Operation & Safety Manual: Models

Operation & Safety Manual
Models
400RTS
500RTS
3120695
November 9, 2007
FOREWORD
FOREWORD
The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine
operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should
be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS
YOUR MOST IMPORTANT TOOL - Keep it with the machine. REMEMBER ANY EQUIPMENT IS ONLY AS
SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER-
ATING PERSONNEL.
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/
OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL
FROM JLG INDUSTRIES, PER OSHA REGULATIONS.
THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION,
IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas. They are
defined as follows:
DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
DEATH. OR DEATH.
IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOL-
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE LOWED, MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE MACHINE.
PRACTICES
JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM-
PLETED ON THE AFFECTED JLG PRODUCT. CALL 1 - 877 - JLG - SAFE
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notifica-
tion. Contact JLG Industries, Inc. for updated information.
3120695 – JLG Sizzor – a

FOREWORD
All procedures herein are based on the use of the machine JLG requirements and to be at least as safe as it was
under proper operating conditions, with no deviations prior to modification.
from original design intent... as per OSHA regulations. 9. Aerial lifts shall not be used near electric power
lines unless the lines have been de energized or ade-
quate clearance is maintained (See OSHA 29 CFR
1910.67 and 1926.453).
READ & HEED! 10. Employees using aerial lifts shall be instructed on
how to recognize and avoid unsafe conditions and
hazards.
The ownership, use, service, and/or maintenance of this 11. Ground controls shall not be operated unless permis-
sion has been obtained from personnel in the plat-
machine is subject to various governmental and local laws
form, except in case of an emergency.
and regulations. It is the responsibility of the owner/user
to be knowledgeable of these laws and regulations and to 12. Regular inspection of the job site and aerial lift shall
comply with them. Owner/user/operator must be familiar be performed by competent persons.
with Sections 6,7,8,9, and 10 of ANSI A92.6-1999. These 13. Personnel shall always stand on the floor of the plat-
sections contain the responsibilities of the owner, users, form, not on boxes, planks, railing or other devices,
operators, lessors, and lessees concerning safety, training, for a work position.
inspection, maintenance, application and operation. The
most prevalent regulations of this type in the United States *Applicable Federal OSHA regulations for the United
are the Federal OSHA Safety Regulations*. Listed below, States, as of the date of publication of this manual,
in abbreviated form are some of the requirements of Fed- include, but are not limited to, 29 CFR 1910.67, 29 CFR
eral OSHA regulations in effect as of the date of publica- 1926.20, 29 CFR 1926.21, 29 CFR 1926.28, and 29 CFR
tion of this handbook. 1926.453.
The listing of these requirements shall not relieve the

owner/user of the responsibility and obligation to deter-
mine all applicable laws and regulations and their exact
wording and requirements, and to comply with the
requirements. Nor shall the listing of these requirements
constitute an assumption of responsibility of liability on
the part of JLG Industries, Inc.
1. Only trained and authorized operators shall be per-

mitted to operate the aerial lift.
2. A malfunctioning lift shall be shut down until
repaired.
3. The controls shall be plainly marked as to their func-
tion.
4. The controls shall be tested each day prior to use to
determine that they are in safe operating condition.
5. All personnel in the platform shall, at all times, wear
approved fall protection devices and other safety
gear as required.
6. Load limits specified by the manufacturer shall not
be exceeded.
7. Instruction and warning placards must be legible.
8. Aerial lifts may be field modified for uses other than
those intended by the manufacturer only if certified
in writing by the manufacturer to be in conformity to
b – JLG Sizzor – 3120695

FOREWORD
REVISION LOG
June 1, 1993 - Original Issue
May 6, 1999 - Revised
October 29, 1999 - Revised
Pro 65 page added - Updated 4-19-00
Revised - Updated 4-19-00
Revised August 20, 2002
Revised December 5, 2002
Revised September 26, 2007
Revised November 9, 2007
3120695 – JLG Sizzor – c

FOREWORD
This page left blank intentionally.
d – JLG Sizzor – 3120695

TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
TABLE OF CONTENTS
SECTION -
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Driving/Towing/Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Pre-operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SECTION 2 - MACHINE 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.6 Lockout Cylinder Check (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.7 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.8 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 Raising and Lowering (Lifting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 Traversing Platform (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.7 Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.8 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.9 Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.10 Safety Props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.11 Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.12 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
SECTION 6 - INSPECTION AND REPAIR LOG
3120695 – JLG Sizzor – i

