JLG LiftPod FS80 Installation and user guide

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
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 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. Contact JLG for updated information.
FS.book Page a Wednesday, February 11, 2009 11:54 AM

FOREWORD
1001070451 LIFTPOD by JLG 1-877-254-3876
bwww.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
1-877-2-LIFTPOD www.liftpod.com 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.
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: [email protected]
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 prod-
uct modifications
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FOREWORD
1001070451 LIFTPOD by JLG 1-877-254-3876
dwww.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
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1001070451 LIFTPOD by JLG 1-877-254-3876
ii www.liftpod.com 1-877-2-LIFTPOD
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
1-877-2-LIFTPOD www.liftpod.com iii
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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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
1001070451 LIFTPOD by JLG 1-877-254-3876
iv www.liftpod.com 1-877-2-LIFTPOD
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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