JLG LiftPod FS80 Operation, Safety, Service And Maintenance Manual

Operation, Safety, Service

and Maintenance 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

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FS.book Page 2 Wednesday, February 11, 2009 11:54 AM

FOREWORD

1-877-254-3876 LIFTPOD by JLG 1001070451

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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.

FOREWORD

1001070451 LIFTPOD by JLG 1-877-254-3876

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

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL

RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. 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 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 possible
injury or death

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FOREWORD

1-877-254-3876 LIFTPOD by JLG 1001070451

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

NOTICE

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.

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: [phone]
E-mail: [e-mail]

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

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

FOREWORD

1001070451 LIFTPOD by JLG 1-877-254-3876

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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

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TABLE OF CONTENTS

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

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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

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 . . . . . . . . . . . . . . . . 3-3

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

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

Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Assembly of the Machine . . . . . . . . . . . . . . . . . . 3-4

Disassembly of the Machine . . . . . . . . . . . . . . . . 3-9

3.4 POWERPACK (OPTIONAL EQUIPMENT). . . . . . . 3-10

Battery Charging Operation. . . . . . . . . . . . . . . . 3-10

Battery Charge Status Lights. . . . . . . . . . . . . . . 3-10

Charging the Batteries Using the Fast Charge

Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Fast Charge Indicator Light Guide . . . . . . . . . . 3-11

Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . 3-12

3.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Cordless Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

TABLE OF CONTENTS

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Powerpack Control Console (Optional

Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Elevating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Descending . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Powerpack Emergency Stop/Shutdown Button 3-16

Unpowered Descent . . . . . . . . . . . . . . . . . . . . . 3-17

3.6 TRANSPORT AND MANEUVERING (MOVING) . . 3-17

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Fully Assembled Maneuvering . . . . . . . . . . . . . 3-18

Disassembled Maneuvering . . . . . . . . . . . . . . . 3-19

Parking and Storage . . . . . . . . . . . . . . . . . . . . . 3-20

Vehicle Transport. . . . . . . . . . . . . . . . . . . . . . . . 3-20

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 . . . . . . . . . . . . . . . . . 5-8

Machine Specifications (assembled) . . . . . . . . . . 5-8

Optional Powerpack Electrical Specifications . . .5-9

Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Machine Component Weights . . . . . . . . . . . . . . 5-11

Serial Number Locations . . . . . . . . . . . . . . . . . . 5-11

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, 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

6.3 PREVENTIVE MAINTENANCE AND INSPECTION

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

6.4 SERVICING AND MAINTENANCE GUIDELINES . 6-8

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

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TABLE OF CONTENTS

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1-877-254-3876 LIFTPOD by JLG 1001070451

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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 . . . . . . . . . . . . . . . . . . . . 6-11

6.7 MAST ROPE INSPECTION PROCEDURE . . . . . 6-12

1. Rope Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

2. Rope Misaligned . . . . . . . . . . . . . . . . . . . . . . 6-12

3. Rope Loose . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

SECTION - 7 - TROUBLESHOOTING

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

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

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 . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

2-4. Examples of new, acceptable and unacceptable

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

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 . . . . . . . . . . . . 3-2

3-3. Platform component description . . . . . . . . . . . . . . 3-3

3-4. Mast/carriage component description . . . . . . . . . . 3-3

3-5. Carriage/mast to base mounting . . . . . . . . . . . . . . 3-5

3-6. Detail view of level bubble . . . . . . . . . . . . . . . . . . . 3-5

3-7. Attaching the platform to the carriage . . . . . . . . . . 3-6

3-8. Platform attachment checks . . . . . . . . . . . . . . . . . . 3-6

3-9. Cordless drill installation . . . . . . . . . . . . . . . . . . . . . 3-7

3-10. Powerpack positioned and latched into place . . . . 3-8

3-11. Tool tray load restriction . . . . . . . . . . . . . . . . . . . . . 3-9

3-12. Battery charging plug and tester . . . . . . . . . . . . . 3-10

3-13. Charge status lights . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-14. Removing the battery from the powerpack . . . . . 3-11

3-15. Recharge dock operations and indicators . . . . . . 3-11

3-16. Typical cordless drill interface devices . . . . . . . . . 3-12

3-17. Powerpack control console . . . . . . . . . . . . . . . . . 3-13

3-18. Cordless drill elevation . . . . . . . . . . . . . . . . . . . . . 3-14

3-19. Detail view of direction selector . . . . . . . . . . . . . . 3-15

3-20. Detail view of enable & speed triggers . . . . . . . . . 3-15

3-21. Emergency stop button operation . . . . . . . . . . . . 3-16

3-22. Activate the handle to extend the swivel castor . . 3-18

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3-23. Maneuvering when tilted back . . . . . . . . . . . . . . . 3-18

3-24. Mast/carriage handle . . . . . . . . . . . . . . . . . . . . . . 3-19

3-25. Moving base through a door . . . . . . . . . . . . . . . . 3-20

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 . . . . . . . . . . . . . . . . 5-4

5-2. 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. Rope alignment through carriage. . . . . . . . . . . . . 6-13

6-4. Loose rope being re-tensioned. . . . . . . . . . . . . . . 6-13

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) . . . . . . . . . . . 5-8

5-3 Optional Powerpack Electrical Specifications . . . . 5-9

5-4 Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-5 Machine Component Weights . . . . . . . . . . . . . . . .5-11

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

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

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SECTION 1 - SAFETY PRECAUTIONS

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SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and
safe machine usage and maintenance. For proper machine use, it
is mandatory that a daily routine is 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.

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

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1.2 PRE-OPERATION

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.

Figure 1-1. Read your manual

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SECTION 1 - SAFETY PRECAUTIONS

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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.

1.3 OPERATION

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.

SECTION 1 - SAFETY PRECAUTIONS

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• 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.

• 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.

MAX = 36 in (91.4cm)

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SECTION 1 - SAFETY PRECAUTIONS

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• 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.

• 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)

MINIMUM SAFE APPROACH

DISTANCE - Feet (Meters)

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.

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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.

