Operation & Safety Manual: Model
Operation & Safety Manual: Model
Operation & Safety Manual: Model
Model
25RTS
33RTS
40RTS
3120690
May 15, 2003
– JLG Sizzor –
This page left blank intentionally.
– JLG Sizzor –
FOREWORD
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 operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
IMPORTANT
INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION AND
WHICH, IF NOT FOLLOWED, MAY RESULT IN A MACHINE MAL-
FUNCTIONED DAMAGE. ON THE MACHINE THIS WILL HAVE A
GREEN BACKGROUND.
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO-
RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE
MANUFACTURER
IMPORTANT
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUS-
TRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
IMPORTANT
JLG INDUSTRIES, INC. 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
FOR :
•Accident Reporting
•Product Safety Publications
•Current Owner Updates
•Questions Regarding Product Safety
•Standards and Regulations Compliance Information
•Questions Regarding Special Product Applications
•Questions Regarding Product Modifications
CONTACT :
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
In USA:
Toll Free: 877-JLG-SAFE
877-554-7233
Outside USA:
717-485-5161
E-mail: ProductSafety@JLG.com
REVISION LOG
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION -
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Pre-operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Towing, Lifting, and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 Additional Hazards / Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
SECTION 2 - PREPARATION AND INSPECTION
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Delivery And Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.4 Daily Walk-around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.6 Lock-out Cylinder Check - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.7 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.8 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
SECTION 4 - MACHINE OPERATION
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 Raising and Lowering - (Lifting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.5 Leveling Jacks (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Mechanical Platform Extension (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.8 Traveling - (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.9 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.10 Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.11 Safety Props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.12 Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SECTION 5 - EMERGENCY PROCEDURES
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.4 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION 6 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Walk-Around Inspection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2-2. Walk-Around Inspection Points (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3. Walk-Around Inspection Points (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-4. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-5. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1 Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
4-1 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
1.3 OPERATION
General
• Do not use the machine for any purpose other than • Before operating the machine, make sure all gates are
positioning personnel, their tools, and equipment. closed and fastened or in their proper position.
• Never operate a machine that is not working properly.
If a malfunctions occurs, shut down the machine.
• Never slam a control switch or lever through neutral to
an opposite direction. Always return switch to neutral
and stop before moving the switch to the next function.
Operate controls with slow and even pressure.
• Hydraulic cylinders should never be left fully extended
or fully retracted before shutdown or for long periods of
time.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the plat- • Keep both feet firmly positioned on the platform floor at
form, except in an emergency. all times. Never use ladders, boxes, steps, planks, or
• Do not carry materials directly on platform railing similar items on platform to provide additional reach.
unless approved by JLG. • Never use the elevating assembly to enter or leave the
• When two or more persons are in the platform, the platform.
operator shall be responsible for all machine opera- • Use extreme caution when entering or leaving plat-
tions. form. Be sure that the platform is fully lowered. Face
• Always ensure that power tools are properly stowed the machine, maintain “three point contact” with the
and never left hanging by their cord from the platform machine, using two hands and one foot or two feet and
work area. one hand during entry and exit.
• Supplies or tools which extend outside the platform are • Check orientation of directional arrows on chassis
prohibited unless approved by JLG. before driving. The direction of drive and steer may be
opposite from normal operation based upon orienta-
tion of chassis.
• Platform-to-structure transfers at elevated positions are Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)
discouraged. Where transfer is necessary, enter/exit
through the gate only with the platform within 1 foot MINIMUM SAFE APPROACH
Voltage Range
(0.3m) of a safe and secure structure. 100% tie-off is DISTANCE
(Phase to Phase)
also required in this situation using two lanyards. One in Meters (Feet)
lanyard must be attached to the platform with the sec- 0 to 300V AVOID CONTACT
ond lanyard attached to the structure. The lanyard con- Over 300V to 50 KV 3 (10)
nected to the platform must not be disconnected until
the transfer to the structure is safe and complete. Over 50KV to 200 KV 5 (15)
Over 200 KV to 350 KV 6(20)
Electrocution Hazards Over 350 KV to 500 KV 8 (25)
• This machine is not insulated and does not provide Over 500 KV to 750 KV 11 (35)
protection from contact or proximity to electrical cur- Over 750 KV to 1000 KV 14 (45)
rent.