TABLE OF CONTENTS (Continued)
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-2. Walk-Around Inspection Points (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-5. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-6. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Control Panel Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Decal Location - Right Side (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5. Decal Location - Left Side (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5-1. Drive Hub Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Drive Hub Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Minimum Approach Distances (M.A.D.) to energized (exposed or insulated) power lines
and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
ii – JLG Sizzor – 3120695

SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL 1.2 DRIVING/TOWING/CARRYING

This section prescribes the proper and safe practices for Before driving the machine the user must be familiar with
major areas of machine usage which have been divided the drive, steer and stopping characteristics. This is espe-
into three basic categories: Driving, Operation, and Main- cially important when driving in close quarters.
tenance. In order to promote proper usage of the
The user should be familiar with the driving surface before
machine, it is mandatory that a daily routine be estab-
driving. The surface should be firm and level and grades
lished based on the instructions given in this manual. A
should not exceed the allowable grade for the machine,
maintenance program, using the information provided in
25%.
the Service and Maintenance Manual, must also be estab-
lished by a qualified person and must be followed to NOTE: Remember that the key to safe and proper usage is
ensure that the machine is safe to operate. common sense and its careful application.
The owner/user/operator/lessor/lessee of the machine
should not accept operating responsibility until this man- It is not recommended that this machine be towed, except
ual has been read and operation of the machine, under in the event of a machine malfunction, a total machine
the supervision of an experienced and qualified operator, power failure, or for loading on a truck. Refer to Section 6
has been completed. Owner/user/operator/lessor/lessee for emergency towing procedures.
must be familiar with Sections 6, 7, 8, 9, and 10 of ANSI
A92.6 -1999. These sections contain the responsibilities of
the owner, users, operators, lessors and lessees concern- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
ing safety, training, inspection, maintenance, application THIS SECTION AND ON MACHINE MAY RESULT IN MACHINE
and operation. If there is a question on application and or DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY
operation, JLG Industries should be consulted VIOLATION.
Carrying or loading the unit should be accomplished

MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM using a forklift vehicle of suitable capacity with the forks
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF being positioned correctly at the indicated areas on the
THE MANUFACTURER. machine frame. Refer to Section 4 for lifting information.
3120695 – JLG Sizzor – 1-1

1.3 ELECTROCUTION HAZARD
NOTE: MAINTAIN M.A.D. FROM ALL OTHER CHARGED

LINES AND PARTS AS WELL AS THOSE SHOWN.
DO NOT MANEUVER MACHINE OR PERSONEL INSIDE PROHIB-
ITED ZONE. ASSUME ALL ELECTRICAL PARTS AND WIRING ARE M.A.D. = MINIMUM APPROACH DISTANCE
ENERGIZED UNLESS KNOWN OTHERWISE.
(SEE TABLE BELOW)
Table 1-1.
Minimum Approach Distances (M.A.D.) to energized
(exposed or insulated) power lines and parts
VOLTAGE RANGE MINIMUM APPROACH DISTANCE

(Phase To Phase) Feet (Meters)
0 to 300V AVOID CONTACT
Over 300V to 50KV 10 (3)
Over 50KV to 200KV 15 (5)
Over 200KV to 350KV 20 (6)
Over 350KV to 500KV 25 (8)
Over 500KV to 750KV 35 (11)
Over 750KV to 1000KV 45 (14)
MAINTAIN SAFE CLEARANCE FROM ELECTRICAL LINES MAINTAIN A CLEARANCE OF AT LEAST 10 FEET (3 M)
AND APPARATUS. ALLOW FOR PLATFORM SWAY, ROCK BETWEEN ANY PART OF THE MACHINE OR ITS LOAD
OR SA G AND ELECT RICAL LI NE SWAYI N G. THE AND ANY ELECTRICAL LINE OR APPARATUS CARRYING
MACHINE DOES NOT PROVIDE PROTECTION FROM UP TO 50,000 VOLTS. ONE FOOT (0.3 M) ADDITIONAL
CONTACT WITH OR PROXIMITY TO ELECTRICAL CUR- CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL
RENT. 30,000 VOLTS OR LESS.
1-2 – JLG Sizzor – 3120695

