JLG GM Engine Supplements User Manual

ANSI / CSA

Operation, Safety, Service

and Maintenance Manual

Keep this manual with the machine at all times.

LiftPod Models FS80 & FS60

1-877-254-3876 LIFTPOD by JLG

1-877-2-LIFTPOD www.liftpod.com

P/N - 1001070451

May 10, 2011

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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. (JLG) reserves the right to make specification changes without prior notification. Contact JLG for updated information.

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FOREWORD

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

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD DECAL WILL HAVE AN ORANGE BACKGROUND.

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RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

RESULT IN MINOR OR MODERATE INJURY. IT MAY

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

NOTICE

TINS. CONTACT JLG OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

JLG 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.

For:

• Accident reporting

• Product safety publications

• Current owner updates

• Questions regarding product safety

• Standards and regulations compliance information

• Questions regarding special product applications

• Questions regarding product modifications

Contact:

Product Safety and Reliability Department JLG Industries, 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

or your local JLG office (see addresses on manual’s rear cover)

FOREWORD

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FOREWORD

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

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . December 02, 2010

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 10, 2011

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operator Training and Knowledge . . . . . . . . . . . 1-2

Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazard . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards . . . . . . . . . . . . . 1-7

1.4 MOVING, LIFTING AND REPOSITIONING. . . . . . . 1-8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Additional Safety Information . . . . . . . . . . . . . . . 1-8

SECTION - 2 - PREPARATION AND INSPECTION

2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 DAILY WALK-AROUND INSPECTION . . . . . . . . . . 2-4

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2.4 FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . . . . 2-10

SECTION - 3 - MACHINE OPERATION

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . 3-1

3.3 MACHINE OPERATION. . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 POWERPACK (OPTIONAL EQUIPMENT). . . . . . . 3-11

3.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Walk-Around Inspection Components . . . . . . . . 2-5

Tool Tray Pre-Start Inspection. . . . . . . . . . . . . . . 2-9

Function Check Items . . . . . . . . . . . . . . . . . . . . 2-10

Detailed Description . . . . . . . . . . . . . . . . . . . . . . 3-2

Platform Configuration. . . . . . . . . . . . . . . . . . . . . 3-3

Mast/Carriage Components . . . . . . . . . . . . . . . . 3-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Assembly of the Machine . . . . . . . . . . . . . . . . . . 3-5

Disassembly of the Machine . . . . . . . . . . . . . . . 3-10

Battery Charging Operation. . . . . . . . . . . . . . . . 3-11

Battery Charge Status Lights. . . . . . . . . . . . . . . 3-11

Charging the Batteries Using the Fast Charge

Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Fast Charge Indicator Light Guide . . . . . . . . . . 3-13

Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . 3-13

Cordless Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Powerpack Control Console (Optional

Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Elevating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Descending . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Powerpack Emergency Stop/Shutdown Button 3-18

Unpowered Descent . . . . . . . . . . . . . . . . . . . . . 3-18

3.6 TRANSPORT AND MANEUVERING (MOVING) . . 3-19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Fully Assembled Maneuvering . . . . . . . . . . . . . 3-19

Disassembled Maneuvering . . . . . . . . . . . . . . . 3-21

Parking and Storage . . . . . . . . . . . . . . . . . . . . . 3-22

Vehicle Transport. . . . . . . . . . . . . . . . . . . . . . . . 3-22

SECTION - 4 - EMERGENCY PROCEDURES

4.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 4-1

Manual Descent Crank . . . . . . . . . . . . . . . . . . . . 4-1

Discharged Battery . . . . . . . . . . . . . . . . . . . . . . . 4-1

Operator Unable to Control Machine . . . . . . . . . 4-2

Platform Caught Overhead . . . . . . . . . . . . . . . . . 4-3

Rope Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . 4-5

SECTION - 5 - GENERAL SPECIFICATIONS

5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 DECAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . 5-10

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SECTION - 6 - SERVICE AND MAINTENANCE

