OPERATORS & SAFETY Model 25RTS 33RTS 40RTS 3120825 March 12, 2004 CORPORATE OFFICE JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA. 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417
JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 2 65 811111 Fax: (61) 2 65 810122 JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035 JLG Industries (Italia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 9359 5845 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025 JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493 JLG Industries (Norge AS) Sofeimyrveien 12 N-1412 Sofienyr Norway Phone: (47) 6682 2000 Fax: (47) 6682 2001 JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: (48) 91 4320 245 Fax: (48) 91 4358 200 JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055 JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342 Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762 JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfalla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534
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. 3120825 JLG Lift a
FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS 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 INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. ON THE MACHINE THIS WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. ON THE MACHINE THIS WILL HAVE AN ORANGE BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES. ON THE MACHINE THIS WILL HAVE A YELLOW BACKGROUND. 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. b JLG Lift 3120825
FOREWORD 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 3120825 JLG Lift c
FOREWORD REVISION LOG Original Issue - March 1, 1993 Revised - September 21, 1999 Revised - October 20, 1999 Revised - May 5, 2000 Revised - October 15, 2001 Revised - March 12, 2004 d JLG Lift 3120825
TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH TABLE OF CONTENTS PAGE NO. 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 SECTION SECTION SECTION 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 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 4 - MACHINE OPERATION 4.1 Description...................................................................4-1 4.2 General......................................................................4-1 4.3 Engine Operation..............................................................4-2 4.4 Raising and Lowering - (Lifting)...................................................4-2 4.5 Leveling Jacks (Optional)........................................................4-3 4.6 Mechanical Platform Extension (Optional)...........................................4-3 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 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 6 - INSPECTION AND REPAIR LOG 3120825 JLG Sizzor i
TABLE OF CONTENTS (Continued) 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 Specifications.........................................................4-1 6-1 Inspection and Repair Log.......................................................6-1 ii JLG Sizzor 3120825
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure that the machine is safe to operate. The owner/user/operator/lessor/lessee of the machine should not operate this machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. ( JLG ). FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROP- ERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.2 PRE-OPERATION Operator Training and Knowledge Read and understand this manual before operating the machine. Do not operate this machine until complete training is performed by authorized persons. Only authorized and qualified personnel can operate the machine. Read, understand, and obey all DANGERS, WARN- INGS, CAUTIONS, and operating instructions on the machine and in this manual. Use the machine in a manner which is within the scope of its intended application set by JLG. All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual. Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine. Workplace Inspection The operator is to take safety measures to avoid all hazards in the work area prior to machine operation. Do not swing turntable or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine. This machine can be operated in temperatures of 0 o F to 104 o F (-20 o C to 40 o C). Consult JLG for operation outside this range. 3120825 JLG Lift 1-1
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions. Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual. Be sure all safety devices are operating properly. Modification of these devices is a safety violation. Do not operate any machine on which safety or instruction placards or decals are missing or illegible. Avoid any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor. Do not assist a stuck or disabled machine by pushing, pulling, or by using machine functions. Only pull the unit from the tie-down lugs on the chassis. Stow elevating assembly and shut off all power before leaving machine. Trip and Fall Hazards When operating a boom lift or vertical mast lift, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. When operating a scissor lift or vertical mast lift, JLG recommends wearing a full body harness. Attach only one (1) lanyard per lanyard anchorage point. 