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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This page intentionally left blank.
FS.book Page 2 Wednesday, February 11, 2009 11:54 AM
FOREWORD
1-877-254-3876 LIFTPOD by JLG 1001070451
1-877-2-LIFTPOD www.liftpod.com a
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
FS.book Page b Wednesday, February 11, 2009 11:54 AM
FOREWORD
1-877-254-3876 LIFTPOD by JLG 1001070451
1-877-2-LIFTPOD www.liftpod.com c
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: 717-485-6591
E-mail: ProductSafety@JLG.com
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
d www.liftpod.com 1-877-2-LIFTPOD
REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . . . May 14, 2008
Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 04, 2008
Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . September 25, 2008
Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . September 29, 2008
Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . February 11, 2009
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1-877-254-3876 LIFTPOD by JLG 1001070451
1-877-2-LIFTPOD www.liftpod.com i
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
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1001070451 LIFTPOD by JLG 1-877-254-3876
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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
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1001070451 LIFTPOD by JLG 1-877-254-3876
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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
1001070451 LIFTPOD by JLG 1-877-254-3876
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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
1001070451 LIFTPOD by JLG 1-877-254-3876
1-4 www.liftpod.com 1-877-2-LIFTPOD
• 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.
SECTION 1 - SAFETY PRECAUTIONS
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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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SECTION 1 - SAFETY PRECAUTIONS
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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.
SECTION 1 - SAFETY PRECAUTIONS
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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.
SECTION 2 - PREPARATION AND INSPECTION
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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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SECTION 2 - PREPARATION AND INSPECTION
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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.
SECTION 2 - PREPARATION AND INSPECTION
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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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SECTION 2 - PREPARATION AND INSPECTION
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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
SECTION 2 - PREPARATION AND INSPECTION
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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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SECTION 2 - PREPARATION AND INSPECTION
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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
SECTION 2 - PREPARATION AND INSPECTION
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Figure 2-7. Platform latch shown engaged
Figure 2-8. Location of manual descent crank
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