JLG LiftPod FS80 Operation, Safety, Service And Maintenance Manual Download Page 6

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FOREWORD

1001070451

LIFTPOD by JLG

1-877-254-3876

www.liftpod.com

1-877-2-LIFTPOD

REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . . . . . . May 14, 2008

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 04, 2008

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . September 25, 2008

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . September 29, 2008

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . February 11, 2009

FS.book Page d Wednesday, February 11, 2009 11:54 AM

Summary of Contents for LiftPod FS80

Page 1: ...enance Manual ANSI CSA Keep this manual with the machine at all times 1 877 254 3876 LIFTPOD by JLG 1 877 2 LIFTPOD www liftpod com LiftPod Model FS80 P N 1001070451 February 11 2009 FS book Page 1 We...

Page 2: ...This page intentionally left blank FS book Page 2 Wednesday February 11 2009 11 54 AM...

Page 3: ...provide owners users 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 produc...

Page 4: ...IF NOT AVOIDED COULD RESULT IN SERIOUS 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 M...

Page 5: ...N SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13244 Fountainhead Plaza Hagerstown MD 21742 USA In USA T...

Page 6: ...254 3876 d www liftpod com 1 877 2 LIFTPOD REVISION LOG Original Issue of Manual May 14 2008 Revised June 04 2008 Revised September 25 2008 Revised September 29 2008 Revised February 11 2009 FS book P...

Page 7: ...erator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 2 3 DAILY WALK AROUND INSPECTION 2 4 Walk Around Inspection Components 2 5 Tool Tray Pre Start Inspect...

Page 8: ...INCIDENT NOTIFICATION 4 5 SECTION 5 GENERAL SPECIFICATIONS 5 1 INTRODUCTION 5 1 5 2 DECAL INSTALLATION 5 1 5 3 GENERAL SPECIFICATIONS 5 8 Machine Specifications assembled 5 8 Optional Powerpack Electr...

Page 9: ...l descent crank 2 8 2 9 Tool tray installation 2 9 3 1 Main components 3 1 3 2 Base frame component description 3 2 3 3 Platform component description 3 3 3 4 Mast carriage component description 3 3 3...

Page 10: ...Carriage Mast Decal Installation ANSI 5 5 5 3 Platform Decal Installation ANSI 5 6 5 4 Powerpack Decal Installation ANSI 5 7 6 1 Replacement Kits 6 9 6 2 Drum view through inspection window 6 12 6 3...

Page 11: ...operator shall 1 Read and understand the manufacturer s remanufac turer s operating instruction s and user s safety rules or have them explained 2 Understand all labels warnings and instructions dis...

Page 12: ...mental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all haz ards in the work area prior to machine operation Do not ope...

Page 13: ...king properly If a malfunction occurs shut down 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 befor...

Page 14: ...ork platform is less than 70dB A Trip and Fall 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...

Page 15: ...rom electrical lines apparatus or any 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 M...

Page 16: ...ance within the designed work ing dimensions of the insulating barrier This determina tion shall be made by a qualified person in accordance with employer local or governmental requirements for work p...

Page 17: ...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 D...

Page 18: ...nnel not to work stand or walk 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...

Page 19: ...egulations 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...

Page 20: ...inspections and maintenance recommended by JLG Consult local regulations for further requirements for aerial work platforms The frequency of inspections and maintenance must be increased as necessary...

Page 21: ...eration Safety Service Maintenance Manualand applicableJLGLiftPod inspection form Annual Machine Inspection Every12months Owner Dealer orUser Qualified Mechanic Operation Safety Service Maintenance Ma...

Page 22: ...ection Refer to Section 2 3 6 Powerpack Charge as required Section 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...

Page 23: ...se Frame Check for cracks or corrosion especially around the mast stump base see Figure 2 2 Check level bubble is clean and secure 3 Mast Assembly No cracks or corrosion especially around base and fla...

Page 24: ...Figure 6 2 Ensure it is seated cor rectly over mast cap Figure 2 5 and at anchor point at back of mast Figure 2 6 Indications that rope needs replacement include 1 Frayed or fluffy rope Figure 2 4 2...

Page 25: ...orrosion visible 11 Tool Tray See next 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...

Page 26: ...D INSPECTION 1001070451 LIFTPOD by JLG 1 877 254 3876 2 8 www liftpod com 1 877 2 LIFTPOD Figure 2 7 Platform latch shown engaged Figure 2 8 Location of manual descent crank FS book Page 8 Wednesday F...

Page 27: ...k the following Tool tray is seated securely 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 legi...

Page 28: ...D SAFE FOR OPERATION Function Check 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 inst...

Page 29: ...on and operation 3 2 MACHINE DESCRIPTION The JLG LiftPod is a battery powered aerial work platform The platform is mounted to a mast and elevating carriage mechanism The personnel lift s intended purp...

Page 30: ...tracts out of ground contact when loaded The base of the machine consists of two fixed wheels and two adjustable feet for leveling and stabilizing the base within 2 degrees of level from front and bac...