1.3 OPERATION General Do not use the machine for any purpose other than positioning personnel, their tools, and equipment. 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 platform, except in an emergency. Do not carry materials directly on platform railing unless approved by JLG. When two or more persons are in the platform, the operator shall be responsible for all machine operations. Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. Supplies or tools which extend outside the platform are prohibited unless approved by JLG Before operating the machine, make sure all gates are closed and fastened or in their proper position. Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach. Never use the elevating assembly to enter or leave the platform. Use extreme caution when entering or leaving platform. Be sure that the platform is fully lowered. Face the machine, maintain three point contact with the machine, using two hands and one foot or two feet and one hand during entry and exit. Check orientation of directional arrows on chassis before driving. The direction of drive and steer may be opposite from normal operation based upon orientation of chassis. 1-2 JLG Lift 3120825
SECTION 1 - SAFETY PRECAUTIONS Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit through the gate only with the platform within 1 foot (0.3m) of a safe and secure structure. 100% tie-off is also required in this situation using two lanyards. One lanyard must be attached to the platform with the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until the transfer to the structure is safe and complete. Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current. Table 1-1.Minimum Safe Approach Distances (M.S.A.D.) Voltage Range (Phase to Phase) MINIMUM SAFE APPROACH DISTANCE in Feet (Meters) 0 to 300V AVOID CONTACT Over 300V to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) NOTE: This requirement shall apply except where employer, local or governmental regulations are more stringent. DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB- ITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND WIR- ING ARE ENERGIZED UNLESS KNOWN OTHERWISE. Tipping Hazards The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.. Maintain safe distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Safe Approach Distance (MSAD) as shown in Table 1-1. Allow for machine movement and electrical line swaying. Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. Never exceed the maximum platform capacity. Distribute loads evenly on platform floor. 3120825 JLG Lift 1-3
SECTION 1 - SAFETY PRECAUTIONS Do not raise the platform or drive from an elevated position unless the machine is on firm, level surfaces and evenly supported. Keep the chassis of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards on the floor/surface unless approved by JLG. Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Do not operate the machine when wind conditions exceed the maximum allowable wind speed. Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability. Do not increase the platform size with unauthorized deck extensions or attachments. If elevating assembly or platform is in a position that 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 appropriate equipment to stabilize machine and remove personnel. Crushing and Collision Hazards Approved head gear must be worn by all operating and ground personnel. Keep hands and limbs out of the elevating assembly during operation. Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving. Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel. Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only. Do not use high speed drive in restricted or close quarters or when driving in reverse. Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform. Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s presence. Disconnect power to overhead cranes. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor if necessary. 1.4 TOWING, LIFTING, AND HAULING Never allow personnel in platform while towing, lifting, or hauling. This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/ unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures. The platform must be completely empty of tools. When lifting machine, lift only at designated areas of the machine. Lift with lifting equipment of adequate capacity. Refer to the Machine Operation section of this manual for lifting information. During operation, keep all body parts inside platform railing. Use elevating assembly functions, not the drive function to position the platform close to obstacles Always post a lookout when driving in areas where vision is obstructed. Keep non-operating personnel at least 1.8m (6 ft.) away from machine during all driving operations. 1.5 ADDITIONAL HAZARDS / SAFETY Do not use machine as a ground for welding. Do not refuel the machine with the engine running. Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. Charge batteries only in a well ventilated area. 1-4 JLG Lift 3120825
SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine. Ensure that all the necessary inspections have been completed successfully before placing the machine into service. These procedures will aid in obtaining maximum service life and safe operation. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR. 2.2 PREPARATION FOR USE Before a new machine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter, as outlined in paragraph 2-3, Delivery and Periodic Inspection. The unit should be thoroughly checked for hydraulic leaks during initial start-up and run. A check of all components should be made to assure their security. All preparations necessary to place the machine in operation readiness status are the responsibility of management personnel. Preparation requires good common sense, (i.e. lift works smoothly and brakes operate properly) coupled with a series of visual inspections. The mandatory requirements are given in paragraph 2-4, Daily Walk Around Inspection. It should be assured that the items appearing in the Delivery and Periodic Inspection and Functional Check are complied with prior to putting the machine into service. 2.3 DELIVERY AND PERIODIC INSPECTION NOTE: This machine requires periodic safety and maintenance inspections by a JLG Dealer. An annual inspection shall be performed on the aerial platform no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be performed by person(s) certified as a mechanic on the specific make and model of the aerial platform. The following checklist provides a systematic inspection to assist in detecting defective, damaged, or improperly installed parts. The checklist denotes the items to be inspected and conditions to examine. Periodic inspection shall be performed monthly or more often when required by environment, severity, and frequency of usage. This inspection checklist is also applicable and must be followed for all machines that have been in storage or for all machines that will be exposed to harsh or changing climates. Handrail Assemblies Properly installed; no loose or missing parts; no visible damage. Platform Assembly No visible damage; free of dirt and debris. Sizzor Arms No visible damage, abrasions and/or distortions. Electrical Cable No visible damage; properly secured. Pivot Pins No loose or missing retaining hardware; no damage or wear to pin heads which would cause pin to rotate; no evidence of pin or bushing wear. Lift Cylinder No rust, nicks, scratches or foreign material on piston rod. No leakage. Evidence of proper lubrication. Frame No visible damage; loose or missing hardware (top and underside). 3120825 JLG Sizzor 2-1
SECTION 2 - PREPARATION AND INSPECTION Drive Hubs Check oil level in drive hub by removing pipe plug and feeling for oil level. (Contact service personnel for assistance if needed.) NOTE: Torque Hubs should be one-half full of lubricant. Tire and Wheel Assemblies No loose or missing lug nuts; no visible damage. Sliding Wear Pad Blocks No excessive wear; adequate lubrication. Hydraulic Oil Supply Operate hydraulic systems through one complete cycle before checking oil level in hydraulic oil tank. Oil should be visible in ADD sight window on hydraulic oil 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. Steer Cylinder Control Boxes. (Console and Ground) Switches operable; no visible damage; placards secure and legible. Hand controller operable; no visible damage. Battery Proper electrolyte level; cable connections tight; no visible damage; no corrosion at battery cable connections. Engine Engine oil level - full mark on dipstick; filler cap secure; air filter secure. Hydraulic Pump and Valves No visible damage; no evidence of leakage; units secure. Platform Placards No visible damage; placards secure and legible. Lock-Out Cylinders (If Equipped) No rust, nicks, scratches or foreign material on piston rod; no leakage. No rust, nicks, scratches or foreign material on piston rod; no leakage. Steer Linkage No loose or missing parts; no visible damage. Steer Spindle Assemblies No excessive wear; no damage. 2-2 JLG Sizzor 3120825
SECTION 2 - PREPARATION AND INSPECTION 2.4 DAILY WALK-AROUND INSPECTION It is the users responsibility to inspect the machine before the start of each workday. It is recommended that each user inspect the machine before operation, even if the machine has already been put into service under another user. This Daily Walk-Around Inspection is the preferred method of inspection. In addition to the Daily Walk-Around Inspection, be sure to include the following as part of the daily inspection: Overall Cleanliness Check all standing surfaces for oil, fuel and hydraulic oil spillage and foreign objects. Ensure overall cleanliness. Placards Keep all information and operating placards clean and unobstructed. Cover when spray painting or shot blasting to protect legibility. Operators and Safety Manual Ensure a copy of this manual is enclosed in the manual storage box. Machine Log Ensure a machine operating record or log is kept. Check to see that it is current and that no entries have been left uncleared, leaving machine in an unsafe condition for operation. Daily Lubrication For those items pointed out in the Daily Walk-Around Inspection requiring daily lubrication, refer to the Lubrication Chart, Figure 2-2, for specific requirements. Perform the following checks and services before attempting to operate the machine. TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC- TIONING MACHINE IS A SAFETY VIOLATION. 1. Start each day with a full fuel tank. If operating an electric machine, start each day with fully charged batteries. 2. Ensure that all items requiring lubrication are serviced in accordance with the Lubrication Chart, Figure 2-2. 3. Perform functional checks in accordance with paragraph 2-5, Daily Functional Check. 3120825 JLG Sizzor 2-3
SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Walk-Around Inspection Diagram 2-4 JLG Sizzor 3120825
SECTION 2 - PREPARATION AND INSPECTION GENERAL Begin the Walk-Around Inspection at Item 1, as noted on the diagram.continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the Walk-Around Inspection Checklist. TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL- FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC- TIONING MACHINE IS A SAFETY VIOLATION. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DUR- ING WALK-AROUND INSPECTION. NOTE: Do not overlook visual inspection of chassis underside. Checking this area often results in discovery of conditions which could cause extensive machine damage. 1. Steer Cylinder and Tie Rod Ends - No loose or missing parts, no visible damage. No steer cylinder leaks or damage. 2. Leveling Jack, Left Front (If Equipped) - No loose or missing parts, no visible damage. No cylinder leaks or damage. 3. Steer Spindle, Left Front - No loose or missing parts, no visible damage, evidence of proper lubrication. 4. Drive Motor, Left Front (4 Wheel Drive) - No visible damage, no evidence of leakage. 5. Drive Brake, Left Front (4 Wheel Drive) - No loose or missing parts, no visible damage, no evidence of leakage. 6. Drive Hub, Left Front (4 Wheel Drive) - No visible damage, no evidence of leakage. Drive hubs should be one half full of EPGL SAE 90. 7. Steer/Drive Wheel and Tire Assembly, Left Front - Properly secured, no loose or missing lug nuts, no visible damage. Refer to inflation psi stenciled on frame. 8. Oscillating Axle (If Equipped) - Properly secured, evidence of proper lubrication. No lockout cylinder leaks or damage. 9. Ground Controls - Switches operable, no visible damage, placards secure and legible. 10. Hydraulic Reservoir - No visible damage or missing parts. No evidence of leaks. Recommended oil level in sight glass. Breather cap secure and working. 11. Hydraulic Filter - No visible damage, properly secured, no evidence of leakage. 12. Control Valves - Valves properly secured, no visible damage, no evidence of leakage. Hoses and fittings properly secured, no visible damage, no evidence of leaks. 13. Tilt Alarm Switch - Properly secured, no loose or missing parts, no visible damage. 14. Fuel Tank - Filler cap secure, sight gauge visible, no damage or leaks. 15. Safety Prop - Stored securely, no missing parts. 16. Travel/Descent/Motion Alarm - Properly secured, no loose or missing parts, no visible damage. 17. Drive Motor, Left Rear - No visible damage, no evidence of leakage. 18. Drive Brake, Left Rear - No loose or missing parts, no visible damage, no evidence of leakage. 19. Drive Hub, Left Rear - No visible damage, no evidence of leakage. Drive hubs should be one half full of EPGL SAE 90. 20. Drive Wheel and Tire Assembly, Left Rear - Properly secured, no loose or missing lug nuts, no visible damage. Refer to inflation psi stenciled on frame or wheel rims. 21. Steer Spindle, Left Rear (If Equipped) - No loose or missing parts, no visible damage, evidence of proper lubrication. 22. Leveling Jack, Left Rear (If Equipped) - No loose or missing parts, no visible damage. No cylinder leaks or damage. 23. Battery Installation (Gasoline or Diesel Engine) - Proper electrolyte level, cables secure, no damage or corrosion. Hold-downs secure. 24. Ladder - No damage, securely attached. 25. Leveling Jack, Right Rear (If Equipped) - No loose or missing parts, no visible damage. No cylinder leaks or damage. 26. Rear Steer Cylinder and Tie Rod Ends (If Equipped) - No loose or missing parts, no visible damage. No steer cylinder leaks or damage. 27. Steer Spindle, Right Rear (If Equipped) - No loose or missing parts, no visible damage, evidence of proper lubrication. Figure 2-2. Walk-Around Inspection Points (Sheet 1 of 2) 3120825 JLG Sizzor 2-5
SECTION 2 - PREPARATION AND INSPECTION 28. Drive Motor, Right Rear - No visible damage, no evidence of leakage. 29. Drive Brake, Right Rear - No loose or missing parts, no visible damage, no evidence of leakage. 30. Drive Hub, Right Rear - No visible damage, no evidence of leakage. Drive hubs should be one half full of EPGL SAE 90. 31. Drive Wheel and Tire Assembly, Left Rear - Properly secured no loose or missing lug nuts, no visible damage. Refer to inflation psi stenciled on frame or wheel rims. 32. Sizzor Arms and Sliding Wear Pads - Properly secured, no visible damage, evidence of proper lubrication. Inspect sizzor arm guards for damage and proper installation. 33. Lift Cylinder - Properly secured, no visible damage, no loose or missing parts, no evidence leakage. 34. Safety Prop - Stored securely, no missing parts. 35. Hydraulic Pump - Pump properly secured, no visible damage, no evidence of leakage. Hoses and fittings properly secured, no visible damage, no evidence of leaks. 