel castor is retracted in the base frame and the base frame is resting on the adjustable feet NOTICE USE ...

Page 53: ... TO ELEVATE THE PLATFORM OR FOR GENERAL OPERATIONS IF THE BATTERIES ARE DISCHARGED WHILE THE UNIT IS ELEVATED DO NOT CLIMB OUT OF THE PLATFORM USE THE MANUAL DESCENT CRANK Discharged Battery If the battery should run out of charge before the platform has fully descended 1 Remove the cordless drill and place it inside the plat form If the optional powerpack is installed remove it and place it sidew...

Page 54: ...e or control the machine other personnel should operate the machine from ground using the manual descent crank on the lower facing shaft stub Figure 4 1 Manual descent crank operation from inside platform Figure 4 2 Manual descent crank operation from outside platform Shaft Stub G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 55: ...R THE MACHINE FROM BELOW WHEN USING THE LANYARD DO NOT ACTIVATE THE POWERPACK WHILE THE MANUAL DESCENT CRANK IS ATTACHED 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 Rescue equipment can be used to remove the platform occupant Cranes and forklifts can be used to stabilize motion of ...

Page 56: ...ACEMENT SHALL ONLY BE CARRIED OUT BY AN AUTHO RIZED JLG SERVICE CENTER Double Rope Failure If both ropes fail while the platform is elevated the emergency brake will activate automatically locking the carriage to the mast In this condition the manual descent crank cannot be used to lower the platform Operator elevated in Platform Platform will not lower If the operator cannot lower the platform to...

Page 57: ...volving a JLG Liftpod product within 48 hours of such an occurrence may void any warranty consideration on that particular machine NOTICE FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS DO NOT ELEVATE PLATFORM UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY G o t o D i s c o u n t E q u i p m e n t c o m t ...

Page 58: ...SECTION 4 EMERGENCY PROCEDURES 1001070465 LIFTPOD by JLG 4 6 This page intentionally left blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 59: ...A4 Step PlateDecal 1001070280 A5 GeneralBrand 1001070281 A6 ContactBranding Base CE 1001070449 BASE 30FS B1 Crushing Hazard ISO 1001070325 B2 Bubble Level ISO 1001070327 B3 30FS BaseCrushHazard ISO 1001071388 B4 30FS StepPlateDecal 1001071387 B5 GeneralBrand 1001070281 B6 LockWheels 30FS ISO 1001070428 B7 ContactBrandingBase CE 1001070449 MAST CARRIAGE FS80 C1 Patent 1001070307 C2 Manual Descent I...

Page 60: ...6 Cowling SideBrand 1001070410 D7 FS60MastBranding 1001070444 D8 GeneralBrand 1001070281 No CE JLG Part Number PLATFORM E1 Capacity ISO 1001070301 E2 Tipping ISO 1001070321 E3 PlatformWarning Chevrons 1001070409 E4 PlatformLatchRelease ISO 1001070461 E5 Drill Instructions ISO 1001070464 E6 Electrocution ISO 1001070322 E7 Read Manual ISO 1001070323 E8 FSQuickstartGuide ISO 1001070459 E9 Manual CE 1...

Page 61: ...Housing ISO 1001070456 F6 PowerpackInstructions ISO 1001070457 F7 BatteryChargerFront ISO 1001070458 F8 BatteryLatchInstructions ISO 1001070460 F9 BatteryWarning ISO 1001070462 F10 Fast ChargerBack ISO 1001070463 F11 BatteryCharger Branding 1001070408 F12 GeneralBrand 1001070281 ACCESSORY TRAY G1 ToolTray ISO 1001070434 No CE JLG Part Number G o t o D i s c o u n t E q u i p m e n t c o m t o o r ...