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• 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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• 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

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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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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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Table 2-1. Inspection and Maintenance Table

TYPE FREQUENCY

PRIMARY

RESPONSIBILITY

SERVICE

QUALIFICATION

REFERENCE

Pre-Star t
Inspection

Before star ting each day or at each workshift
change

Operator User or Operator Operation, Safety, Service &

Maintenance Manual

Frequent
Inspection

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

Owner, Dealer or User Qualified Mechanic

(*)

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

Annual Machine
Inspection

Every 12 months Owner, Dealer or User Qualified Mechanic

(*)

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

5 Year
Replacement

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

Owner, Dealer or User Authorized JLG

Service Centre

Factory Training

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.

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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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Walk-Around Inspection Components

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.

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.).

Figure 2-1. Daily Walk-Around Inspection

(Sheet 1 of 2)

1

2

3

4

REAR

FRONT

Figure 2-2. Examples of cracks

Parent Metal Crack

Weld Crack

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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.

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 6-2.). 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
legible; emergency stop switch reset for operation; con­trol markings legible. Battery is installed and secure.

Figure 2-3. Daily Walk-Around Inspection

(Sheet 2 of 2)

5

7

9

10

8

FRONT

REAR

11

6

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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

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 should
be tight around anchor.

Top o f
Mast

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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.

Figure 2-9. Tool tray installation

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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

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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

2. Carriage/Mast Assembly

3. Platform

4. Powerpack (optional)

5. Spare Battery (optional)

6. Charger (optional)

7. Tool Tray (optional)

Figure 3-1. Main components

1

2

3

6

5

7

4

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The primary control console is located within the removable and
rechargeable powerpack.

The powerpack is attached to the machine within the platform.

With the installed powerpack, the operator can raise or lower the
platform through its controls.

The machine has a self retracting swivel castor mounted under the
front of the base which retracts 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 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 3-6.).

Detailed Description

Figure 3-2. Base frame component description

Fixed Wheel

Adjustable Foot

Self Retracting Swivel Castor

Adjustable Foot

Fixed Wheel

Carriage Rests

Mast Stump

Level Bubble

Retracting Castor
Release Lever

FRONT

(travel stops)

Step Plate

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Platform Configuration Mast/Carriage Components

Figure 3-3. 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)

Figure 3-4. Mast/carriage component description

Mast Cap

Carriage Frame

Gearbox

Carry Handle

Drum Inspection

Rope Anchor (at back)

Driveshaft

Lifting Ropes

Window

Platform Mounting
Pin Holes

Mast

(orange)

Lower Facing Shaft Stub

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3.3 MACHINE OPERATION

General

When the platform reaches the bottom of its travel, the rest posi­tion, the drive mechanism overrunning clutch creates a ratcheting,
or buzzing noise, indicating that the machine has reached the fully
lowered position.

The machine is fitted with an emergency brake which activates
when the tension in the lifting ropes goes below 40kg (88 lbs).

When the platform is lowered to the rest position, the emer­gency brake swings into position, stopping 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 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 controls:

• Batteries must contain enough voltage to operate. Low
battery warning on battery test panel indicates the need to
charge the batteries. Batteries should be charged for 24

hours prior to first use.

• Emergency stop switch on optional powerpack must be in
the RESET position (out).

• Both platform swing-in entry gates must be closed.

Assembly of the Machine

The JLG LiftPod is a user assembled machine. There are three
basic parts that need to be assembled for operation. These parts
are the Base Frame 1, Carriage/Mast Assembly 2, and the Plat­form 3. Optional parts include the Powerpack 4, and the Tool Tray

5 (Figure 3-1.).

1. Position the base frame on a firm, level, uniform, sup-

porting surface.

2. Push down on the base frame’s step plate until the
swivel castor retracts and the base sits on the adjustable
feet (Figure 3-5.). The machine now rests on the two rear
wheels, and the two adjustable feet at the front.

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CRUSH HAZARD - KEEP FEET CLEAR OF ADJUSTABLE FEET AND
UNDERNEATH BASE WHEN STEPPING 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 mounting

PUSH DOWN

Adjustable Foot

Adjustable Foot

Figure 3-6. Detail view of level bubble

Level Bubble

Rotating Knob
adjusts foot height

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4. Slide the carriage/mast assembly onto the mast stump.

Make sure it is properly aligned and fully engaged.
Never force it into position (see Figure 3-5.).

5. Attach the platform to the carriage (see Figure 3-7.).

• Make 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 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 3-7. Attaching the platform to the carriage

Fully Engaged

Figure 3-8. Platform attachment checks

(C)

(B)

(A)

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NOTE: When reversing the procedure to disassemble the

machine, pull the platform latch handle (C) to disengage
the platform from the carriage.

6. Fasten lanyard securely around the handle of the cord­less drill. Attach the cordless drill to the top of the drive­shaft, 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 3-9.).

CORDLESS DRILL LANYARD MUST BE INSTALLED BEFORE ELEVATING.
DO NOT DROP DRILL.

Figure 3-9. Cordless drill installation

Driveshaft

Drive Socket

Lanyard

Cordless Drill

(optional)

Manual Pouch

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7. Place the powerpack (optional equipment) against the

platform uprights, closest to the mast, and slide it down
until it clicks, indicating it is fully seated (see Figure 3-

10.).

NOTE: When reversing the procedure to disassemble the

machine, pull the powerpack release latch (see Figure 3-

17.) while 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 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 THE TOOL TRAY’S TOP SURFACE (SEE FIGURE
3-11.).

Figure 3-10. Powerpack positioned and latched into

place

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Disassembly of the Machine

Reverse the above steps to disassemble the machine.

DO NOT ATTEMPT TO LIFT THE MAST OFF THE BASE UNLESS THE CAR­RIAGE HAS BEEN FULLY LOWERED.

Figure 3-11. Tool tray load restriction

NO-LOAD AREA

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3.4 Powerpack (Optional Equipment)

Battery Charging Operation

DO NOT SHORT CIRCUIT THE BATTERY. DO NOT OPEN THE BATTERY
PACK AS THERE IS A DANGER OF CAUSING A SHORT CIRCUIT.
PROTECT THE BATTERY AGAINST HEAT, INCLUDING AGAINST CONTIN­UOUS DIRECT SUN EXPOSURE OR OPEN FLAME.