Page 31: ...uthorized Lanyard Anchorage Point Platform Locator Platform Latch Mounting Pin Powerpack Mounts Powerpack Latch Mount Manual Storage Compartment other side Figure 3 4 Mast carriage component descripti...

Page 32: ...empt to lift the mast off the base unless the car riage has been fully lowered Getting Started The following control conditions must be met before the machine can be operated from the platform control...

Page 33: ...PING ON BASE TO RETRACT CASTOR 3 Turn the adjustable feet until the level bubble is centred see Figure 3 6 DO NOT USE THE MACHINE IF THE BASE CAN NOT BE LEVELLED Figure 3 5 Carriage mast to base mount...

Page 34: ...ke sure the platform s mounting pins are 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...

Page 35: ...the cord less drill Attach the cordless 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...

Page 36: ...ile lifting to disengage the powerpack from the platform 8 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 OBJEC...

Page 37: ...w liftpod com 3 9 Disassembly of the 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 11 Too...

Page 38: ...attery performance 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 i...

Page 39: ...EFULLY FOL LOW THESE INSTRUCTIONS If the shape of the plug does not fit the power outlet use an attachment plug adaptor of the proper configuration for the power outlet Unless the battery is being cha...

Page 40: ...to flash the charger is faulty Power Supply Cord Below is the specification of the power supply chord to be used with the fast charger within the U S A Use UL listed detachable power supply cord No 18...

Page 41: ...Drill mode on medium to high torque 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 O...

Page 42: ...ARGE INDICATOR TEST BUTTON IF ONLY ONE 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...

Page 43: ...omatically 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...

Page 44: ...rigger 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...

Page 45: ...ee Section 4 Emergency Pro cedures 3 6 TRANSPORT AND MANEUVERING MOVING General The machine may be manually maneuvered or transported in a vehicle disassembled DO NOT ATTEMPT TO TRANSPORT OR MOVE MACH...

Page 46: ...r will retract automatically Lift the handle to engage the swivel castor The machine is easily positioned as required The swivel castor underneath the step plate toggles out of the way when loaded and...

Page 47: ...BEING THROWN BY THE MOVING WEIGHT OF THE MACHINE Disassembled Maneuvering The machine is designed to be used and assembled by a single operator To improve portability it is divided into a number of s...

Page 48: ...n the adjustable feet NOTICE DO NOT STORE IN LOCATIONS WHERE THE MACHINE MAY ACCUMU LATE ICE GREASE OR AIRBOURNE DEBRIS Vehicle Transport When transporting the machine by vehicle it should be disassem...

Page 49: ...OSS OF POWER ONLY IT MUST NOT BE USED 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 DESCE...

Page 50: ...is pinned trapped or unable to operate 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 des...

Page 51: ...CK 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...

Page 52: ...SUPPORTED BY A SIN GLE ROPE ROPE REPLACEMENT 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 wi...

Page 53: ...es Inc 13244 Fountainhead Plaza Hagerstown MD 21742 USA In USA Toll Free 877 JLG SAFE 877 554 7233 Outside USA Phone 717 485 6591 E mail ProductSafety JLG com Failure to notify the manufacturer of an...

Page 54: ...SECTION 4 EMERGENCY PROCEDURES 1001070451 LIFTPOD by JLG 1 877 254 3876 4 6 www liftpod com 1 877 2 LIFTPOD This page intentionally left blank FS book Page 6 Wednesday February 11 2009 11 54 AM...

Page 55: ...SI 1001070306 A2 BubbleLevel ANSI 1001070413 A3 BaseCrushHazard ANSI 1001070438 A4 Step PlateDecal 1001070280 A5 GeneralBrand 1001070281 A6 MaxWheel Load ANSI 1001070310 A7 BarcodeBase 1001070418 Repl...

Page 56: ...ckstart Guide 1001070415 C9 Manual 1001070451 C10 BarcodePlatform 1001070417 No ANSI JLG Part Number Replacement Decal Kit POWERPACK ANSI 100 107 1602 D1 PowerpackSocketWarning 1001070400 D2 E Stop 10...

Page 57: ...liftpod com 5 3 Table 5 1 Decal Descriptions D12 GeneralBrand 1001070281 D13 BarcodePowerpack 1001070420 D14 BarcodeCharger 1001070421 Replacement Decal Kit ACCESSORY TRAY ANSI 100 107 1358 E1 ToolTr...

Page 58: ...RAL SPECIFICATIONS 1001070451 LIFTPOD by JLG 1 877 254 3876 5 4 www liftpod com 1 877 2 LIFTPOD Figure 5 1 Base Decal Installation ANSI A7 A1 A1 A6 A6 A2 A3 A5 A4 FS book Page 4 Wednesday February 11...

Page 59: ...SPECIFICATIONS 1 877 254 3876 LIFTPOD by JLG 1001070451 1 877 2 LIFTPOD www liftpod com 5 5 Figure 5 2 Carriage Mast Decal Installation ANSI B1 B3 B2 B8 B4 B5 B6 B7 B7 S book Page 5 Wednesday February...