Page 62: ...L SPECIFICATIONS 1001070465 LIFTPOD by JLG 5 4 Figure 5 1 Base Decal Installation CE FS80 FS80 Base Serial Number A1 A1 A6 A2 A3 A5 A4 A6 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 63: ...PECIFICATIONS LIFTPOD by JLG 1001070465 5 5 Figure 5 2 Base Decal Installation CE 30FS B1 B1 B6 B6 B2 B3 B5 B4 B7 B7 30FS Base Serial Number G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 64: ...IONS 1001070465 LIFTPOD by JLG 5 6 Figure 5 3 Carriage Mast Decal Installation CE FS80 C1 C3 C7 C2 FS80 Mast Carriage Serial Number C4 C5 C6 C6 C8 C8 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 65: ...IONS LIFTPOD by JLG 1001070465 5 7 Figure 5 4 Carriage Mast Decal Installation CE FS60 D1 D3 D4 D2 FS60 Mast Carriage Serial Number D5 D6 D6 D6 D8 D8 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 66: ...CATIONS 1001070465 LIFTPOD by JLG 5 8 Figure 5 5 Platform Decal Installation CE E1 E3 E3 E3 E8 Platform Serial Number G1 E6 E2 E4 E7 E5 E9 E11 E10 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 67: ...D by JLG 1001070465 5 9 Figure 5 6 Powerpack Decal Installation CE F1 F2 F10 F3 F4 F5 F6 F11 F8 Powerpack Serial Number Fast Charger Serial Number F9 F7 F12 F12 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 68: ... 2 37m 7ft9in MaximumPlatformFloor Height 2 32m 7ft7in 1 71m 5ft7in 1 71m 5ft7in MaximumWindSpeed 5m sec 18kph 5m sec 18 kph 5m sec 18kph MaximumWorking Height typicalperson 4 32m 14ft4in 3 71m 12ft2in 3 71m 12ft2in Machine Overall Footprint 1 250mmx1 040mm 4ft1inx3ft5in 1 100mmx 760mm 3ft7inx 2ft6in 1 250mmx1 040mm 4ft1inx3ft5in Rated Horizontal Force 100N 22lb 100N 22lb 100N 22lb ForAustralia Ne...

Page 69: ...es athigh and low ambienttemperature BatterySpecifications BatteryType NickelMetalHydride Voltage 28 8Volts DC Amp Hour AH Rating 4 5Ah Weight 2 3kg 5lb BatteryFast Charger Input 110 240VoltsAC 2 2A 50 60Hz FC1001071732 Output 28 8VoltsDC 2 5A w AutoChargeSensingCircuit Approvals UL cUL CE Table 5 3 Optional Powerpack Electrical Specifications G o t o D i s c o u n t E q u i p m e n t c o m t o o ...

Page 70: ...001070465 LIFTPOD by JLG 5 12 Platform Data SPECIFICATION FS80 Occupants PersonsallowedinPlatform 1 PlatformCapacity CE 150kg 330lb Table 5 4 Platform Data G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 71: ...rm FS80B 30FSB FS80M FS60M AT PP Platform FS80B 30FSB FS80M FS60M AT PP Module Abbreviation Name of Module Part Number FS80B FS80Base 1001071599 ForAustraliathe FS80 Mast CarriagePart Numberis1001071193 ForAustraliatheFS60 Mast CarriagePart Numberis1001071194 30FSB 30FS FS60Base 1001071485 FS80M FS80Mast Carriage 1001071197 FS60M FS60Mast Carriage 1001071416 AT AccessoryTray 1001071725 PP Powerpac...

Page 72: ...ered machines the equivalent continuous A Weighted sound pressure level at the work platform is less than 70dB A 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 SPECIFICATION WEIGHT BaseFrame FS80 25 2kg 55 4lb BaseFrame 30FS 21 5k...

Page 73: ... BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT Due to continuous product improvement JLG reserves the right to make specification changes without prior notification MODIFICATION OF THE MACHINE WITHOUT THE MANUFACTURERS APPROVAL IS A PROHIBITED PRACTICE AND A DIRECT SAFETY VIOLA TION Your sa...

Page 74: ...QUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAUTION AND OTHER INSTRUCTIONS ON MACHINE AND IN OPERA TION SAFETY SERVICE MAINTENANCE MANUAL KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING BEFORE MAKING ADJUSTMENTS OR PERFORMING ANY OTHER MAINTENANCE SHUT...