New batteries and batteries that have not been used for a long
period must be fully charged. They will not reach their full capacity
until fully charged and discharged through several cycles. Battery
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-

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 3-12. Battery charging plug and tester

Figure 3-13. Charge status lights

Trickle Charge Indicator

Tri c k le C h a r g e P l u g

Charge Status Test Button

Charge Status Lights

3 green lights - Battery
is fully charged.

2 green lights - Battery
needs recharging/
replacing soon.

1 green light - Battery
needs recharging/
replacing as soon as
possible.

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Charging the Batteries Using the Fast Charge Station

NOTE: USE ONLY THE SUPPLIED CHARGING STATION.

1. Remove battery from powerpack (Figure 3-14.).

2. Place battery into recharging dock.

3. Plug recharge dock into AC voltage wall outlet.

4. Once the green LED has stopped flashing, the power-

pack is fully charged.

TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY FOL­LOW 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 charged, always remove the battery
from the fast charger.

Fast Charge Indicator Light Guide

SOLID GREEN: Insert battery or remove fully charged battery

Figure 3-14. Removing the battery from the powerpack

Pull and lift battery
release latch to
disengage battery
from powerpack

Figure 3-15. Recharge dock operations and indicators

Fault Indicator (RED)

Charge Indicator (GREEN)

Battery

Battery Release

Recharging Dock

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FLASHING GREEN: Battery is charging.

SOLID RED: Charging is temporarily halted to allow battery to

cool down. Charging will continue automatically.

FLASHING 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.

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 AWG, two
conductors, VW-1, 221°F (105°C), 125V, Type:SPT-2, minimum 5 ft.
11 in. (1.8m), maximum 9 ft. 10 in. (3m) long. Provided with a
molded-on, polarized attachment plug with a 15A, 125V (NEMA 1­15P) configuration and a molded-on connector which mates with
the power inlet.

3.5 Operation

Cordless Drill

1. Drive Socket (optional)

2. Chuck

3. Torque Control (optional)

4. Power Trigger

5. Speed Controller (optional)

6. Drill/Hammer Function Selector (optional)

Figure 3-16. Typical cordless drill interface devices

7

3

2

8

5

6

1

4

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7. Direction Selector

8. Battery Pack

Please follow the manufacturer’s instructions on safe operation
and maintenance of the cordless drill.

JLG recommends a cordless drill of at least 18V capacity.

Ensure cordless drill’s optional "Hammer" setting is disabled and
cordless drill is in "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 ON MEDUIM TO HIGH TORQUE SETTING, BUT NOT MAX­IMUM 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 Selector

6. Speed Trigger

7. Powerpack Release Latch

Figure 3-17. Powerpack control console

1

2

3

4

5

6

7

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3-14 www.liftpod.com 1-877-2-LIFTPOD

The powerpack is splash resistant allowing a safe descent if it
starts to rain while the unit is elevated, but JLG does not recom­mend that the powerpack be used in rain or exposed to water.

Whenever the machine is not in use, set the direction selector to
the OFF position.

DISCONTINUE USE OF THE POWERPACK IF A FAULT IS DETECTED.

NOTICE

DO NOT PRESSURE-WASH THE POWERPACK.

MAKE SURE YOU CHECK THE REMAINING CHARGE INSIDE THE POW­ERPACK’S BATTERY BEFORE ELEVATING THE PLATFORM BY PRESSING
THE CHARGE 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 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" (clock­wise) direction.

Hold the drill’s handle firmly, push it down to automatically disen­gage the driveshaft interlock, and squeeze the trigger to elevate.

Stop using the cordless drill if any part of it becomes excessively
hot. Wait until drill has cooled down and then continue operation.

Figure 3-18. Cordless drill elevation

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If using the optional powerpack instead of a cordless drill, move
the direction selector switch to the UP position (Figure 3-19.).

Hold the handle so the enable trigger is pressed and squeeze the
speed trigger. The function speed is proportional to how far the
speed trigger is pressed.

To stop, simply release the speed trigger. A slow release makes
the platform come to a smooth stop.

Most cordless drills and the motor in the powerpack are fitted with
thermal overload protection. In case of overheating, this cuts
power to the motor. The cutout automatically 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 ther­mal 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 capacity of 150kg (330 lb.).

• The machine is not intended for use by children.

• Children must be supervised to
ensure they do not use or play with
the machine.

•Only one person is allowed to be
lifted by the platform.

Figure 3-19. Detail view of direction selector

Direction Selector

UP Position

DOWN Position

OFF Position

Figure 3-20. Detail view of enable & speed triggers

Enable Trigger

Speed Trigger

SECTION 3 - MACHINE OPERATION

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Descending

CRUSHING HAZARD - BE AWARE OF DESCENDING PLATFORM WHEN
LOWERING THE PLATFORM. KEEP HANDS OR FEET OFF THE MAST
ASSEMBLY AND FROM BENEATH PLATFORM.

On the cordless drill, move the direction selector to the "unscrew"
(anti-clockwise) direction. Push the cordless drill down to disen­gage the driveshaft interlock and squeeze the trigger to descend.

If using the optional powerpack, move the direction 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 mecha­nism’s overdrive ratchet, making a ratcheting sound. This means
the platform has reached its lowest position and the trigger should
be released.

NOTE: Before transporting, maneuvering or disassembling

machine, ensure the platform is all the way down. The
carriage lock is engaged automatically when the platform
is fully lowered and all load is removed.

Powerpack Emergency Stop/Shutdown Button

If the platform stops responding to operator input at any time while
the platform is moving, use the emergency stop button to cut the

power to the motor.

Figure 3-21. Emergency stop button operation

Press down to activate

Rotate clockwise

Emergency Stop

to release/reset

Emergency Stop

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SECTION 3 - MACHINE OPERATION

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Unpowered Descent

The platform manual descent crank (Figure 2-8.) is provided to:

• Allow 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 Pro­cedures.

