JLG LiftPod FS60 Installations- und Benutzerhandbuch

Operation, Safety, Service

and Maintenance Manual

- English

Keep this manual with the machine at all times.

LIFTPOD by JLG

LiftPod Models

FS80 & FS60

P/N - 1001070465

24 October 2011

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We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,

Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,

Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,

Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic,

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FOREWORD

LIFTPOD by JLG 1001070465

FOREWORD

Original Instructions. Keep this manual with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operat-

ing procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. (JLG) reserves the right to make specification changes

without prior notification.

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FOREWORD

1001070465 LIFTPOD by JLG

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

LIFTPOD by JLG 1001070465

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG OR THE LOCAL AUTHORIZED JLG REPRESENTA-

TIVE 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.

NOTICE

JLG INDUSTRIES INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORDS OF THIS MACHINE. CONTACT JLG INDUSTRIES

INC. TO INSURE THAT THE OWNER RECORDS ARE UPDATED AND

ACCURATE.

For:

• Accident reporting

• Product safety publica-

tions

• Current owner updates

• Questions regarding

product safety

• Standards and regulations

compliance information

• Questions regarding spe-

cial product applications

• Questions regarding prod-

uct modifications

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FOREWORD

1001070465 LIFTPOD by JLG

REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . . . . . . . 24 July 2009

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 August 2009

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 August 2009

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 December 2009

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 April 2011

Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 April 2011

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

Revised. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 October 2011

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TABLE OF CONTENTS

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

LIFTPOD by JLG 1001070465

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 REQUIREMENTS . . . . . . . . . . . . . . . 2-1

Operator Requirements . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . 3-4

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

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

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

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

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

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

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

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

Charging the Batteries Using the Fast Charge

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

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

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

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

Powerpack Control Console (Optional

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

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

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

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TABLE OF CONTENTS

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

1001070465 LIFTPOD by JLG

Powerpack Emergency Stop/Shutdown Button 3-18

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

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

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

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

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

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

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

SECTION - 4 - EMERGENCY PROCEDURES

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

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

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

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

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

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

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

SECTION - 5 - GENERAL SPECIFICATIONS

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

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

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

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

Optional Powerpack Electrical Specifications. . 5-11

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

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

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

Serial Number Locations . . . . . . . . . . . . . . . . . . 5-14

5.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . 5-14

SECTION - 6 - SERVICE AND MAINTENANCE

6.1 INTRODUCTION - MAINTENANCE SAFETY

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

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

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

6.2 MACHINE PREPARATION, INSPECTION AND

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

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

Preparation, 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

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

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

Component Disassembly and Reassembly. . . . . 6-8

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

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TABLE OF CONTENTS

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

LIFTPOD by JLG 1001070465

iii

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

Country Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.6 DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . 6-13

6.7 MAST ROPE INSPECTION PROCEDURE . . . . . 6-14

1. Rope Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

2. Rope Misaligned . . . . . . . . . . . . . . . . . . . . . . 6-14

3. Rope Loose . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

SECTION - 7 - TROUBLESHOOTING

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

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

SECTION - 8 - INSPECTION AND REPAIR LOG

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

SECTION - 9 - EC DECLARATIONS OF CONFORMITY

EC Declaration of Conformity - English . . . . . . . 9-1

LIST OF FIGURES

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

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

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

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

2-4. Examples of new, acceptable and unacceptable

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

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

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

2-7. Platform latch shown engaged . . . . . . . . . . . . . . . . 2-8

2-8. Location of manual descent crank . . . . . . . . . . . . . 2-8

2-9. Tool tray installation . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3-1. Main components . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2. Base frame component description - FS80 . . . . . . 3-2

3-3. Base frame component description - FS60 . . . . . . 3-3

3-4. Platform component description . . . . . . . . . . . . . . 3-3

3-5. Mast/carriage component description . . . . . . . . . . 3-4

3-6. Carriage/mast to base mounting . . . . . . . . . . . . . . 3-6

3-7. Castor lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-8. Detail view of level bubble . . . . . . . . . . . . . . . . . . . 3-6

3-9. Attaching the platform to the carriage . . . . . . . . . . 3-7

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

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

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

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

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

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

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

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

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

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

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

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

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