JLG LiftPod FS60 Installation and user guide

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
Go to Discount-Equipment.com to order your parts

Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on one of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
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,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin,
Rice, CH&E, General Equipment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent,
Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air,
APT, Wylie, Ingersoll Rand / Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith
Surface Prep,Small Line, Wanco, Yanmar

This page intentionally left blank.
Go to Discount-Equipment.com to order your parts

FOREWORD
LIFTPOD by JLG 1001070465
a
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.
Go to Discount-Equipment.com to order your parts

FOREWORD
1001070465 LIFTPOD by JLG
b
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
Go to Discount-Equipment.com to order your parts

FOREWORD
LIFTPOD by JLG 1001070465
c
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
Go to Discount-Equipment.com to order your parts

FOREWORD
1001070465 LIFTPOD by JLG
d
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
Go to Discount-Equipment.com to order your parts

TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIFTPOD by JLG 1001070465
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 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
Go to Discount-Equipment.com to order your parts

TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1001070465 LIFTPOD by JLG
ii
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
Go to Discount-Equipment.com to order your parts

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
Go to Discount-Equipment.com to order your parts