Tipping Hazards
• The user should be familiar with the surface before
driving. Do not exceed the allowable sideslope and
grade while driving..
• Do not raise the platform or drive from an elevated • Limit travel speed according to conditions of ground
position unless the machine is on firm, level surfaces surface, congestion, visibility, slope, location of per-
and evenly supported. sonnel, and other factors which may cause collision or
injury to personnel.
• Keep the chassis of the machine at least 2 ft. (0.6m)
from holes, bumps, drop-offs, obstructions, debris, • Be aware of stopping distances in all drive speeds.
concealed holes, and other potential hazards on the When driving in high speed, switch to low speed
floor/surface unless approved by JLG. before stopping. Travel grades in low speed only.
• Never attempt to use the machine as a crane. Do not • Do not use high speed drive in restricted or close quar-
tie-off machine to any adjacent structure. ters or when driving in reverse.
• Do not operate the machine when wind conditions • Exercise extreme caution at all times to prevent obsta-
exceed the maximum allowable wind speed. cles from striking or interfering with operating controls
and persons in the platform.
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will • Be sure that operators of other overhead and floor level
decrease stability. machines are aware of the aerial work platform’s pres-
ence. Disconnect power to overhead cranes.
• Do not increase the platform size with unauthorized
deck extensions or attachments. • Warn personnel not to work, stand, or walk under a
raised platform. Position barricades on floor if neces-
• If elevating assembly or platform is in a position that
sary.
one or more wheels are off the ground, all persons
must be removed before attempting to stabilize the
machine. Use cranes, forklift trucks, or other appropri-
ate equipment to stabilize machine and remove per- 1.4 TOWING, LIFTING, AND HAULING
sonnel. • Never allow personnel in platform while towing, lifting,
or hauling.
Crushing and Collision Hazards • This machine should not be towed, except in the event
• Approved head gear must be worn by all operating of emergency, malfunction, power failure, or loading/
and ground personnel. unloading. Refer to the Emergency Procedures section
• Keep hands and limbs out of the elevating assembly of this manual for emergency towing procedures.
during operation. • The platform must be completely empty of tools.
• Check work area for clearances overhead, on sides, • When lifting machine, lift only at designated areas of
and bottom of platform when lifting or lowering plat- the machine. Lift with lifting equipment of adequate
form, and driving. capacity.
• Refer to the Machine Operation section of this manual
for lifting information.
Check oil level in drive hub by removing pipe plug and Control Boxes (Console and Ground)
feeling for oil level. (Contact service personnel for assis-
tance if needed.) Switches operable; no visible damage; placards secure
and legible. Hand controller operable; no visible damage.
NOTE: Torque Hubs should be one-half full of lubricant.
Battery
Tire and Wheel Assemblies Proper electrolyte level; cable connections tight; no visible
damage; no corrosion at battery cable connections.
No loose or missing lug nuts; no visible damage.
Engine
Sliding Wear Pad Blocks
Engine oil level - full mark on dipstick; filler cap secure; air
No excessive wear; adequate lubrication. filter secure.
Machine Log
2.4 DAILY WALK-AROUND INSPECTION
Ensure a machine operating record or log is kept. Check
It is the users responsibility to inspect the machine before
to see that it is current and that no entries have been left
the start of each workday. It is recommended that each
uncleared, leaving machine in an unsafe condition for
user inspect the machine before operation, even if the
operation.
machine has already been put into service under another
user. This Daily Walk-Around Inspection is the preferred
method of inspection.
Daily Lubrication
For those items pointed out in the Daily Walk-Around
In addition to the Daily Walk-Around Inspection, be sure to
Inspection requiring daily lubrication Refer to Table 2-1,
include the following as part of the daily inspection:
Lubrication Chart, for specific requirements.
Overall Cleanliness Perform the following checks and services before attempt-
ing to operate the machine.
Check all standing surfaces for oil, fuel and hydraulic oil
spillage and foreign objects. Ensure overall cleanliness.
5. Drive Brake, Left Front (4 Wheel Drive) - No loose or 22. Leveling Jack, Left Rear (If Equipped) - No loose or
missing parts, no visible damage, no evidence of missing parts, no visible damage. No cylinder leaks
leakage. or damage.