36. Engine Installation - Engine oil to full mark on dipstick, oil fillercap secure. Muffler/exhaust system properly secured, no leakage. Air filter assembly secure, no loose or missing parts, element clean. Gasoline Engine Only - Radiator cap secure, coolant to correct level. 37. Handrail installation - All railings securely attached, no damage or missing parts, chains securely attached. 38. Steer/Drive Wheel and Tire Assembly, Right Front - Properly secured, no loose or missing lug nuts, no visible damage. Refer to inflation psi stenciled on frame or wheel rims. 39. Drive Motor, Right Front (4 Wheel Drive) - No visible damage, no evidence of leakage. 40. Drive Brake, Right Front (4 Wheel Drive) - No loose or missing parts, no visible damage, no evidence of leakage. 41. Drive Hub, Right Front (4 Wheel Drive) - No visible damage, no evidence of leakage. Drive hubs should be one half full of EPGL SAE 90. 42. Steer Spindle, Right Front - No loose or missing parts, no visible damage, evidence of proper lubrication. 43. Leveling Jack, Right Front (If Equipped) - No loose or missing parts, no visible damage. No cylinder leaks or damage. 44. Drive and Lift Cutout Switches (If Equipped) - No visible damage, properly secured. 45. Platform Controls - Properly secured, no loose or missing parts, no visible damage. Placards secure and legible, control switches return to neutral. Control markings legible, manual in manual storage box. 46. Manual Descent Cable - Properly secured, no loose or missing parts, no visible damage. Figure 2-3. Walk-Around Inspection Points (Sheet 2 of 2) 2-6 JLG Sizzor 3120825
SECTION 2 - PREPARATION AND INSPECTION 2.5 DAILY FUNCTIONAL CHECK TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. A functional check of all systems should be performed, under no load, once the walk-around inspection is complete, in an area free of overhead and ground level obstructions. Perform pre-load functional check in accordance with the following procedure: 1. Raise and lower platform several times. Check for smooth elevation and lowering. Check that high function speeds cut out at 15.2 cm (6 in.) above fully retracted platform height. 2. Drive forward and reverse, check for proper operation. 3. Check that drive brakes hold when machine is driven up a hill, not to exceed rated gradeability, and stopped. 4. Steer left and right. Check for proper operation. 5. Check hydraulic oil reservoir sight gauge. Refer to Lubrication Chart. TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC- TIONING MACHINE IS A SAFETY VIOLATION. 2.6 LOCK-OUT CYLINDER CHECK - (IF EQUIPPED) To be performed quarterly, any time a system component is replaced, or when improper system operation is suspected on machines with oscillating axles. NOTE: Ensure platform is fully lowered prior to beginning lockout cylinder check. 1. Place an 20 cm (8 in) high block with ascension ramp in front of the left front wheel. 2. Activate the machines hydraulic system from the platform control station. 3. Place the engine speed and drive speed control switches to their respective low positions. 4. Place the drive controller to the forward position and carefully drive the machine up the ascension ramp until the left front wheel is on top of the block. 5. Raise the machine platform approximately 61 cm (24 in.); ensure the lockout cylinder cam valve is free of the sizzor arm trip bar. 6. Place the drive controller to the reverse position and carefully drive the machine off of the block and ramp. 7. Have an assistant check to see that the left front wheel remains locked in position off of the ground. 8. Lower the machine platform; the lockout cylinder 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 prior to any further operation. 3120825 JLG Sizzor 2-7
SECTION 2 - PREPARATION AND INSPECTION Figure 2-4. Lubrication Diagram 2-8 JLG Sizzor 3120825
SECTION 2 - PREPARATION AND INSPECTION INDEX NO Table 2-1. Lubrication Chart COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD INTERVAL 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 ** JLG Industries recommends replacing the hydraulic filter after the first 40 hours of operation and every 250 hours thereafter. KEY TO LUBRICANTS: MPG - Multi-purpose Grease EPGL - Extreme Pressure Gear Lube HO - Hydraulic Oil (Mobil 424) TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED. NOTE: 1. Be sure to lubricate like items on each side 2. Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly. 3. Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank. Oil should be visible in ADD sight window on 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 prior to assembly. (gasoline or diesel engine only). 3120825 JLG Sizzor 2-9