Page 60: ...IFICATIONS 1001070451 LIFTPOD by JLG 1 877 254 3876 5 6 www liftpod com 1 877 2 LIFTPOD Figure 5 3 Platform Decal Installation ANSI C1 C3 C3 C3 C8 C10 E1 C6 C2 C4 C7 C5 C9 FS book Page 6 Wednesday Feb...

Page 61: ...IONS 1 877 254 3876 LIFTPOD by JLG 1001070451 1 877 2 LIFTPOD www liftpod com 5 7 Figure 5 4 Powerpack Decal Installation ANSI D1 D2 D10 D3 D4 D5 D6 D11 D8 D13 D14 D9 D7 D12 D12 S book Page 7 Wednesda...

Page 62: ...cations assembled SPECIFICATION FS80 GrossMachineWeight withoutoptionaltooltrayorpowerpack 64 8kg 142 9lb MachineHeight 2 97m 9ft9in MaximumPlatformFloorHeight 2 32m 7ft7in MaximumWind Speed 12 5m sec...

Page 63: ...PECIFICATION FS80 Batteries Powerpack 28 8VoltsDC NominalDutyCycle 4 cyclesper15minutes reduces athigh and low ambienttemperature BatterySpecifications BatteryType NickelMetalHydride Voltage 28 8Volts...

Page 64: ...POD by JLG 1 877 254 3876 5 10 www liftpod com 1 877 2 LIFTPOD Platform Data Table 5 4 Platform Data SPECIFICATION FS80 Occupants PersonsallowedinPlatform 1 PlatformCapacity ANSI C S A 150kg 330lb FS...

Page 65: ...cations For machine component identification serial number barcode decals are affixed to the various modules The barcodes are located as indicated in Figure 5 1 to Figure 5 4 SPECIFICATION FS80 BaseFr...

Page 66: ...SECTION 5 GENERAL SPECIFICATIONS 1001070451 LIFTPOD by JLG 1 877 254 3876 5 12 www liftpod com 1 877 2 LIFTPOD This page intentionally left blank FS book Page 12 Wednesday February 11 2009 11 54 AM...

Page 67: ...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 res...

Page 68: ...TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAUTION AND OTHER INSTRUCTIONS ON MACHINE AND IN OPERA TION SAFETY SERVICE MAINTENANCE MANUAL KEEP STANDING SURFACES A...

Page 69: ...perator Reference Section 2 in this manual for com pletion procedures for the Pre Start Inspection The manual must be read in its entirety and understood prior to performing the Pre Start Inspection F...

Page 70: ...equipment mechanic 6 3 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basi...

Page 71: ...ear and or proper routing 11 Check for proper tolerances 12 Check proper and authorized components installed 13 Verify 14 Perform 15 Replace 16 Inspect per Service and Maintenance Manual Area on Machi...

Page 72: ...12 1 3 12 CarriageRollers 3 7 3 7 11 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 Base Frame 3 4 5 3 4 5 3 4 5 Adjustable Feet 1...

Page 73: ...nualin StoragePouch 13 13 13 AllDecals Placards Installed Secure Legible 13 13 13 MachineInspection orRopeReplacementDue 16 16 14 15 No Unauthorized Modifications orAdditions 13 13 AllRelevant SafetyP...

Page 74: ...st in an unstable position When raising 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...

Page 75: ...ww liftpod com 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 2 3 1 4 5 6...

Page 76: ...ray Kit JLG Part No 1001071725 14 Plastic Cowlings Kit JLG Part No 1001071250 15 Carriage Handle Kit JLG Part No 1001071251 16 Fixed Wheel Kit 2 wheels per kit JLG Part No 1001071560 17 Level Bubble K...

Page 77: ...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 Rem...

Page 78: ...any loss of original strength such 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 servi...

Page 79: ...the mast 3 Rope Loose In normal operation 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...

Page 80: ...ear a ratchet ing noise and the drum will wind up the slack rope 5 Re check proper rope alignment Figure 6 2 and Figure 6 3 Both ropes must be tight If ropes are not tight contact an Authorized JLG Se...

Page 81: ...ble causes and the remedial action should 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 rela...

Page 82: ...ature cutoutresets itselfautomatically Alternativelyusemanual descentproceduretolower platform Section 4 1 Platformdoes notliftup frombottomof travel motor starts Driveshaft interlock isengaged Pushco...

Page 83: ...Machinewas disassembledwithoutplatform beingfullyloweredtoengagethe carriage lock downlatch Carriagethen movedupthemast loosening theropes Ifcarriageisnotwithin1m 3ft ofthe baseof themastcontactAuthor...

Page 84: ...cksslightlyside to side Supportsurfaceisnotlevel Only use themachine on firmandlevel surfaces Adjustable feetarenotBOTHin contactwith supportingsurface Adjustthe feet sothatBOTHfeetare infirm contactw...

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Page 86: ...13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Bo...

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JLG LiftPod FS80, Operation, Safety, Service And Maintenance Manual

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