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 MACHINE UNLESS THE
CARRIAGE IS FULLY DOWN AND THE CARRIAGE TO MAST LOCK IS
ENGAGED. DO NOT MOVE MACHINE WITH PERSONNEL IN PLATFORM.

WHEN TRANSPORTING THE MACHINE, ENSURE THE ROPES ARE PRO­TECTED AND NOT DAMAGED.

The machine may be moved around a worksite using the following
methods:

• Fully assembled, pushed around the floor using the
wheels and castor;

• Fully assembled, tilted over.

• Disassembled, with each major component carried sepa­rately.

SECTION 3 - MACHINE OPERATION

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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 machine while it is being

rolled around, or the swivel castor 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 the machine rests securely on the rear wheels
and two adjustable feet.

PUSHED TILTED OVER

The machine can be tilted over and maneuvered as shown in
Figure 3-23.

NOTE: Ensure powerpack and tool tray are securely attached

and tool tray and platform are empty before moving.

Figure 3-22. Activate the handle to extend the swivel

castor

Figure 3-23. Maneuvering when tilted back

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ONLY ATTEMPT TO TILT THE UNIT BACK, OR RETURN TILTED UNIT TO
THE UPRIGHT POSITION, ON A FLAT AND LEVEL SURFACE, CLEAR OF
ANY PERSONNEL. WHEELS SHOULD BE CHOCKED TO AVOID ROLLING
DURING TILT OPERATION. ENSURE A FIRM GRIP WITH TWO HANDS ON
THE MAST, AND ENSURE WEIGHT IS DISTRIBUTED TO AVOID THE
USER OR THE MACHINE 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 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 assembly can be carried by the built-in handle
(see Figure 3-24.).

Figure 3-24. Mast/carriage handle

SECTION 3 - MACHINE OPERATION

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The base frame can be moved by the mast stump and the frame to
fit through doorways sideways (see Figure 3-25.).

Parking and Storage

• Move machine to a dry, well-protected and well-ventilated
area out of direct sunlight.

• Ensure the platform is fully lowered. If installed, move the
powerpack’s direction control switch to the OFF position.

• If necessary, remove the cordless drill or optional power­pack from the platform to prevent unauthorized use.

• Ensure the swivel castor is retracted and the machine is
resting on the adjustable feet.

NOTICE

DO NOT STORE IN LOCATIONS WHERE THE MACHINE MAY ACCUMU­LATE ICE, GREASE OR AIRBOURNE DEBRIS.

Vehicle Transport

When transporting the machine by vehicle, it should be disassem­bled into its major components (see Figure 3-1.) and each compo­nent 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 OF EXCESSIVE FORCE WHEN SECURING MACHINE CAN CAUSE
DAMAGE TO THE MACHINE.

Secure machine to the transport vehicle with adequately rated
rope or straps. Do not overtension such devices and place a
buffer between the device and any part of the machine.

Figure 3-25. Moving base through a door

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SECTION 4 - EMERGENCY PROCEDURES

1-877-254-3876 LIFTPOD by JLG 1001070451

1-877-2-LIFTPOD www.liftpod.com 4-1

SECTION 4. EMERGENCY PROCEDURES

4.1 GENERAL INFORMATION

This section explains the steps to be taken in case of an emer­gency situation during operation.

Manual Descent Crank

The platform manual descent crank is provided to:

• Allow 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 the event
that the platform operator cannot lower the platform once
elevated.

NOTICE

THE CRANK IS DESIGNED FOR DESCENT IN CASE OF LOSS 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 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 plat­form. If the optional powerpack is installed, remove it
and place it sideways against the back panel in the plat­form (see Figure 4-1.).

2. Remove the manual descent crank from the mounting
clips inside the platform.

3. Engage the hexagon at the top of the driveshaft with the
socket end of the manual crank.

4. Push down on top of the handle to disengage the drive­shaft lock and wind anti clockwise until the platform

comes to rest against the stops on the base.

SECTION 4 - EMERGENCY PROCEDURES

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Operator Unable to Control Machine

If the platform operator 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 descent crank operation from

inside platform

Figure 4-2. Manual descent crank operation from

outside platform

Shaft Stub

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SECTION 4 - EMERGENCY PROCEDURES

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NOTICE

IF THE OPTIONAL POWERPACK IS NOT INSTALLED, USE THE LANYARD
IN THE PLATFORM TO SECURE THE DRIVESHAFT IN A DEPRESSED

(PUSHED-IN) POSITION, RELEASING THE DRIVE INTERLOCK.

DO NOT ACTIVATE THE POWERPACK WHILE THE MANUAL DESCENT
CRANK IS ATTACHED.

Platform Caught Overhead

If the platform becomes jammed or snagged in overhead struc­tures 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 the
machine.

Figure 4-3. Releasing the drive interlock using the

lanyard

SECTION 4 - EMERGENCY PROCEDURES

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Rope Failure

The carriage and platform are elevated by two ropes.

Single Rope Failure

If one of the ropes fails while the platform is elevated, the other
rope will allow safe descent.

Upon failure of one of the ropes, immediately lower the platform.
Inform other personnel that the machine is out of service. Disas­semble and clearly label the machine as being out of service. Con­tact your nearest Authorized JLG Service Center to arrange rope
replacement.

DO NOT ELEVATE PLATFORM WHEN IT IS ONLY SUPPORTED BY A SIN­GLE ROPE.

ROPE REPLACEMENT SHALL ONLY BE CARRIED OUT BY AN AUTHO­RIZED 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 the support surface
call for help. The operator should then be safely removed from the
platform using suitable equipment.

DO NOT CLIMB OUT OF THE PLATFORM WHILE ELEVATED. THIS MAY
AFFECT THE MACHINE'S BALANCE, CAUSING IT TO TIP OVER. ONLY
EXIT THE PLATFORM VIA THE PLATFORM GATES. DO NOT ATTEMPT TO
CLIMB DOWN MAST.

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SECTION 4 - EMERGENCY PROCEDURES

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4.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro­vided with all necessary details.