SECTION 2 - PREPARATION AND INSPECTION 2.7 DUAL FUEL SYSTEM IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. Changing from Gasoline to LP Gas 1. Start the engine from the ground control station. 2. Open the hand valve on the LP Gas supply tank by turning counterclockwise. BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS. 3. While the engine is operating, place the three position LPG/GAS SELECT switch at the ground control station to the center OFF position. Allow the engine to operate, without load, until the engine begins to stumble from lack of gasoline. 4. As the engine begins to stumble place the switch to the LPG position, allowing the LP fuel to be sent to the fuel regulator. Changing from LP Gas to Gasoline 1. With engine operating on LP under a no-load condition, position the LPG/GAS SELECT switch at ground control to the GAS SELECT position. 2. If engine stumbles because of lack of gasoline, place the switch to the LPG position until engine regains smoothness, then return the switch to the GAS SELECT position. Repeat as necessary until engine runs smoothly on gasoline. 3. Close the hand valve on the LP gas supply tank by turning clockwise. 2.8 TORQUE REQUIREMENTS Figure 2-5., Torque Chart consists of standard torque values based on bolt diameter and grade, also specifying dry and wet torque values in accordance with recommended shop practices. This chart is provided as an aid to the operator in the event he/she notices a condition that requires prompt attention during the walk-around inspection 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 components. 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. 2-10 JLG Sizzor 3120825
SECTION 2 - PREPARATION AND INSPECTION Figure 2-5. Torque Chart 3120825 JLG Sizzor 2-11
SECTION 2 - PREPARATION AND INSPECTION This page intentionally left blank. 2-12 JLG Sizzor 3120825
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 GENERAL SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI- BILITY OF THE USER AND HIS OPERATING PERSONNEL. This section provides the necessary information needed to understand control functions. Included in this section are the operating characteristics and limitations, and functions and purposes of controls and indicators. It is important that the user read and understand the proper procedures before operating the machine. These procedures will aid in obtaining optimum service life and safe operation. 3.2 PERSONNEL TRAINING The sizzor lift is a personnel handling device; therefore, it 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 machine. It is important that all personnel who are assigned to and responsible for the operation and maintenance of the machine undergo a thorough training program and check out period in order to become familiar with the characteristics prior to operating the machine. Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not be permitted to operate the machine. Operator Training Operator training must include instruction in the following: 1. Use and limitations of the platform controls, ground controls, emergency controls and safety systems. 2. Knowledge and understanding of this manual and of the control markings, instructions and warnings on the machine itself. 3. Knowledge and understanding of all safety work rules of the employer and of Federal, State and Local Statutes, including training in the recognition and avoidance of potential hazards in the work place; with particular attention to the work to be performed. 4. Proper use of all required personnel safety equipment. 5. Sufficient knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction. 6. The safest means to operate near overhead obstructions, other moving equipment, obstacles, depressions, holes, dropoffs, etc. on the supporting surface. 7. Means to avoid the hazards of unprotected electrical conductors. 8. Any other requirements of a specific job or machine application. Training Supervision Training must be done under the supervision of a qualified operator or supervisor in an open area free of obstructions until the trainee has developed the ability to safely control a sizzor lift in congested work locations. Operator Responsibility The operator must be instructed that he has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site and to request further information from his supervisor or JLG Distributor before proceeding. NOTE: Manufacturer or Distributor will provide qualified persons for training assistance with first unit(s) delivered and thereafter as requested by user or his personnel. 3.3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first requirement for any user, regardless of user s experience with similar types of equipment. Placards Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This information is placed at various locations for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine. See foreword for definitions of the above placards. 3120825 JLG Sizzor 3-1
