Document Outline

• FOREWORD
• SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
  • Contact:
• REVISION LOG
• SECTION 1. SAFETY PRECAUTIONS
  • 1.1 GENERAL
    • 1. Read and understand the manufacturer’s (remanufacturer’s) operating instruction(s) and user’s safety rules or have them explained.
    • 2. Understand all labels, warnings and instructions displayed on the aerial platform or have them explained.
    • 3. Ensure all occupants of the aerial platform wear appropriate personal protection equipment (PPE) for the conditions, including the environment in which the aerial platform will be operated.
  • 1.2 PRE-OPERATION
  • Operator Training and Knowledge
  • Workplace Inspection
  • Machine Inspection
    • 1.3 OPERATION
  • General
  • Trip and Fall Hazard
  • Electrocution Hazard
    • Table 1-1. Minimum Approach Distances (M.A.D.)
  • Tipping Hazards
  • Crushing and Collision Hazards
    • 1.4 MOVING, LIFTING AND REPOSITIONING
  • General
  • Additional Safety Information
• SECTION 2. PREPARATION AND INSPECTION
  • 2.1 Personnel Training
  • Operator Training
    • 1. Use and limitations of the controls in the platform and emergency controls.
    • 2. Decals, instructions, and warnings on the machine.
    • 3. Rules of the employer and government regulations.
    • 4. Correct assembly of the machine.
    • 5. Use of approved fall protection device.
    • 6. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.
    • 7. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs are present.
    • 8. Means to avoid the hazards of unprotected electrical conductors.
    • 9. Specific job requirements or machine application.
  • Training Supervision
  • Operator Responsibility
    • 2.2 Preparation, Inspection, and Maintenance
      • Table 2-1. Inspection and Maintenance Table
  • Pre-Start Inspection
    • 1. Cleanliness - Check all surfaces for leakage, debris or foreign objects.
    • 2. Decals and Placards - Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced. (Reference Section 5.2, Decal Installation).
    • 3. Operation, Safety Service & Maintenance Manual - Make sure a copy of the Operation, Safety, Service & Maintenance Manual and ANSI Manual of Responsibilities (U.S.A. only) is enclosed in the weather resistant storage container.
    • 4. Assembly - The machine must be fully assembled in accordance with Section 3.3.
    • 5. Walk-Around Inspection - Refer to Section 2.3.
    • 6. Powerpack - Charge as required (Section 3.4).
    • 7. Function Check - Once the Walk-Around Inspection is complete, perform a function check of all systems in an area free of overhead and ground level obstructions. Refer to Section 2.4 for more specific instructions.
    • 2.3 DAILY WALK-AROUND INSPECTION
  • Walk-Around Inspection Components
    • 1. Rear Wheels - Check for any debris stuck to or around wheels. Make sure bolts are fastened. Make sure castor locks operate properly (if equipped).
    • 2. Base Frame - Check for cracks or corrosion, especially around the mast-stump base (see Figure 2-2.). Check level bubble is clean and secure.
    • 3. Mast Assembly - No cracks or corrosion, especially around base and flange; no excess wear, kinks, nicks or damage; carriage running surfaces smooth and unobstructed; free of dust, oil & grease.
    • 4. Carriage Frame - check for visible cracks; check rollers for visible wear; check carriage frame welds for visible cracks (see Figure 2-2.).
    • 5. Gearbox - check for any oil leaks, especially around bottom shaft seal.
    • 6. Swivel Castor Mechanism and Adjustable Feet - Check for any debris stuck to or around wheels or mechanism. Check adjustable feet for damage. Rubber pads and tire must be in good order.
    • 7. Rope Assembly - Check rope is not frayed or damaged (Figure 2-4.). Ensure it is tensioned tightly and seated properly around ...
    • 8. Manual Descent Crank - Ensure it is present and securely attached (Figure 2-8.).
    • 9. Powerpack and Control Console (optional) - Ensure it is properly mounted and secured. Button, triggers and switches not obscu...