6. Drive Hub, Left Front (4 Wheel Drive) - No visible 23. Battery Installation (Gasoline or Diesel Engine) -
damage, no evidence of leakage. Drive hubs Proper electrolyte level, cables secure, no damage
should be one half full of EPGL SAE 90. or corrosion. Hold-downs secure.
7. Steer/Drive Wheel and Tire Assembly, Left Front - 24. Ladder - No damage, securely attached.
Properly secured, no loose or missing lug nuts, no 25. Leveling Jack, Right Rear (If Equipped) - No loose
visible damage. Refer to inflation psi stenciled on or missing parts, no visible damage. No cylinder
frame. leaks or damage.
8. Oscillating Axle (If Equipped) - Properly secured, 26. Rear Steer Cylinder and Tie Rod Ends (If Equipped)
evidence of proper lubrication. No lockout cylinder - No loose or missing parts, no visible damage. No
leaks or damage. steer cylinder leaks or damage.
9. Ground Controls - Switches operable, no visible 27. Steer Spindle, Right Rear (If Equipped) - No loose
damage, placards secure and legible. or missing parts, no visible damage, evidence of
10. Hydraulic Reservoir - No visible damage or missing proper lubrication.
parts. No evidence of leaks. Recommended oil level
in sight glass. Breather cap secure and working.
28. Drive Motor, Right Rear - No visible damage, no evi- 38. Steer/Drive Wheel and Tire Assembly, Right Front -
dence of leakage. Properly secured, no loose or missing lug nuts, no
visible damage. Refer to inflation psi stenciled on
29. Drive Brake, Right Rear - No loose or missing parts,
frame or wheel rims.
no visible damage, no evidence of leakage.
39. Drive Motor, Right Front (4 Wheel Drive) - No visible
30. Drive Hub, Right Rear - No visible damage, no evi-
damage, no evidence of leakage.
dence of leakage. Drive hubs should be one half full
of EPGL SAE 90. 40. Drive Brake, Right Front (4 Wheel Drive) - No loose
or missing parts, no visible damage, no evidence of
31. Drive Wheel and Tire Assembly, Left Rear - Properly
leakage.
secured no loose or missing lug nuts, no visible
damage. Refer to inflation psi stenciled on frame or 41. Drive Hub, Right Front (4 Wheel Drive) - No visible
wheel rims. damage, no evidence of leakage. Drive hubs
should be one half full of EPGL SAE 90.
32. Sizzor Arms and Sliding Wear Pads - Properly
secured, no visible damage, evidence of proper 42. Steer Spindle, Right Front - No loose or missing
lubrication. Inspect sizzor arm guards for damage parts, no visible damage, evidence of proper lubri-
and proper installation. cation.
33. Lift Cylinder - Properly secured, no visible damage, 43. Leveling Jack, Right Front (If Equipped) - No loose
no loose or missing parts, no evidence leakage. or missing parts, no visible damage. No cylinder
leaks or damage.
34. Safety Prop - Stored securely, no missing parts.
44. Drive and Lift Cutout Switches (If Equipped) - No
35. Hydraulic Pump - Pump properly secured, no visi-
visible damage, properly secured.
ble damage, no evidence of leakage. Hoses and fit-
tings properly secured, no visible damage, no 45. Platform Controls - Properly secured, no loose or
evidence of leaks. missing parts, no visible damage. Placards secure
and legible, control switches return to neutral. Con-
36. Engine Installation - Engine oil to full mark on dip-
trol markings legible, manual in manual storage
stick, oil fillercap secure. Muffler/exhaust system
box.
properly secured, no leakage. Air filter assembly
secure, no loose or missing parts, element clean. 46. Manual Descent Cable - Properly secured, no loose
Gasoline Engine Only - Radiator cap secure, cool- or missing parts, no visible damage.
ant to correct level.
37. Handrail installation - All railings securely attached,
no damage or missing parts, chains securely
attached.
A functional check of all systems should be performed, 1. Place an 8 in (20 cm) high block with ascension
ramp in front of the left front wheel.
under no load, once the walk-around inspection is com-
plete, in an area free of overhead and ground level 2. Activate the machines hydraulic system from the
obstructions. Perform pre-load functional check in accor- platform control station.
dance with the following procedure: 3. Place the engine speed and drive speed control
switches to their respective low positions.