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Capacities Raising platform above horizontal with or without any load in platform, is based on the following criteria: 1. Machine is positioned on a smooth, firm and level surface. 2. Load is within manufacturer s rated capacity. 3. All machine systems are functioning properly. Stability This machine, as originally manufactured by JLG and operated within its rated capacity on a smooth, firm and level supporting surface, provides a stable aerial platform for all platform positions. 3.4 CONTROLS AND INDICATORS RTS SERIES SCISSOR LIFTS MANUFACTURED AFTER AUGUST 26, 1996 ARE EQUIPPED WITH A HYDRAULIC OIL TEMPERATURE SWITCH THAT SHUTS DOWN THE ENGINE WHEN THE HYDRAU- LIC OIL REACHES A TEMPERATURE OF APPROXIMATELY 111 DEGREES C (230 DEGREES F). THIS SHUT DOWN IS INTENDED TO PROTECT THE HYDRAULIC SYSTEM AND ITS COMPONENTS FROM DAMAGE DUE TO EXCESSIVE HEAT. HEAT MAY BUILD UP DUE TO EXTENDED DRIVING, IN CONJUNCTION WITH HIGH AMBIENT TEMPERATURES, ACTIVATING THIS SWITCH AND SHUTTING DOWN THE MACHINE. IF THE MACHINE SHUTS DOWN, ALLOW THE HYDRAULIC OIL TO COOL, THEN RESUME NORMAL OPERATION. 2. Platform/Ground Select Switch - A three position Platform/Ground Select switch supplies operating power to the platform or ground controls, as selected. When positioned to platform, the switch provides power to the platform controls. When positioned to ground, the switch provides power to the ground controls. With the power selector switch in the center off position, power is shut off to both platform and ground controls. NOTE: With the Platform/Ground Select switch positioned to ground, engine speed will stay in low at all times. 3. Start Button - A momentary contact, push-buttontype switch that supplies electrical power to the starter solenoid when the ignition/emergency stop switch is in the on position and the start button is depressed. 4. Lift Switch - A three position, momentary contact lift control switch provides raising and lowering of the platform when positioned to up or down. 5. High Engine Circuit Breaker (Diesel Engine) - A push button reset 3 Amp circuit breaker, located at the ground control panel, returns interrupted power to the machine functions when depressed. Ground Control Station DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPEC- TIONS FROM THE GROUND CONTROL STATION AS POSSIBLE. 1. Ignition/Emergency Stop - A two-position, red mushroom shaped switch supplies electrical power to the Start button when positioned up. When positioned down, the switch shuts off electrical power to the ignition circuit, acting as an emergency stop switch. NOTE: With the Main Power switch in the off position, the key can be removed in order to incapacitate the machine on the jobsite to avoid unauthorized use of the machine. 3-2 JLG Sizzor 3120825
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-1. Ground Control Station 6. Choke Switch - (If Equipped) - A momentary contact, push-button type switch supplies power to the choke solenoid, when depressed, to assist cold start operation. 7. Gasoline/LPG Select Switch - (Dual Fuel Only) - A three position toggle-type switch is used to select the desired method of powering the unit. Placing the switch in the gasoline position shuts off the fuel flow from the LP gas supply tank and allows fuel flow from the gasoline tank. Moving the switch to the LPG position shuts off fuel flow from the gasoline tank and allows LP gas from supply tank to be used to power the unit. With the switch in the center position, fuel flow is restricted from both supply tanks. 9. Voltmeter - With the emergency stop switch in the up position, and before starting the engine, the voltmeter indicates output voltage of the alternator. Normal reading for the voltmeter will be 12-14 volts with a properly charged or charging battery. 10. Water Temperature Gauge - (Gasoline Engine) - The water temperature gauge provides a visual display of the engine coolant temperature. 11. Oil Pressure Gauge - The oil pressure gauge displays the engine lubrication system operating pressure. 8. Hourmeter - The hourmeter records engine or electric motor operating time. 3120825 JLG Sizzor 3-3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-2. Platform Control Station Platform Control Station 1. Enable Switch -These machines are equipped with an enable switch on the side of the platform control console. On machines built with a serial number before 0200058922, the enable switch must be pressed before activating the drive, lift or steer functions. A built-in timer shuts off power to these functions if they are not activated within 3 seconds after the enable switch is depressed. In addition, this timer will shut off power to the drive and lift functions 3 seconds after they are deactivated, making if necessary to depress the enable switch before activating drive and lift again. The steer function, unless activated in conjunction with the drive or lift functions, will automatically cut off after 3 seconds of operation. On machines built from, and including, serial number 0200058922, the enable switch must be depressed and held for the duration of lift. The enable switch works in conjunction with the lift switch only. 2. Ignition/Emergency Stop Switch - An ignition/ emergency stop red mushroom-type switch is provided in order to turn on machine power in the platform and also to turn off machine power in the event of an emergency. Power is turned on by positioning the switch to the up (on) position, and is turned off by positioning the switch to the down (off) position. 3. Start Button - A momentary contact, push-buttontype switch that supplies electrical power to the starter solenoid when the ignition/emergency stop switch is in the on position and the start button is depressed. 4. Tilt Alarm Warning Horn - The Tilt Alarm Warning Horn is activated by the tilt alarm switch when the chassis is on a severe slope (over 3 ) with the platform raised. 3-4 JLG Sizzor 3120825