JLG LiftPod FT70 Installations- und Benutzerhandbuch

ANSI / CSA

Keep this manual with the machine at all times.

Operation, Safety, Service and

Maintenance Manual

LiftPod Models

FT70

FT140

3121296

June 29, 2018 - Rev C

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

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WARNING

Operating, servicing and maintaining this vehicle or equipment

can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of

California to cause cancer and birth defects or other

reproductive harm. To minimize exposure, avoid breathing

exhaust, do not idle the engine except as necessary, service your

vehicle or equipment in a well-ventilated area and wear gloves

or wash your hands frequently when servicing. For more

information go to www.P65Warnings.ca.gov.

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FOREWORD

3121296 LIFTPOD by JLG 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 oper-

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

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

without prior notification. Contact JLG for updated information.

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FOREWORD

bLIFTPOD by JLG 3121296

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.

NOTICE

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY

OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROP-

ERTY.

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 possi-

ble injury or death

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FOREWORD

3121296 LIFTPOD by JLG c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CON-

TACT JLG OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-

TION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN

ISSUED FOR THIS PRODUCT.

NOTICE

JLG MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PROD-

UCTS 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 publica-

tions

• Current owner

updates

• Questions regarding

product safety

• Standards and regulations

compliance information

• Questions regarding spe-

cial product applications

• Questions regarding

product modifications

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FOREWORD

dLIFTPOD by JLG 3121296

REVISION LOG

Original Issue

Revised

A - November 2, 2015

B - March 1, 2016

C - June 29, 2018 - Revised, Prop 65

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TABLE OF CONTENTS

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

3121296 LIFTPOD by JLG 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Trip and Fall Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . 1-9

1.4 MOVING, LIFTING AND REPOSITIONING . . . . . . . 1-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Additional Safety Information . . . . . . . . . . . . . . . 1-10

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . 1-10

Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

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

2.3 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . 2-3

Walk-Around Inspection Components. . . . . . . . .2-3

Tool Tray Pre-Start Inspection . . . . . . . . . . . . . . . . .2-7

2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Function Check Items. . . . . . . . . . . . . . . . . . . . . . . . .2-8

SECTION - 3 - MACHINE OPERATION

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

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

Base Component Detailed Description . . . . . . . .3-4

Platform Configuration . . . . . . . . . . . . . . . . . . . . . . .3-5

Mast Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.3 MACHINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

Assembly of the Machine . . . . . . . . . . . . . . . . . . . . .3-7

Power Pack Control Unit Installation

(Optional for FT70) . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Machine Disassembly. . . . . . . . . . . . . . . . . . . . . . . 3-13

3.4 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Positioning and Leveling Machine . . . . . . . . . . 3-14

Entering/Exiting The Platform. . . . . . . . . . . . . . . 3-15

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TABLE OF CONTENTS

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

ii LIFTPOD by JLG 3121296

Platform Operation Using Cordless Drill . . . . . 3-16

Platform Operation Using The Power Pack

Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Platform Operation Using Manual Descent

Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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

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

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

Disassembled Maneuvering. . . . . . . . . . . . . . . . . 3-20

Parking and Storage . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.6 POWER PACK (OPTIONAL FOR FT70). . . . . . . . . . . 3-22

Emergency Stop/Shutdown Button . . . . . . . . . 3-23

Mast Select Button. . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Function Enable Button . . . . . . . . . . . . . . . . . . . . . 3-23

Platform UP/DOWN Buttons. . . . . . . . . . . . . . . . . 3-23

Battery Status LED Indicator. . . . . . . . . . . . . . . . . 3-23

Latch Release Handles (1 each side) . . . . . . . . . 3-24

Control Unit/Drive Unit Driveshaft. . . . . . . . . . . 3-24

Latch Locking Tabs . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Lithium-Ion Battery . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Connection Port for FT140 Drive Unit . . . . . . . . 3-24

Battery Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Removing Battery From Power Pack

Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Battery Charge Status Lights. . . . . . . . . . . . . . . . . 3-26

SECTION - 4 - EMERGENCY PROCEDURES

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

Manual Descent Tool. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Platform - Manual Descent Tool Operation . . . . 4-2

Ground - Manual Descent Tool Operation. . . . . 4-3

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

Operator Elevated In Platform - Platform

Will Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

SECTION - 5 - GENERAL SPECIFICATIONS

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

5.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . 5-1

Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Optional Powerpack Electrical Specifications . . 5-2

Machine Component Weights . . . . . . . . . . . . . . . . 5-3

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 DECAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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TABLE OF CONTENTS

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

3121296 LIFTPOD by JLG iii

SECTION - 6 - SERVICE/MAINTENANCE AND REPLACEMENT

PARTS

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

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 FT70 AND FT140 MAST SERVICE PROCEDURE. . . . 6-9

Relieving Gas Strut Cylinder Pressure . . . . . . . . 6-11

Removing Mast Top Cap . . . . . . . . . . . . . . . . . . . . 6-13

Outer-Mast Section Gas Strut Removal . . . . . . 6-14

GearBox Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Mid-Mast Section Gas Strut Removal . . . . . . . . 6-16

Gearbox Housing Disassembly . . . . . . . . . . . . . . 6-16

6.6 MAST DRIVE SCREW LUBRICATION . . . . . . . . . . . . 6-18

6.7 REPLACEMENT PART/KITS OVERVIEW. . . . . . . . . . 6-20

BASE - FT140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

BASE - FT70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

MAST - FT70 and FT140 . . . . . . . . . . . . . . . . . . . . . 6-21

PLATFORM - FT70 and FT140. . . . . . . . . . . . . . . . 6-22

ACCESSORIES - FT70 and FT140 . . . . . . . . . . . . . 6-22

6.8 FT140 BASE FRAME COMPONENTS -

SERVICE KIT - LOCATIONS . . . . . . . . . . . . . . . . . . . . . 6-24

6.9 FT70 BASE FRAME COMPONENTS -

SERVICE KIT - LOCATIONS . . . . . . . . . . . . . . . . . . . . . 6-25

6.10 PLATFORM COMPONENT -

SERVICE KIT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 6-26

6.11 ACCESSORY COMPONENTS - SERVICE KITS . . . . 6-27

SECTION - 7 - TROUBLESHOOTING

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

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

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