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: [phone]
E-mail: [e-mail]

Failure to notify the manufacturer of an incident involving 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.

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SECTION 5 - GENERAL SPECIFICATIONS

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SECTION 5. GENERAL SPECIFICATIONS

5.1 Introduction

This section of the manual provides operating specifications and
information necessary for proper maintenance of this machine.

5.2 Decal Installation

No. ANSI JLG Part Number

Replacement Decal Kit,

BASE, ANSI

100 107 1564

A1 Cr ushing Hazard-ANSI 100 107 0306

A2 Bubble Level-ANSI 100 107 0413

A3 Base Cr ush Hazard-ANSI 100 107 0438

A4 Step Plate Decal 100 107 0280

A5 General Brand 100 107 0281

A6 Max Wheel Load-ANSI 100 107 0310

A7 Barcode Base 100 107 0418

Replacement Decal Kit,
MAST/CARRIAGE, ANSI

100 107 1253

B1 Patent 100 107 0307

B2 Manual Descent-ANSI 100 107 0309

B3 Manufacturer Nameplate-ANSI 100 107 0442

B4 Mast Cap Warning-ANSI 100 107 0432

B5

Sharp Object & Mast Disassembly
Combo-ANSI

100 107 0433

B6 Cowling Side Brand 100 107 0410

B7 General Brand 100 107 0281

B8 Barcode Carriage 100 107 0419

No. ANSI JLG Part Number

SECTION 5 - GENERAL SPECIFICATIONS

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Replacement Decal Kit,

PLATFORM, ANSI

100 107 1356

C1 Capacity-ANSI 100 107 0441

C2 Electrocution-ANSI 100 107 0303

C3 Platform Warning Chevrons 100 107 0409

C4 Platform Latch Release 100 107 0429

C5 Dril l Instructions 100 107 0445

C6 Summar y-ANSI 100 107 0302

C7 Lanyard Location-Length-ANSI 100 107 0411

C8 FS Quickstar t Guide 100 107 0415

C9 Manual 100 107 0451

C10 Barcode Platform 100 107 0417

No. ANSI JLG Part Number

Replacement Decal Kit,

POWERPACK, ANSI

100 107 1602

D1 Powerpack Socket Warning 100 107 0400

D2 E-Stop 100 107 0401

D3 Powerpack Drive Directions 100 107 0403

D4 Powerpack Battery Test 100 107 0404

D5 Powerpack Front Main Housing 100 107 0405

D6 Powerpack Instructions 100 107 0406

D7 Batter y Charger Front 100 107 0407

D8 Batter y Latch Instructions 100 107 0416

D9 Batter y Warning 100 107 0440

D10 Fast Charger Back 100 107 0443

D11 Battery Charger Branding 100 107 0408

No. ANSI JLG Part Number

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Table 5-1. Decal Descriptions.

D12 General Brand 100 107 0281

D13 Barcode Powerpack 100 107 0420

D14 Barcode Charger 100 107 0421

Replacement Decal Kit,

ACCESSORY TRAY, ANSI

100 107 1358

E1 Tool Tray-ANSI 100 107 0425

No. ANSI JLG Part Number

SECTION 5 - GENERAL SPECIFICATIONS

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Figure 5-1. Base Decal Installation - ANSI

A7.

A1.

A1.

A6.

A6.

A2.

A3.

A5.

A4.

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SECTION 5 - GENERAL SPECIFICATIONS

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Figure 5-2. Carriage/Mast Decal Installation - ANSI

B1.

B3.

B2.

B8.

B4.

B5.

B6.

B7.

B7.

SECTION 5 - GENERAL SPECIFICATIONS

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Figure 5-3. Platform Decal Installation - ANSI

C1.

C3.

C3.

C3.

C8.

C10.

E1.

C6.

C2.

C4.

C7.

C5.

C9.

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Figure 5-4. Powerpack Decal Installation - ANSI

D1.

D2.

D10.

D3.

D4.

D5.

D6.

D11.

D8.

D13.

D14.

D9.

D7.

D12.

D12.

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5.3 General Specifications

Machine Specifications (assembled)

Table 5-2. Machine Specifications (assembled)

SPECIFICATION FS80

Gross Machine Weight: (without optional tool trayor powerpack) 64.8kg (142.9 lb.)

Machine Height: 2.97m (9 ft 9 in)

Maximum Platform Floor Height: 2.32m (7 ft 7 in)

Maximum Wind Speed: 12.5m/sec (30 mph)

Maximum Working Height: (typical person) 4.32m (14 ft 4 in)

Machine Overall Footprint: 1,250mm x 1,040mm (4 ft 1 in x 3 ft 5 in)

Rated Horizontal Force 110N (24 lb.)

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SECTION 5 - GENERAL SPECIFICATIONS

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Optional Powerpack Electrical Specifications

Table 5-3. Optional Powerpack Electrical Specifications

SPECIFICATION FS80

Batteries - Powerpack: 28.8 Volts DC

Nominal Duty Cycle: 4 cycles per 15 minutes (reduces at high and low ambient temperature)

Battery Specifications: Battery Type Nickel Metal Hydride

Voltage 28.8 Volts DC

Amp Hour (AH) Rating 4.5 Ah

Weight 2.3kg (5 lb.)

Battery Fast Charger: Input: 110/240 Volts AC - 2.2A - 50/60 Hz

FC 100 107 1675 Output: 28.8 Volts DC - 2 .5A - w/Auto Charge Sensing Circuit

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Platform Data

Table 5-4. Platform Data

SPECIFICATION FS80

Occupants: (Persons allowed in Platform) 1

P l a t f o r m C a p a c it y : ANSI/C.S.A.: 150kg (330 lb.)

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Machine Component Weights

Table 5-5. Machine Component Weights

Serial Number Locations

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

Base Frame 27.9kg (61.5 lb.)

Carriage/Mast 22.2kg (48.9 lb.)

Platform 14.7kg (32.4 lb.)

Optional Powerpack (inc Battery) 8kg (17.6 lb.)

Optional Tool Tray 3.6kg (7.9 lb.)