6.1 INTRODUCTION - MAINTENANCE SAFETY

6.2 MACHINE PREPARATION, INSPECTION AND

6.3 PREVENTIVE MAINTENANCE AND INSPECTION

6.4 SERVICING AND MAINTENANCE GUIDELINES . 6-8

Machine Specifications (assembled) . . . . . . . . . 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

PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . 6-2

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Preparation, Inspection, and Maintenance . . . . . 6-3

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . 6-3

Frequent and Pre-Delivery Inspection . . . . . . . . .6-3

Annual Machine Inspection . . . . . . . . . . . . . . . . . 6-3

5 Year Machine Inspection & Rope

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . 6-4

SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Safety and Workmanship . . . . . . . . . . . . . . . . . . 6-8

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Component Disassembly and Reassembly . . . . 6-8

6.5 REPLACEMENT KITS OVERVIEW . . . . . . . . . . . . . 6-9

6.6 DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . 6-12

6.7 MAST ROPE INSPECTION PROCEDURE . . . . . 6-13

1. Rope Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

2. Rope Misaligned . . . . . . . . . . . . . . . . . . . . . . 6-13

3. Rope Loose . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

SECTION - 7 - TROUBLESHOOTING

7.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Troubleshooting Information . . . . . . . . . . . . . . . 7-1

SECTION - 8 - INSPECTION AND REPAIR LOG

8.1 INSPECTION AND REPAIR LOG TABLE . . . . . . . . 8-1

LIST OF FIGURES

1-1. Read your manual . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2-1. Daily Walk-Around Inspection (Sheet 1 of 2) . . . . . 2-5

2-2. Examples of cracks . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3. Daily Walk-Around Inspection (Sheet 2 of 2) . . . . . 2-6

2-4. Examples of new, acceptable and unacceptable

ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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2-5. Ropes retained in mast cap . . . . . . . . . . . . . . . . . . 2-7

2-6. Rope anchor points . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-7. Platform latch 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 the platform to the carriage . . . . . . . . . . 3-7

3-10. Platform attachment checks . . . . . . . . . . . . . . . . . . 3-7

3-11. Cordless drill installation . . . . . . . . . . . . . . . . . . . . . 3-8

3-12. Powerpack positioned and latched into place . . . . 3-9

3-13. Tool tray load restriction . . . . . . . . . . . . . . . . . . . . 3-10

3-14. Battery charging plug and tester . . . . . . . . . . . . . 3-11

3-15. Charge status lights . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-16. Removing the battery from the powerpack . . . . . 3-12

3-17. Recharge dock operations and indicators . . . . . . 3-12

3-18. Typical cordless drill interface devices . . . . . . . . . 3-13

3-19. Powerpack control console . . . . . . . . . . . . . . . . . 3-14

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

3-20. Cordless drill elevation . . . . . . . . . . . . . . . . . . . . . 3-15

3-21. Detail view of direction selector . . . . . . . . . . . . . . 3-16

3-22. Detail view of enable & speed triggers . . . . . . . . . 3-16

3-23. Emergency stop button operation . . . . . . . . . . . . 3-18

3-24. Activate the handle to extend the swivel castor . . 3-19

3-25. Maneuvering when tilted back . . . . . . . . . . . . . . . 3-20

3-26. Maneuvering FS60 through doorway . . . . . . . . . . 3-20

3-27. Mast/carriage handle . . . . . . . . . . . . . . . . . . . . . . 3-21

3-28. Moving base through a door . . . . . . . . . . . . . . . . 3-21

4-1. Manual descent crank operation from inside

platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Manual descent crank operation from outside

platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-3. Releasing the drive interlock using the lanyard . . . 4-3

5-1. Base Decal Installation - ANSI - FS80. . . . . . . . . . . 5-4

5-2. Base Decal Installation - ANSI - FS60. . . . . . . . . . . 5-5

5-3. Carriage/Mast Decal Installation - ANSI - FS80 . . . 5-6 5-4. Carriage/Mast Decal Installation - ANSI - FS60 . . . 5-7