    • 10. Platform Assembly and Gate - Check mounting pins are not loose; platform railing is undamaged; platform latch is engaged on carriage (Figure 2-7.); self-closing entry gates are in proper working order; no cracks or corrosion visible.
    • 11. Tool Tray - See next page for Tool Tray Pre-Start Inspection Procedure.
  • Tool Tray Pre-Start Inspection
    • 2.4 FUNCTION CHECK
  • Function Check Items
    • 1. Base Brake - Step on base to ensure the swivel castor retracts properly.
    • 2. Adjustable Feet - Check both rotate freely up and down; check that rubber pads are installed and not excessively worn.
    • 3. Emergency Stop Button (optional powerpack) - ensure all machine functions are disabled when the emergency stop button is activated (pressed in) - then RESET the emergency stop button by twisting it in the direction indicated by the arrows.
• SECTION 3. MACHINE OPERATION
  • 3.1 GENERAL
  • 3.2 MACHINE DESCRIPTION
    • 1. Base Frame (FS80 base shown)
    • 2. Carriage/Mast Assembly
    • 3. Platform
    • 4. Powerpack (optional)
    • 5. Spare Battery (optional)
    • 6. Charger (optional)
    • 7. Tool Tray (optional)
  • Detailed Description
  • Platform Configuration
  • Mast/Carriage Components
    • 3.3 MACHINE OPERATION
  • General
  • Getting Started
  • Assembly of the Machine
    • 1. Position the base frame on a firm, level, uniform, supporting surface.
    • 2. Push down on the base frame’s step plate until the swivel castor retracts and the base sits on the adjustable feet (Figure 3-6.). The machine now rests on the two rear wheels, and the two adjustable feet at the front.
    • 3. For the FS60 machine’s base (the 30FS base module), lock the castor wheels (Figure 3-7.).
    • 4. Turn the adjustable feet until the level bubble is centred (see Figure 3-8.)
    • 5. Slide the carriage/mast assembly onto the mast stump. Make sure it is properly aligned and fully engaged. Never force it into position (see Figure 3-6.).
    • 6. Attach the platform to the carriage (see Figure 3-9.).
    • 7. Fasten lanyard securely around the handle of the cordless drill. Attach the cordless drill to the top of the driveshaft, eith...
    • 8. Place the powerpack (optional equipment) against the platform uprights, closest to the mast, and slide it down until it clicks, indicating it is fully seated (see Figure 3- 12.).
    • 9. Tool tray: (optional equipment) Place on top rail of platform, and fasten the two clips firmly around the rail (see Figure 2-9.).
  • Disassembly of the Machine
    • 3.4 Powerpack (Optional Equipment)
  • Battery Charging Operation
  • Battery Charge Status Lights
  • Charging the Batteries Using the Fast Charge Station
    • 1. Remove battery from powerpack (Figure 3-16.).
    • 2. Place battery into recharging dock.
    • 3. Plug recharge dock into AC voltage wall outlet.
    • 4. Once the green LED has stopped flashing, the powerpack is fully charged.
  • Fast Charge Indicator Light Guide
  • Power Supply Cord
    • 3.5 Operation
  • Cordless Drill
    • 1. Drive Socket (optional)
    • 2. Chuck
    • 3. Torque Control (optional)
    • 4. Power Trigger
    • 5. Speed Controller (optional)
    • 6. Drill/Hammer Function Selector (optional)
    • 7. Direction Selector
    • 8. Battery Pack
  • Powerpack Control Console (Optional Equipment)
    • 1. Enable Trigger
    • 2. Battery Release Latch
    • 3. Battery Trickle Charge Plug
    • 4. Emergency Stop Button
    • 5. Direction Selector
    • 6. Speed Trigger
    • 7. Powerpack Release Latch
  • Elevating
  • Descending
  • Powerpack Emergency Stop/Shutdown Button
  • Unpowered Descent
    • 3.6 TRANSPORT AND MANEUVERING (MOVING)
  • General
  • Fully Assembled Maneuvering
  • Disassembled Maneuvering
  • Parking and Storage
  • Vehicle Transport
• SECTION 4. EMERGENCY PROCEDURES
  • 4.1 GENERAL INFORMATION
  • Manual Descent Crank
  • Discharged Battery
    • 1. Remove the cordless drill and place it inside the platform. If the optional powerpack is installed, remove it and place it sideways against the back panel in the platform (see Figure 4-1.).