SECTION 5 - GENERAL SPECIFICATIONS

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SECTION 6 - SERVICE AND MAINTENANCE

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SECTION 6. SERVICE AND MAINTENANCE

6.1 INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS

General

This section contains the general safety precautions which must
be observed during maintenance of the aerial platform. It is
important that maintenance personnel pay strict attention to these
warnings and precautions to avoid possible injury to themselves
or others or damage to the equipment. A maintenance program
must be established by a competent person and must be followed
to ensure that the machine is safe to operate.

NOTICE

JLG MAY HAVE ISSUED SAFETY BULLETINS FOR YOUR JLG PRODUCT.
CONTACT JLG OR THE LOCAL AUTHORIZED JLG SERVICE CENTRE FOR
INFORMATION CONCERNING SAFETY RELATED 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. Contact JLG
for updated information.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A
RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE
AS ORIGINALLY MANUFACTURED IS AN OHSA SAFETY VIOLATION.

Your safety, and that of others, is the first consideration when
engaging in the maintenance of equipment. Always be conscious
of moving parts and pinch points. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the equip­ment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THESE AREAS
IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

SECTION 6 - SERVICE AND MAINTENANCE

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Maintenance Safety

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS
SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY
OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS, WATCHES, AND JEWELRY WHEN
PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE
FITTING CLOTHING AND NECKTIES WHICH ARE APT TO
BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL DANGER, WARNING, CAUTION
AND OTHER INSTRUCTIONS ON MACHINE AND IN OPERA­TION, 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 OFF ALL POWER CON­TROLS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL­VENTS.

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6.2 MACHINE PREPARATION, INSPECTION AND
MAINTENANCE

General

This section provides the necessary information needed by those
personnel that are responsible to place the machine in operation
readiness and maintain its safe operating condition. For maximum
service life and safe operation, ensure that all necessary inspec­tion and maintenance has been completed before placing the
machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive
inspection and preventive maintenance program. Table 2-1 out­lines the periodic machine inspection and maintenance recom­mended by JLG. Consult your national, regional, or local
regulations for further requirements for aerial work platforms. The
frequency of inspection and maintenance must be increased as
environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the user's or operator's primary responsibility to perform a Pre­Start Inspection of the machine prior to use daily or at each
change of operator. Reference Section 2 in this manual for com­pletion 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 per­formed by a competent person or a qualified mechanic.

The Frequent Inspection and Pre-Delivery Inspection procedures
are performed in the same manner, but at different times. The Pre­Delivery Inspection shall be performed prior to each sale, lease, or
rental delivery. The Frequent Inspection shall be accomplished for
each machine in service for 3 months; out of service for a period of
more than 3 months; or when purchased used. The frequency of
this inspection must be increased as environment, severity and
frequency of usage requires.

Reference the appropriate areas of this manual for servicing and
maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a compe­tent person or a qualified mechanic on an annual basis, no later
than thirteen (13) months from the date of the prior Annual
Machine Inspection.

Reference the Service and Maintenance Sections of this Manual
and appropriate JLG inspection form for performance of this
inspection.

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Reference the appropriate areas of this manual for servicing and
maintenance procedures.

5 Year Machine Inspection & Rope Replacement

The mast and carriage module must be inspected and the ropes
replaced by an Authorized JLG Service Center when:

• The rope is worn beyond specification (see Figure 2-4.);

• A rope is tangled, damaged or broken;

• When the machine has been in service for 5 years.

NOTICE

IT IS IMPORTANT THAT JLG HAS UPDATED OWNERSHIP INFORMATION
FOR EACH MACHINE COMPONENT. WHEN PERFORMING EACH ANNUAL
MACHINE INSPECTION, NOTIFY JLG OF THE CURRENT MACHINE COM­PONENT OWNERSHIP.

Preventive Maintenance

In conjunction with the specified inspections, maintenance shall
be performed by a competent person such as a qualified JLG
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 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 table is divided
into four columns representing the various inspection time peri­ods. The numbers listed within the interval column represent the
applicable inspection code for which that component is to be
checked.

The checks and services listed in this schedule are not intended to
replace any local or regional regulations that may pertain to this
type of equipment nor should the lists be considered as all inclu­sive. Variances in interval times may occur due to climate and/or
conditions and depending on the location and use of the machine.

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Inspection and Maintenance Codes:

1. Check for proper and secure installation

2. No gouges, excessive wear, or dents showing

3. Visually inspect for excessive wear, damage, cracks, or

distortion

4. Check for cracked or broken welds

5. Check area is clean and free of debris

6. Check for proper adjustment

7. Check proper operation

8. Check returns to neutral or "off" position when released

9. Check for signs of leakage

10. Check for wear 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 Machine Interval

Pre-Start Inspection Pre-Delivery or Frequent

Inspection

Annual (Yearly) Inspec­tion

5 Year Inspection

Prior to use each day; or
at each operator change

Prior to each sale, lease
or delivery; in ser vice for
3 months or more; or
purchased used

Actually no later than 13
months from the date of
the prior inspection

Addition item - When
rope worn or no more
than 5 years from first
use

Mast 1, 5, 1, 2, 5 1, 2, 3, 5

Mast Stump 3, 5 3, 4, 5 3, 4, 5

Rope 10, 16 10, 16 10, 16 15

Carriage 5 3, 5 1, 3, 4, 5, 7

Gearbox 3, 9 3, 9 1, 3, 9

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Area on Machine Pre-Start Inspection Pre-Delivery or Frequent

Inspection

Annual (Yearly) Inspec­tion

5 Year Inspection

Manual Descent Crank 1 1, 12 1, 3, 12

Carriage Rollers 3, 7 3, 7, 11

Platform 1, 5 1, 5 1, 3, 4, 5, 7

Platform Latch 1, 7 1, 3, 6, 7 1, 3, 6, 7

Platform Gates 1, 7 1, 3, 5, 7 1, 3, 5, 7

Lanyard Anchor 3, 4 3, 4

Base Frame 3, 4, 5 3, 4, 5 3, 4, 5

Adjustable Feet 1 1, 3, 7 1, 3, 7

Bubble Level 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; Battery Charge Test Button 1, 8 1, 3, 7, 8 1, 3, 7, 8