5-5. Platform Decal Installation - ANSI . . . . . . . . . . . . . . 5-8

5-6. Powerpack Decal Installation - ANSI . . . . . . . . . . . 5-9

6-1. Replacement Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-2. Replacement Kits for 30FS Base . . . . . . . . . . . . . 6-10

6-3. Drum view through inspection window . . . . . . . . 6-13

6-4. Rope alignment through carriage. . . . . . . . . . . . . 6-14

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6-5. Loose rope being re-tensioned . . . . . . . . . . . . . . .6-14

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

2-1 Inspection and Maintenance Table . . . . . . . . . . . . .2-3

5-1 Decal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2 Machine Specifications (assembled) . . . . . . . . . . 5-10

5-3 Optional Powerpack Electrical Specifications. . . . 5-11

5-4 Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-5 Interchangeable Modules . . . . . . . . . . . . . . . . . . . 5-13

5-6 Module Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-7 Machine Component Weights . . . . . . . . . . . . . . . .5-14

6-1 Preventative Maintenance & Inspection Schedule .6-7

7-1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

8-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . .8-2

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

Before operation, the operator shall:

1. Read and understand the manufacturer’s (remanufacturer’s) operating instruction(s) and user’s safety rules or have them explained.

2. Understand all labels, warnings and instructions displayed on the aerial platform or have them explained.

3. Ensure all occupants of the aerial platform wear appropriate personal protection equipment (PPE) for the conditions, including the environment in which the aerial platform will be operated.

If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG.

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FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SECTION 1 - SAFETY PRECAUTIONS

1.2 PRE-OPERATION

Figure 1-1. Read your manual

Operator Training and Knowledge

• Do not operate this machine until complete training is performed by authorised persons.

• Only authorised and qualified personnel can operate the machine.

• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.

• Use the machine in a manner which is within the scope of its intended application set by JLG.

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

• Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.

• This machine can be operated in temperatures of 0°C to 40°C (32°F to 104°F). Consult JLG for operation outside this range. Machine performance may vary from published specification in very hot or cold conditions.

Machine Inspection

• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for further instructions.

• Do not operate this machine until it has been serviced and maintained according to requirements specified in accordance with this manual.

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SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.

• Avoid any build up of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

General

• Do not use the machine for any purpose other than positioning personnel, their tools and equipment.

• Never operate a machine that is not working 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 before moving the switch to the next function. Operate controls with slow and even pressure.

• Do not allow personnel to tamper with, or operate the machine from the ground with personnel in the platform, except in an emergency.

• Do not carry materials directly on platform railing unless approved by JLG.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• Fully lower platform and shut off all power before leaving machine.

• No riders are permitted on the machine. Only the operator is permitted in the machine during operation.

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SECTION 1 - SAFETY PRECAUTIONS

• Do not allow ropes to contact surfaces with a temperature higher than 60°C/140°F

• When performing welding, cutting or grinding operations, avoid direct contact of heat, sparks and debris with the ropes and carriage drive assembly.

• Charge batteries only in a well ventilated area.

This machine is a powered personnel lift equipped with a work platform that travels up and down a mast. Vibrations emitted by this machine is not hazardous to an operator in the work platform. The equivalent continuous A-Weighted sound pressure level at the work platform is less than 70dB(A).

Trip and Fall Hazard

• Do not enter or leave the platform while elevated.

MAX = 36 in (91.4cm)

• 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 their proper position.

• Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach.

• Never use the mast assembly to enter or leave the platform.

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SECTION 1 - SAFETY PRECAUTIONS

• Use extreme caution when entering or leaving the platform. Ensure that the mast assembly is fully lowered. Face the machine when entering or leaving the platform.

• Always maintain "three point contact" with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

Electrocution Hazard

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

• Maintain distance from 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.

Table 1-1. Minimum Approach Distances (M.A.D.)