    • 2. Remove the manual descent crank from the mounting clips inside the platform.
    • 3. Engage the hexagon at the top of the driveshaft with the socket end of the manual crank.
    • 4. Push down on top of the handle to disengage the driveshaft lock and wind anti clockwise until the platform comes to rest against the stops on the base.
  • Operator Unable to Control Machine
  • Platform Caught Overhead
  • Rope Failure
    • 4.2 INCIDENT NOTIFICATION
• SECTION 5. GENERAL SPECIFICATIONS
  • 5.1 Introduction
  • 5.2 Decal Installation
    • Table 5-1. Decal Descriptions.
  • 5.3 General Specifications
  • Machine Specifications (assembled)
    • Table 5-2. Machine Specifications (assembled)
  • Optional Powerpack Electrical Specifications
    • Table 5-3. Optional Powerpack Electrical Specifications
  • Platform Data
    • Table 5-4. Platform Data
  • Interchangeable Modules
    • Table 5-5. Interchangeable Modules
    • Table 5-6. Module Key
  • Machine Component Weights
    • Table 5-7. Machine Component Weights
  • Serial Number Locations
• SECTION 6. SERVICE AND MAINTENANCE
  • 6.1 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • General
  • Maintenance Safety
    • 6.2 MACHINE PREPARATION, INSPECTION AND MAINTENANCE
  • General
  • Preparation, Inspection, and Maintenance
  • Pre-Start Inspection
  • Frequent and Pre-Delivery Inspection
  • Annual Machine Inspection
  • 5 Year Machine Inspection & Rope Replacement
  • Preventive Maintenance
    • 6.3 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
      • 1. Check for proper and secure installation
      • 2. No gouges, excessive wear, or dents showing
      • 3. Visually inspect for excessive wear, damage, cracks, or distortion
      • 4. Check for cracked or broken welds
      • 5. Check area is clean and free of debris
      • 6. Check for proper adjustment
      • 7. Check proper operation
      • 8. Check returns to neutral or "off" position when released
      • 9. Check for signs of leakage
      • 10. Check for wear and/or proper routing
      • 11. Check for proper tolerances
      • 12. Check proper and authorized components installed
      • 13. Verify
      • 14. Perform
      • 15. Replace
      • 16. Inspect per Service and Maintenance Manual
      • Table 6-1. Preventative Maintenance & Inspection Schedule
    • 6.4 SERVICING AND MAINTENANCE GUIDELINES
  • General
  • Safety and Workmanship
  • Cleanliness
  • Component Disassembly and Reassembly
    • 6.5 REPLACEMENT KITS OVERVIEW
      • 1. Mast Cap Kit (JLG Part No. 1001071255)
      • 2. Quick Start Guide Kit (JLG Part No. 1001071355)
      • 3. Powerpack Battery (JLG Part No. 1001071678)
      • 4. Manual Pouch Kit (JLG Part No. 1001071354)
      • 5. Gate Assembly Kit LH (JLG Part No. 1001071351)
      • 6. Gate Assembly Kit RH (JLG Part No. 1001071352)
      • 7. Powerpack (JLG Part No. 1001071680)
      • 8. Manual Descent Crank Kit (JLG Part No. 1001071353)
      • 9. Adjustable Foot Kit (2 feet per kit) (JLG Part No. 1001071562)
      • 10. Base Castor Mechanism Kit (JLG service only) (JLG Part No. 1001071566)
      • 11. Swivel Castor Wheel Kit (JLG Part No. 1001071561)
      • 12. Rope (JLG service only) (JLG Part No. 1001070257)
      • 13. Accessory Tray Kit (JLG Part No. 1001071725)
