JLG LiftPod FT70 Installation and user guide

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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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: [phone]
E-mail: [e-mail]
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
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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