VOLTAGE RANGE

(PHASE TO PHASE)

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 requirement shall apply except where empl oyer, local, or gov-

ernmental regulations are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus car-

MINIMUM SAFE APPROACH

DISTANCE - Feet (Meters)

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SECTION 1 - SAFETY PRECAUTIONS

rying up to 50,000 volts. One foot (0.3m) additional clearance is required for every additional 30,000 volts or less.

• The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact, and if the 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 safe approach distance shall be reduced to a distance within the designed working 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.

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 two wheels and the two adjustable feet are in contact with the ground prior to using the machine. Adjust the front feet to eliminate any base frame movement and check the bubble level indicates level prior to use.

• Ensure castor wheels are locked (if equipped).

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SECTION 1 - SAFETY PRECAUTIONS

• Do not perform work that will subject unit to a horizontal force or create a swaying motion of the platform.

• Do not elevate in windy conditions. See Table 5-2 Machine Specifications

• The user should be familiar with the operating surface.

• Do not elevate platform while on a slope, or on an uneven or soft surface.

• Before using on floors, bridges, and other surfaces, check allowable capacity of the surfaces.

• Never exceed the maximum platform capacity. Distribute 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, concealed holes, and other potential hazards at the ground level.

• Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure.

• Do not increase the platform size with unauthorised extensions or attachments, increasing the area exposed to wind will decrease stability.

• If mast assembly or platform is caught so that one or more wheels are off the ground, the operator must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel.

Crushing and Collision Hazards

• Appropriate personal protection equipment must be worn by all operating and ground personnel.

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SECTION 1 - SAFETY PRECAUTIONS

• Check work area clearances above, on sides, and bottom of platform while moving, lifting or lowering platform.

• During operation keep all body parts inside platform railing.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Ensure that operators of other overhead and floor level machines are aware of the aerial work platform's presence. Disconnect power to overhead cranes.

• Warn personnel 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 repositioning 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 platform when transporting in a vehicle.

Refer to the Machine Operation section of this manual for lifting information.

Additional Safety Information

• Do not use machine as ground for welding.

• Keep all naked flames and sharp edges away from ropes.

• Do not attempt to transport assembled machinery by forklift.

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SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 Personnel Training

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

The manual supplied with the machine is an important part of operator training.

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 emergency controls.

2. Decals, instructions, and warnings on the machine.

3. Rules of the 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 malfunction.

7. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs are present.

8. Means to avoid the hazards of unprotected electrical conductors.

9. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

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SECTION 2 - PREPARATION AND INSPECTION

2.2 Preparation, Inspection, and Maintenance

The following table covers the periodic machine 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 when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

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SECTION 2 - PREPARATION AND INSPECTION

Table 2-1. Inspection and Maintenance Table

TYPE FREQUENCY

Pre-Star t Inspection

Frequent Inspection

Annual Machine Inspection

5 Year Replacement

NOTE: Use this manual to perform inspections.

NOTE: (*) A person who has acquired by training, qualifications, experience or a combination of these, the knowledge and skill enabling the person to

inspect and repair the machine to the level required by the complexity of the task.

Before star ting each day or at each workshift change

In service for 3 months; out of ser vice for a period of more than 3 months; or purchased used.

Every 12 months Owner, Dealer or User Qualified Mechanic

W h e n r o p e i s w o r n o r n o m o r e t h a n 5 y e a r s f r o m first use. Refer to Figure 2-4. for wear criteria.

PRIMARY

RESPONSIBILITY

Operator User or Operator Operation, Safety, Service &

Owner, Dealer or User Qualified Mechanic

Owner, Dealer or User Authorized JLG

SERVICE

QUALIFICATION

(*)

Service Centre

REFERENCE

Maintenance Manual

Operation, Safety, Service & Maintenance Manual and applicable JLG LiftPod inspection form

Factory Training

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SECTION 2 - PREPARATION AND INSPECTION

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for leakage, debris or foreign objects.