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Table 6-1. Preventative Maintenance & Inspection Schedule

General Pre-Start Inspection Pre-Delivery or Frequent

Inspection

Annual (Yearly) Inspec­tion

5 Year Inspection

Operator, Safety, Service & Maintenance Manual in
Storage Pouch

13 13 13

All Decals/Placards Installed, Secure & Legible 13 13 13

Machine Inspection or Rope Replacement Due 16 16 14, 15

No Unauthorized Modifications or Additions 13 13

All Relevant Safety Publications Incorporated 13 13

General Structural Conditio n and Welds 3, 4 3, 4

All Fasteners, Pins, Shields and Covers 1, 3

Function Test of all Systems 14 14 14

Paint and Appearance 2, 5 2, 5

Record Inspection Date in Log Book 14

Notify JLG of Machine Ownership 14 (delivery) 14

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6.4 SERVICING AND MAINTENANCE
GUIDELINES

General

The following information is provided to assist you in the use and
application of service and maintenance procedures contained in
this chapter.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CON­TAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREG­ULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED
GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

Safety and Workmanship

Your safety, and that of others, is the first consideration when
engaging in the maintenance of equipment. Always be conscious
of moving components and pinch points. Do not allow heavy
objects to rest 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 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 MACHINE. ENSURE THAT THE MAST AND
EMERGENCY BRAKE ARE CLEAN AND FREE OF DEBRIS, OIL AND
GREASE.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the
procedural steps in sequence. Do not partially disassemble or
assemble one part, then start on another. Always recheck your
work to assure that nothing has been overlooked. Do not make
any adjustments, other than those recommended, without obtain­ing proper approval.

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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.

9.

13.

16.

15.

14.

11.

10.

17.

12.

7.

18.

8.

19.

20.

21.

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1. Mast Cap Kit (JLG Part No. 1001071255)

2. Quick Start Guide Kit (JLG Part No. 1001071355)

3. Powerpack Battery (JLG Part No. 1001071635)

4. Manual Pouch Kit (JLG Part No. 1001071354)

5. Gate Assembly Kit LH (JLG Part No. 1001071351)

6. Gate Assembly Kit RH (JLG Part No. 1001071352)

7. Powerpack (JLG Part No. 1001071730)

8. Manual Descent Crank Kit

(JLG Part No. 1001071353)

9. Adjustable Foot Kit (2 feet per kit)

(JLG Part No. 1001071562)

10. Base Castor Mechanism Kit (JLG service only)

(JLG Part No. 1001071566)

11. Swivel Castor Wheel Kit (JLG Part No. 1001071561)

12. Rope (JLG service only) (JLG Part No. 1001070257)

13. Accessory Tray 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 Kit (JLG Part No. 1001071563)

18. Lower Rear Roller Kit (JLG Part No. 1001071252)

19. Complete Base Kit (JLG Part No. 1001071567)

20. Complete Platform Kit (JLG Part No. 1001071328)

21. Complete Mast/Carriage Kit

(JLG Part No. 1001071256)

NOTE: Following items not pictured.

22. Fast Charger - 110V (JLG Part No. 1001071675)

23. AC Lead - 110V (JLG Part No. 1001071750)

24. Charger Wall Plate Kit (JLG Part No. 1001071695)

25. Powerpack Carry Case (JLG Part No. 1001071705)

NOTE: Following items not pictured. Refer to Table 5-1 and Fig-

ure 5-1. to Figure 5-4 for replacement decal positions.

26. Decal Kit, Base, ANSI (JLG Part No. 1001071564)

27. Decal Kit, Mast/Carriage, ANSI

(JLG Part No. 1001071253)

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28. Decal Kit, Platform, ANSI

(JLG Part No. 1001071356)

29. Decal Kit, Powerpack, ANSI
(JLG Part No. 1001071602)

30. Decal Kit, Accessory Tray, ANSI
(JLG Part No. 1001071358)

31. Drill Strap Kit (JLG Part No. 1001071361)

32. Drill Socket Kit (JLG Part No. 1001071362)

33. Replacement Manual (JLG Part No. 1001071360)

34. Replacement Pouch Rivets (JLG Part No. 1001071339)

35. CSA Kit (JLG Part No. 1001071338)

6.6 Decal 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 sol­vent on inconspicuous area first, to ensure it does not mark or
damage the underlying surface finish.

NOTICE

SURFACE DAMAGE COULD RESULT IN CORROSION AND STRUCTURAL
DAMAGE.

Before applying new decal, ensure the surface is clean and dry.

Remove backing paper, apply decal along one edge then seat it
gently and evenly.

If there are any air bubbles, work them gently towards the edge
with a clean cloth.

Pressure sensitive adhesive reaches full strength after a several
days.

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6.7 Mast Rope Inspection Procedure

NOTICE

MAST ROPES ARE TO BE INSPECTED EVERY THREE MONTHS OR MORE
FREQUENTLY AS DESCRIBED FOLLOWING.

The ropes should be inspected more frequently if used in a harsh
environment or high duty cycle applications. Inspection should be
more frequent as ropes approach the end of their useful lives. The
periodic inspection shall cover the entire length of the rope.

Only the surface of the ropes require inspection, do not attempt to
open the rope or remove any carriage covers. Any deterioration
resulting in 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 service
for five (5) years, regardless of rope condition, or sooner if condi­tions 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 (of the rope) or increasing the fre­quency of inspection:

1. Rope Wear

Check rope is not frayed or damaged as per Figure 2-4. in the
Daily Walk-Around Inspection Section.

2. Rope Misaligned

With carriage lowered and the platform removed, check the follow­ing:

a. Ropes on drum should be neatly wound on adja-

cent grooves.

Figure 6-2. Drum view through inspection window

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b. Ropes must be parallel going into and through the

carriage, looking down 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 use.