1. Raise and lower platform several times. Check for
smooth elevation and lowering. Check that high 4. Place the drive controller to the forward position and
function speeds cut out at 6 in. (15.2 cm) above fully carefully drive the machine up the ascension ramp
until the left front wheel is on top of the block.
retracted platform height.
5. Raise the machine platform approximately 24 in. (61
2. Drive forward and reverse, check for proper opera- cm.); ensure the lockout cylinder cam valve is free of
tion. the sizzor arm trip bar.
3. Check that drive brakes hold when machine is 6. Place the drive controller to the reverse position and
driven up a hill, not to exceed rated gradeability, and carefully drive the machine off of the block and
ramp.
stopped.
7. Have an assistant check to see that the left front
4. Steer left and right. Check for proper operation. wheel remains locked in position off of the ground.
5. Check hydraulic oil reservoir sight gauge. Refer to 8. Lower the machine platform; the lockout cylinder
Lubrication Chart. should then release the wheel and allow it to rest on
the ground.
9. If the lockout cylinder does not function properly,
have qualified personnel correct the malfunction
TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL prior to any further operation.
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
TIONING MACHINE IS A SAFETY VIOLATION.
INDEX INTERVAL
COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD
NO HOURS
1 Oscillating Axle Pivot Point (Optional) 1 Grease Fitting MPG - Pressure Gun 100
2 Lockout Cylinders (Optional) 2 Grease Fittings (1 each cylinder) MPG - Pressure Gun 100
3 Front Steering Spindles (2-W/D) 2 Grease Fittings MPG - Pressure Gun 100
4 Front Steering Spindles (4-W/D) 2 Grease Fittings MPG - Pressure Gun 100
(Optional)
5 Tow Bar Hitch (Optional) 1 Grease Fitting MPG - Pressure Gun 100
6 Wheel Bearings (2-W/D) N/A MPG - Repack 2000
7 *Wheel Drive Hub (4-W/D) (Optional) Fill Plug EPGL (SAE 90) 500
8 Engine Crankcase Fill Cap/Drain Plug Check Engine Oil Level 10/100
9 Lift Cylinder 2 Grease Fittings MPG - Pressure Gun 100
10 *Wheel Drive Hub Fill Plug EPGL (SAE 90) 500
11 Rear Steering Spindles (4-W/S) 2 Grease Fittings MPG - Pressure Gun 100
(Optional)
12 Rail Slides N/A MPG - Brush 100
13 Hydraulic Oil Reservoir Fill Cap/Drain Plug HO - Check HO Level (See note 4)/ 10/500
HO - Change HO
14 ** Hydraulic Filter Element N/A Initial Change - 40 Hours 250
*Torque Hubs should be 1/2 full of lubricant NOTE: 1. Be sure to lubricate like items on each side
2. Recommended lubricating intervals are based
** JLG Industries recommends replacing the hydraulic
on machine operations under normal conditions.
filter after the first 40 hours of operation and every 250
For machines used in multi-shift operations and/or
hours thereafter.
exposed to hostile environments or conditions,
KEY TO LUBRICANTS: lubrication frequencies must be increased accord-
ingly.
MPG - Multi-purpose Grease 3. Operate hydraulic functions through one com-
EPGL - Extreme Pressure Gear Lube plete cycle before checking hydraulic oil level in
tank. Oil should be visible in ADD sight window on
HO - Hydraulic Oil (Mobil 424) hydraulic tank. If oil is not visible, add oil until oil is
visible in both ADD and FULL sight windows on
tank. Do not overfill tank.
4. Any time the pump coupling is removed, coat
splines of coupling with Texaco Code 1912 grease
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL prior to assembly. (gasoline or diesel engine only).
MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE Changing from LP Gas to Gasoline
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS 1. With engine operating on LP under a no-load condi-
MUST BE FOLLOWED. tion, position the LPG/GAS SELECT switch at
ground control to the GAS SELECT position.
Changing from Gasoline to LP Gas 2. If engine stumbles because of lack of gasoline,
place the switch to the LPG position until engine
1. Start the engine from the ground control station. regains smoothness, then return the switch to the
2. Open the hand valve on the LP Gas supply tank by GAS SELECT position. Repeat as necessary until
turning counterclockwise. engine runs smoothly on gasoline.