2. 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. (Reference Section 5.2, Decal Installation).

3. Operation, Safety Service & Maintenance Manual – Make sure a copy of the Operation, Safety, Service & Maintenance Manual and ANSI Manual of Responsibilities (U.S.A. only) is enclosed in the weather resistant storage container.

4. Assembly – The machine must be fully assembled in accordance with Section 3.3.

5. Walk-Around Inspection – 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 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 conditions listed in the following check list.

TO AVOID POSSIBLE INJURY, BE SURE DIRECTION SELECTOR IS IN THE “OFF” POSITION DURING WALK-AROUND INSPECTION. DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

NOTE: Do not overlook visual inspection of the base frame

underside. Check this area for objects, debris, corrosion and cracks.

NOTE: The mast and carriage components should be clean and

free from oil, grease and dirt. Do not lubricate mast or carriage components, especially brake shoes.

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SECTION 2 - PREPARATION AND INSPECTION

REAR

FRONT

(FS80 base shown)

Walk-Around Inspection Components

Figure 2-1. Daily Walk-Around Inspection

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(Sheet 1 of 2)

NOTE: On all components, make sure there are no loose or miss-

ing parts, everything is securely fastened, no visible damage, or excessive wear exists in addition to any other criteria mentioned.

1. Rear Wheels - Check for any debris stuck to or around wheels. Make sure bolts are fastened. Make sure castor locks operate properly (if equipped).

2. Base 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 flange; no excess wear, kinks, nicks or damage; carriage running surfaces smooth and unobstructed; 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 seal.

6. Swivel Castor Mechanism and Adjustable Feet Check for any debris stuck to or around wheels or mechanism. Check adjustable feet for damage. Rubber pads and tire must be in good order.

SECTION 2 - PREPARATION AND INSPECTION

Parent Metal Crack

Weld Crack

FRONT

REAR

(FS80 base shown)

Figure 2-2. Examples of cracks

7. Rope Assembly - Check rope is not frayed or damaged

(Figure 2-4.). Ensure it is tensioned tightly and seated properly around take-up drum (view via carriage inspection window - see Figure 6-3.). Ensure it is seated correctly 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. Braiding 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

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Figure 2-3. Daily Walk-Around Inspection

(Sheet 2 of 2)

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 should be tight around anchor.

Top of Mast

SECTION 2 - PREPARATION AND INSPECTION

legible; emergency stop switch reset for operation; control markings legible. Battery is installed and secure.

10. Platform Assembly and Gate - Check mounting pins are not loose; platform railing is undamaged; platform latch is engaged on carriage (Figure 2-7.); self-closing entry gates are in proper working order; no cracks or corrosion visible.

11. Tool Tray - See next page for Tool Tray Pre-Start Inspection Procedure.

Figure 2-4. Examples of new, acceptable and

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unacceptable ropes

Figure 2-5. Ropes retained in mast cap

Figure 2-6. Rope anchor points

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-7. Platform latch shown engaged

Figure 2-8. Location of manual descent crank

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Tool Tray Pre-Start Inspection

Prior to use of the tool tray, check 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 legible.

Maximum Load: The maximum permissible load on the tool tray is 15kg (33 lb.) evenly distributed.

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-9. Tool tray installation

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SECTION 2 - PREPARATION AND INSPECTION

2.4 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.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DEEMED 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 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 direction indicated by the arrows.

TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL IS RELEASED, USE THE EMERGENCY STOP BUTTON TO STOP THE MACHINE.

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SECTION 3 - MACHINE OPERATION

SECTION 3. MACHINE OPERATION

3.1 GENERAL

NOTE: The manufacturer has no direct control over machine

application and operation. The user and operator are responsible for conforming with good safety practices.

This section provides the necessary information needed to understand control function 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 purpose is to provide personnel 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. Powerpack (optional)

5. Spare Battery (optional)

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Figure 3-1. Main components

6. Charger (optional)

7. Tool Tray (optional)

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