Figure 6-3. Rope alignment through carriage

Incorrect, tangled - DO NOT USE

Correct - OK to use

Figure 6-4. Loose rope being re-tensioned

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To correct a loose rope:

1. If carriage is not within 1m (3 ft) of the base of the mast
contact JLG. Otherwise assemble the mast onto the
base lifting via mast tube above carriage.

2. Check the rope is correctly on drum (Figure 6-2.).

3. Check rope is in correct location in carriage

(Figure 6-3.).

4. Connect the manual descent handle directly to the car­riage drive shaft (Figure 6-4.). Press down on crank and
simultaneously rotate clockwise. You will hear a ratchet­ing 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 Service Center.

6. Install platform and cordless drill (or optional power­pack). 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 of travel.

7. Perform all pre-operation checks before further use.
Also, remove platform and re-check rope alignment per
Figure 6-2. and Figure 6-3. after first elevation - which
should be no higher than 1m (3 ft). Ensure both ropes
are tight and remain so at all times.

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SECTION 7 - TROUBLESHOOTING

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SECTION 7. TROUBLESHOOTING

7.1 GENERAL

This section contains troubleshooting information to be used for
locating and correcting most of the operating problems which
may develop in the aerial platform. If a problem should develop
which is not presented in this section or which is not corrected by
listed corrective actions, technically qualified guidance should be
obtained before proceeding with any maintenance.

Troubleshooting Information

The troubleshooting procedures applicable to the product are
listed and defined in Table 7-1, Troubleshooting (below).

Each malfunction within an individual group or system is followed
by a listing of probably causes which will enable determination of
the applicable remedial action. The probable 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 knowl­edge 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 fullest possible treatment. In the remain­ing machine groups, only those problems which are symptomatic
of greater problems which have more than one probable cause
and remedy are included. This means that problems for which the
probable cause and remedy may be immediately obvious are not

listed in this section.

TROUBLE PROBABLE CAUSE REMEDY

Machine does not assemble properly

Improper alignment on assembly Check each component and assembly alignment is correct.

Platform not fully engaged Check alignment and slide parts on until platform latch is properly engaged.

SECTION 7 - TROUBLESHOOTING

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Powerpack (optional) motor does not start

Emergency stop button is engaged (PUSHED
IN) on powerpack

Disengage emergency stop button until it pops up (TURN CLOCKWISE).

Direction selector or enable trigger or speed
control trigger not activated

Select 'UP' on direction selector, then activate both the enable trigger and speed
control continuously for operation.

Battery not installed or no charge Properly install charged battery in powerpack.

Motor has overheated Wait until motor cools. The temperature cutout resets itself automatically.

Alternatively use manual descent procedure to lower platform (Section 4.1).

Platform does not lift up from bottom of travel - motor starts

Driveshaft interlock is engaged Push cordless drill on driveshaft down fir mly to disengage driveshaft safety inter-

lock.

(If using powerpack) Powerpack driveshaft not
engaged

Check powerpack is correctly fitted to platform, latch is down and drive shaft is
connected to carriage drive shaft.

Emergency brake not released from carriage
lock down latch position

E ns u re a l oa d gr e at er t ha n 5 0 kg (1 1 0 l b s .) i s i n t he p la t fo r m (1 p er s on ) a n d l if t i ng
ropes are tight. If latch has not released, attempt to lower the loaded platform
slightly then try again to lift up.

TROUBLE PROBABLE CAUSE REMEDY

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Platform will not move when in elevated position - motor starts

Driveshaft interlock is engaged Push cordless drill on driveshaf t down firmly to disengage driveshaft safety inter-

lock.

(If using powerpack) Powerpack shaft not
engaged

Check powerpack charged and in correctly fitted and is fully down and latched
down.

Drive shaft malfunction Lower platform using manual descent procedure (see Section 4.1). Refer to

Authorized JLG Service Center.

Ropes are loose (ropes must never be loose)

Machine was disassembled without platform
being fully lowered to engage the carriage lock
down latch. Carriage then moved up the mast
loosening the ropes

I f c a r ri a ge i s no t wi t hi n 1 m ( 3 f t) o f t h e base of the mast contact Authorized JLG
Service Center. Otherwise follow rope re-tensioning procedure detailed in Section

6.7, point 3. Ensure both ropes are tight and remain so at all times.

Machine does not wheel properly

Retractable Swivel Castor is not properly
deployed

W i t h n o l o a d i n t he p l a t f o r m o r o n t h e b a s e - lift the castor deploy handle on front of
base, adjacent to platform gate. Castor should deploy and lift front of machine off
adjustable feet to allow machine to roll easily on rear wheels and front castor.

Castor is damaged Replace castor.

TROUBLE PROBABLE CAUSE REMEDY

SECTION 7 - TROUBLESHOOTING

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Table 7-1. Troubleshooting

Base will not level (DO NOT ELEVATE UNLESS BASE FIRM AND LEVEL)

C as t or d e pl o ye d W it h n o l o ad i n p l a tf o rm a nd pe o ple clear of adjustable feet - exert approximately

25kg pressure onto front of base. Castor should retract. Adjustable feet should
then be able to be used to level the machine on slopes less than 2 degrees front to
back. Do not use the machine on any side slope.

Machine rocks slightly side to side

Suppor t surface is not level Only use the machine on firm and level surfaces.

Adjustable feet are not BOTH in contact with
suppor ting surface

Adjust the feet so that BOTH feet are in firm contact with suppor ting surface AND
the machine is level.

Ropes are worn or a rope is broken or machine is 5 years old or machine has been in service for 5 years since previous service

Damage or wear or machine is 5 years old Deliver unit to an Authorized JLG Service Center for replacement.

Platform will not lift full rated load

Battery not fully charged Charge or replace battery.

Overload clutch is slipping Contact Authorized JLG Service Center.

TROUBLE PROBABLE CAUSE REMEDY

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JLG Worldwide Locations

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Transpolis Building
Polarisavenue 63
2132 JH HOOFDORP
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

www.jlg.com

Corporate Office
JLG Industries, Inc.
13244 Fountainhead Plaza
Hagerstown, MD 21742-2678
USA
Phone 877-2-LIFTPOD (877-254-38763)
Fax [phone]

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