3. Close the hand valve on the LP gas supply tank by
turning clockwise.
BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING
TO LP GAS.
2.8 TORQUE REQUIREMENTS
3. While the engine is operating, place the three posi- The Torque Chart, Figure 2-3, consists of standard torque
tion LPG/GAS SELECT switch at the ground control values based on bolt diameter and grade, also specifying
station to the center OFF position. Allow the engine dry and wet torque values in accordance with recom-
to operate, without load, until the engine begins to mended shop practices. This chart is provided as an aid
stumble from lack of gasoline. to the operator in the event he/she notices a condition that
requires prompt attention during the walk-around inspec-
tion or during operation until the proper service personnel
can be notified. Section 1 of the Service and Maintenance
Manual provides specific torque values and periodic
maintenance procedures with a listing of individual com-
ponents. Utilizing this Torque Chart in conjunction with the
preventive maintenance section in Section 2 of the Service
and Maintenance Manual, will enhance safety, reliability
and performance of the machine.
This section provides the necessary information needed 5. Sufficient knowledge of the mechanical operation of
to understand control functions. Included in this section the machine to recognize a malfunction or potential
are the operating characteristics and limitations, and func- malfunction.
tions and purposes of controls and indicators. It is impor-
6. The safest means to operate near overhead obstruc-
tant that the user read and understand the proper
tions, other moving equipment, obstacles, depres-
procedures before operating the machine. These proce-
sions, holes, dropoffs, etc. on the supporting
dures will aid in obtaining optimum service life and safe
surface.
operation.
7. Means to avoid the hazards of unprotected electrical
conductors.
3.2 PERSONNEL TRAINING
8. Any other requirements of a specific job or machine
The sizzor lift is a personnel handling device; therefore, it
application.
is essential that it be operated and maintained only by
authorized personnel who have demonstrated that they
understand the proper use and maintenance of the Training Supervision
machine. It is important that all personnel who are
Training must be done under the supervision of a qualified
assigned to and responsible for the operation and mainte-
operator or supervisor in an open area free of obstructions
nance of the machine undergo a thorough training pro-
until the trainee has developed the ability to safely control
gram and check out period in order to become familiar
a sizzor lift in congested work locations.
with the characteristics prior to operating the machine.
1. Use and limitations of the platform controls, ground 3.3 OPERATING CHARACTERISTICS AND
controls, emergency controls and safety systems.
LIMITATIONS
2. Knowledge and understanding of this manual and of
the control markings, instructions and warnings on General
the machine itself.
A thorough knowledge of the operating characteristics
and limitations of the machine is always the first require-
ment for any user, regardless of user’s experience with
similar types of equipment.
6. Choke Switch - (If Equipped) - A momentary con- 9. Voltmeter - With the emergency stop switch in the
tact, push-button type switch supplies power to the up position, and before starting the engine, the volt-
choke solenoid, when depressed, to assist cold start meter indicates output voltage of the alternator. Nor-
operation. mal reading for the voltmeter will be 12-14 volts with
a properly charged or charging battery.
7. Gasoline/LPG Select Switch - (Dual Fuel Only) -
A three position toggle-type switch is used to select 10. Water Temperature Gauge - (Gasoline Engine) -
the desired method of powering the unit. Placing the The water temperature gauge provides a visual dis-
switch in the gasoline position shuts off the fuel flow play of the engine coolant temperature.
from the LP gas supply tank and allows fuel flow
11. Oil Pressure Gauge - The oil pressure gauge dis-
from the gasoline tank. Moving the switch to the LPG
plays the engine lubrication system operating pres-
position shuts off fuel flow from the gasoline tank
sure.
and allows LP gas from supply tank to be used to
power the unit. With the switch in the center posi-
tion, fuel flow is restricted from both supply tanks.
8. Hourmeter - The hourmeter records engine or elec-
tric motor operating time.
4. Tilt Alarm Warning Horn - The Tilt Alarm Warning 9. PQ Controller - The PQ Controller performs three
Horn is activated by the tilt alarm switch when the functions: Drive, Steer and Drive Speed. On all
chassis is on a severe slope (over 3°) with the plat- machines built before serial number 0200058922,
form raised. tilting the controller in the direction you want to go
(forward or reverse) activates drive in that direction.