Page 75: ...om pletion procedures for the Pre Start Inspection The manual must be read in its entirety and understood prior to performing the Pre Start Inspection Frequent and Pre Delivery Inspection The Frequent Inspection and Pre Delivery Inspection shall be per formed by a competent person or a qualified mechanic The Frequent Inspection and Pre Delivery Inspection procedures are performed in the same manne...

Page 76: ...NTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the ...

Page 77: ... proper tolerances 12 Check proper and authorized components installed 13 Verify 14 Perform 15 Replace 16 Inspect per Service and Maintenance Manual Area on Machine Interval Pre StartInspection Pre DeliveryorFrequent Inspection Annual Yearly Inspec tion 5Year Inspection Priorto useeachday or ateachoperatorchange Priorto eachsale lease ordelivery inservicefor 3monthsor more or purchasedused Actuall...

Page 78: ... Platform 1 5 1 5 1 3 4 5 7 PlatformLatch 1 7 1 3 6 7 1 3 6 7 PlatformGates 1 7 1 3 5 7 1 3 5 7 LanyardAnchor 3 4 3 4 BaseFrame 3 4 5 3 4 5 3 4 5 Adjustable Feet 1 1 3 7 1 3 7 BubbleLevel 1 7 1 7 1 7 Wheels 1 3 7 1 3 7 1 3 7 Powerpack optional 1 3 1 3 7 1 3 7 Switches Controls 1 1 3 7 1 3 7 Speed Safety Triggers BatteryChargeTestButton 1 8 1 3 7 8 1 3 7 8 G o t o D i s c o u n t E q u i p m e n t ...

Page 79: ...Placards Installed Secure Legible 13 13 13 MachineInspection orRope ReplacementDue 16 16 14 15 No UnauthorizedModifications orAdditions 13 13 AllRelevantSafetyPublicationsIncorporated 13 13 General Structural ConditionandWelds 13 3 4 3 4 AllFasteners Pins Shieldsand Covers 13 1 3 Function Testofall Systems 14 14 14 PaintandAppearance 2 5 2 5 RecordInspection DateinLog Book 14 NotifyJLGof MachineOw...

Page 80: ...ng a portion of the equipment ensure that adequate support is provided Cleanliness The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components Precautions have been taken to safeguard against this However these items must be maintained on a scheduled basis in order to function properly DO NOT LUBRICATE THE MACHIN...

Page 81: ...OVERVIEW The following details the various replacement kits that can be ordered from your Authorized JLG Service Center Figure 6 1 Replacement Kits 2 1 3 4 5 8 12 15 14 13 10 9 16 11 6 17 7 19 21 22 23 24 25 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 82: ...astor Wheel Kit JLG Part No 1001071561 11 Rope JLG service only JLG Part No 1001071257 12 Accessory Tray Kit JLG Part No 1001071725 13 Plastic Cowlings Kit JLG Part No 1001071250 14 Carriage Handle Kit JLG Part No 1001071251 15 Fixed Wheel Kit FS80 base 2 wheels per kit JLG Part No 1001071560 16 Level Bubble Kit JLG Part No 1001071563 17 Lower Rear Roller Kit JLG Part No 1001071252 18 Replacement ...

Page 83: ...No 1001070578 Drill Strap Kit JLG Part No 1001071361 Drill Socket Kit JLG Part No 1001071362 Replacement Pouch Rivets JLG Part No 1001071339 Decal Kit Powerpack CE JLG Part No 1001071345 Manuals NOTE Following items refer to the FS80 Operation Safety Ser vice and Maintenance Manual CE not pictured NOTE Not all language Manuals or Country Kits may be avail able Contact your local JLG location for m...

Page 84: ... Country Kits CE not pic tured Country Kit UK JLG Part No 1001070548 Country Kit French JLG Part No 1001070549 Country Kit German JLG Part No 1001070550 Country Kit Dutch JLG Part No 1001070551 Country Kit Italian JLG Part No 1001070552 Country Kit Spanish JLG Part No 1001070553 Country Kit Finnish JLG Part No 1001070554 Country Kit Swedish JLG Part No 1001070555 Country Kit Norwegian JLG Part No ...