      • 14. Plastic Cowlings Kit (JLG Part No. 1001071250)
      • 15. Carriage Handle Kit (JLG Part No. 1001071251)
      • 16. Fixed Wheel Kit (FS80 Base) (2 wheels per kit) (JLG Part No. 1001071560)
      • 17. Level Bubble Kit (JLG Part No. 1001071563)
      • 18. Lower Rear Roller Kit (JLG Part No. 1001071252)
      • 19. Complete Base Kit - FS80 (JLG Part No. 1001071567)
      • 20. Complete Platform Kit (JLG Part No. 1001071328)
      • 21. Complete Mast/Carriage Kit - FS80 (JLG Part No. 1001071256)
      • 22. Replacement Rotating Castors (30FS Base) (2 wheels per kit) (JLG Part No. 1001071386)
      • 23. Fast Charger - 110V (JLG Part No. 1001071707)
      • 24. AC Lead - 110V (JLG Part No. 1001071750)
      • 25. Powerpack Carry Case (JLG Part No. 1001071705)
      • 26. Decal Kit, Base, ANSI - FS80 (JLG Part No. 1001071564)
      • 27. Decal Kit, Mast/Carriage, ANSI - FS80 (JLG Part No. 1001071253)
      • 28. Decal Kit, Platform, ANSI (JLG Part No. 1001071356)
      • 29. Decal Kit, Powerpack, ANSI (JLG Part No. 1001071602)
      • 30. Decal Kit, Accessory Tray, ANSI (JLG Part No. 1001071358)
      • 31. Drill Strap Kit (JLG Part No. 1001071361)
      • 32. Drill Socket Kit (JLG Part No. 1001071362)
      • 33. Replacement Manual (JLG Part No. 1001071360)
      • 34. Replacement Pouch Rivets (JLG Part No. 1001071339)
      • 35. CSA Kit (JLG Part No. 1001071338)
      • 36. Decal Kit, Mast/Carriage, ANSI - FS60 (JLG Part No. 1001071385)
      • 37. Complete 30FS Base Assembly - ANSI (JLG Part No. 1001071484)
      • 38. Complete FS60 Mast/Carriage Kit - ANSI (JLG Part No. 1001071419)
      • 39. Decal Kit, Base, ANSI - 30FS (JLG Part No. 1001071392)
    • 6.6 Decal Replacement
    • 6.7 Mast Rope Inspection Procedure
  • 1. Rope Wear
  • 2. Rope Misaligned
    • a. Ropes on drum should be neatly wound on adjacent grooves.
    • b. Ropes must be parallel going into and through the carriage, looking down the mast.
  • 3. Rope Loose
    • 1. If carriage is not within 1m (3 ft) of the base of the mast contact JLG. Otherwise assemble the mast onto the base lifting via mast tube above carriage.
    • 2. Check the rope is correctly on drum (Figure 6-3.).
    • 3. Check rope is in correct location in carriage (Figure 6-4.).
    • 4. Connect the manual descent handle directly to the carriage drive shaft (Figure 6-5.). Press down on crank and simultaneously rotate clockwise. You will hear a ratcheting noise and the drum will wind up the slack rope.
    • 5. Re-check proper rope alignment (Figure 6-3. and Figure 6-4.). Both ropes must be tight. If ropes are not tight, contact an Authorized JLG Service Center.
    • 6. Install platform and cordless drill (or optional powerpack). Use applicable safety precautions to enter the platform safely. Raise the platform 50mm (2 inch) to reset the emergency brake and then lower the platform to bottom of travel.
    • 7. Perform all pre-operation checks before further use. Also, remove platform and re-check rope alignment per Figure 6-3. and Fi...
• SECTION 7. TROUBLESHOOTING
  • 7.1 GENERAL
  • Troubleshooting Information
    • Table 7-1. Troubleshooting
• SECTION 8. INSPECTION AND REPAIR LOG
  • 8.1 Inspection and Repair Log Table
    • Table 8-1. Inspection and Repair Log