The thumb-operated steer switch on top of the con-
troller handle activates the steer wheels in the direc-
IF TILT ALARM IS ON WHEN PLATFORM IS RAISED, LOWER tion it is moved. If machine is equipped with four
PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO wheel steer, this switch operates only the front steer
THAT IT IS LEVEL BEFORE RAISING PLATFORM. wheels. On all machines built after, and including,
serial number 0200058922 there is a red trigger
5. Tilt Alarm Warning Light - A warning light on the switch on the front of the controller. This switch must
control console that lights when the chassis is on a be depressed and held in order to drive the
severe slope (over 3 °). machine.
NOTE: The lift toggle switch automatically returns to the 10. Travel Warning Horn - A push-button type horn
center off position when released. switch supplies electrical power to an audible warn-
ing device when pressed.
11. Light - (If Equipped) - A two position LIGHT control
switch supplies electrical power to lights.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF LIFT 12. Leveling Jacks - (If Equipped) - The four momen-
TOGGLE SWITCH DOES NOT RETURN TO THE CENTER OFF tary contact type toggle switches correspond to the
POSITION WHEN RELEASED. four leveling jacks, one at each corner of the
machine.
6. Lift Switch - The lift toggle switch provides for rais-
ing and lowering the platform when positioned to up
or down.
BE AWARE OF OTHER PERSONNEL AND EQUIPMENT WHEN
7. Engine Speed Switch - A two position engine EXTENDING OR RETRACTING LEVELING JACKS.
speed control switch provides the operator either
high or low engine rpm as required. 13. Engine Distress Light - The engine distress light is
connected to a sensor on the engine that detects
8. Pump Speed Switch - A two position pump speed when oil pressure falls below a preset level, illumi-
control switch allows the operator to select low (one nating the warning light.
pump section operating) or high (both pump sec-
tions operating) speed pump operation.
Starting Procedure
Post-Incident Inspection
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE Following any accident, thoroughly inspect the machine
TO OPERATE OR CONTROL THE MACHINE. and test all functions first from the ground controls, then
from the platform controls. Do not lift above 10 ft (3 m)
1. USE THE MANUAL DESCENT SYSTEM AS FIRST until you are secure that all damage has been repaired, if
CHOICE for bringing the platform and operator required, and that all controls are operating correctly.
down, particularly IF THERE IS INDICATION OF
CONTROL MALFUNCTION. Further use of hydraulic
power may cause severe injury or death. 5.5 INCIDENT NOTIFICATION
2. Operate the machine from ground controls ONLY It is imperative that JLG Industries, Inc. be notified imme-
with the assistance of other personnel and equip- diately of any incident involving a JLG product. Even if no
ment (cranes, overhead hoists, etc.) as may be injury or property damage is evident, the factory should
required to safely remove the danger or emergency be contacted by telephone and provided with all neces-
condition. sary details.
3. Other qualified personnel on the platform may use Contact at 1-877-JLG-SAFE (554-7223) between the hours
the platform controls. DO NOT CONTINUE OPERA- of 8:00 AM - 4:45 PM Eastern Standard time.
TION IF CONTROLS DO NOT FUNCTION NOR- It should be noted that failure to notify the Manufacturer of
MALLY. an incident involving a JLG Industries product within 48
4. Cranes, forklift trucks or other equipment which may hours of such an occurrence may void any warranty con-
be available are to be used to remove platform sideration on that particular machine.
occupants and stabilize motion of the machine in
case machine controls are inadequate or malfunc-
tion when used.
Date Comments
Date Comments
TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and Sky Trak product owner:
If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like
to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG
Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each
JLG product and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current ownership of JLG
Products. Please return completed form to the JLG Product Safety & Reliability Department via facsimile (717) 485-
6573 or mail to address as specified on the back of this form.
Thank you,
Product Safety & Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533
Telephone: (717) 485-5161
Fax: (717) 485-6573
Mfg. Model:
Serial Number:
Previous Owner:
Address:
Please cut on the dotted line and fax to 717-485-6573
City: State:
Zip: Telephone: ( )
Date Of Transfer:
Current Owner:
Address:
City: State:
Zip: Telephone: ( )
Name:
Title:
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762