Page 85: ...al Replacement All decals must be mounted to the machine as specified and be clearly legible Please see Figure 5 1 to Figure 5 4 and refer to Table 5 1 for positions and JLG part numbers To replace a damaged decal first remove it completely without damaging the underlying surface Remove any remaining adhesive with a suitable solvent Test sol vent on inconspicuous area first to ensure it does not m...

Page 86: ...as described below shall be noted and then a determination made if further use would constitute a hazard Mast ropes must be replaced after machine has been in service for five 5 years regardless of rope condition or sooner if condi tions dictate This must only be conducted by a Authorized JLG Service Center Conditions such as the following shall be sufficient reason for questioning continual use o...

Page 87: ...ation the rope is always taut and should never come loose Should the rope lose tension say through incorrect transport or storage it must be corrected before next use Figure 6 4 Rope alignment through carriage Incorrect tangled DO NOT USE Correct OK to use Figure 6 5 Loose rope being re tensioned G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 88: ... will wind up the slack rope 5 Re check proper rope alignment Figure 6 3 and Figure 6 4 Both ropes must be tight If ropes are not tight contact an Authorized JLG Service Center 6 Install platform and cordless drill or optional power pack Use applicable safety precautions to enter the platform safely Raise the platform 50mm 2 inch to reset the emergency brake and then lower the platform to bottom o...

Page 89: ... where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowl edge of the equipment and related systems It should be recognised that the majority of the problems arising in the machine will be centred in the power system For this reason every effort has been made to ensure that all likely problems in these areas are given the fulle...

Page 90: ...y Alternativelyusemanualdescentproceduretolower platform Section 4 1 Platformdoes notliftup frombottomof travel motor starts Driveshaft interlock isengaged Pushcordlessdrill ondriveshaftdownfirmlyto disengagedriveshaftsafetyinter lock Ifusingpowerpack Powerpackdriveshaftnot engaged Checkpowerpack iscorrectly fitted toplatform latch isdown anddriveshaft is connected tocarriagedrive shaft Emergency ...

Page 91: ...atform will not lower Ifcarriageisnotwithin1m 3ft ofthe baseof themastcontactAuthorizedJLG ServiceCenter Ifcarriage iswithin 1m 3ft fromground applyloadin platform driveup1 thendrivedown Ropesareloose ropesmust neverbe loose Machinewas disassembledwithoutplatform beingfullyloweredtoengagethe carriage lock down latch Carriagethen movedupthemast loosening theropes Ifcarriageisnotwithin1m 3ft ofthe b...

Page 92: ...ssure onto frontofbase Castorshould retract Adjustablefeetshould thenbeabletobeused to level themachine on slopesless than 2degreesfrontto back Donotusethe machineonanysideslope Machinerocksslightlyside to side Supportsurfaceisnotlevel Only use themachine on firmandlevel surfaces Adjustable feetarenotBOTHin contactwith supportingsurface Adjustthe feet sothatBOTHfeetare infirm contactwithsupporting...

Page 93: ...Troubleshooting Platform will notliftfull ratedload Batterynotfullycharged Chargeorreplace battery Overloadclutchisslipping ContactAuthorized JLGServiceCenter TROUBLE PROBABLE CAUSE REMEDY G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 94: ...SECTION 7 TROUBLESHOOTING 1001070465 LIFTPOD by JLG 7 6 This page intentionally left blank G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 95: ...CTION AND REPAIR LOG LIFTPOD by JLG 1001070465 8 1 SECTION 8 INSPECTION AND REPAIR LOG 8 1 Inspection and Repair Log Table Date Comments G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 96: ...SECTION 8 INSPECTION AND REPAIR LOG 1001070465 LIFTPOD by JLG 8 2 Table 8 1 Inspection and Repair Log Date Comments G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 97: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

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JLG LiftPod FS60, Operation, Safety, Service And Maintenance Manual

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