1.4 PRE-OPERATIONAL
• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE • DO NOT OPERATE MACHINE WHEN WIND CONDI-
READ - THEN BEGIN OPERATIONS. TIONS EXCEED 30 MPH.
• ALLOW ONLY THOSE AUTHORIZED AND QUALIFIED • NEVER OPERATE OR RAISE PLATFORM WHEN
PERSONNEL TO OPERATE MACHINE WHO HAVE MACHINE IS ON A TRUCK OR OTHER VEHICLE.
DEMONSTRATED THAT THEY UNDERSTAND SAFE
• THIS MACHINE CAN BE OPERATED IN NOMINAL
AND PROPER OPERATION AND MAINTENANCE OF
AMBIENT TEMPERATURES OF 0° F TO 104° F (-20° C
THE UNIT. TO 40° C). CONSULT FACTORY TO OPTIMIZE OPER-
• AN OPERATOR MUST NOT ACCEPT OPERATING ATION OUTSIDE THIS TEMPERATURE RANGE
RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS .
BEEN GIVEN BY COMPETENT AND AUTHORIZED

PERSONS.
• READ AND OBEY ALL WARNINGS, CAUTIONS AND

OPERATING INSTRUCTIONS ON MACHINE AND IN
THIS MANUAL.
• BE FAMILIAR WITH LOCATION AND OPERATION OF

GROUND CONTROLS.
• BEFORE OPERATION CHECK WORK AREA FOR • APPROVED HEAD GEAR MUST BE WORN WHEN
OVERHEAD ELECTRIC LINES, MACHINE TRAFFIC REQUIRED BY ALL OPERATING AND GROUND PER-
SUCH AS BRIDGE CRANES, HIGHWAY, RAILWAY AND SONNEL.
CONSTRUCTION EQUIPMENT.
• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN

THE WORK AREA MUST BE TAKEN BY THE OPERA-
TOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.
• DO NOT OPERATE THIS MACHINE UNLESS IT HAS

BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.
• ENSURE DAILY INSPECTION AND FUNCTION CHECK • ALWAYS USE ‘THREE POINT CONTACT’ WITH THE
ARE PERFORMED PRIOR TO PLACING MACHINE MACHINE. FACE THE MACHINE WHEN ENTERING
INTO OPERATION. OR LEAVING THE PLATFORM. ‘THREE POINT CON-
TACT’ MEANS THAT TWO HANDS AND ONE FOOT
• NEVER DISABLE OR MODIFY ANY SAFETY DEVICE. OR ONE HAND AND TWO FEET ARE IN CONTACT
ANY MODIFICATION OF THE MACHINE IS A SAFETY WITH THE MACHINE AT ALL TIMES DURING MOUNT
VIOLATION AND IS A VIOLATION OF OSHA RULES. AND DISMOUNT.
3120695 – JLG Sizzor – 1-3

• KEEP NON-OPERATING PERSONNEL AT LEAST 6

1.5 DRIVING FEET (1.8 M) AWAY FROM MACHINE DURING DRIV-
ING OPERATIONS.
1.6 OPERATION
• WATCH FOR OBSTRUCTIONS AROUND MACHINE

AND OVERHEAD WHEN DRIVING.
• READ YOUR MANUAL, UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.
• DO NOT OPERATE ANY MACHINE ON WHICH DAN-
GER, WARNING, CAUTION OR INSTRUCTION PLAC-
ARDS OR DECALS ARE MISSING OR ILLEGIBLE.
• CHECK TRAVEL PATH FOR PERSONS, HOLES,

BUMPS, DROP-OFF, OBSTRUCTIONS, DEBRIS, AND
COVERINGS WHICH MAY CONCEAL HOLES AND
OTHER HAZARDS.
• DO NOT DRIVE WITH PLATFORM RAISED OR RAISE • NEVER USE SCISSOR ARMS TO GAIN ACCESS TO
PLATFORM WHILE ON A SLOPING, UNEVEN, OR OR LEAVE PLATFORM.
SOFT SURFACE.
• WHEN APPLICABLE BY REASON OF LOCAL REGULA-
• BEFORE DRIVING ON FLOORS, BRIDGES, TRUCKS TIONS OR JOBSITE/EMPLOYER SAFETY RULES, ALL
AND OTHER SURFACES, CHECK ALLOWABLE PERSONNEL IN THE PLATFORM SHALL AT ALL
CAPACITY OF SURFACES. T I M E S W E A R A P P R OV E D FA L L P R O T E C T I O N
• DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES, DEVICES AND OTHER SAFETY GEAR AS REQUIRED.
AS TIPPING WILL OCCUR. • TO AVOID FALLING - USE EXTREME CAUTION WHEN
E N T E R I N G O R L E A V I N G P L AT F O R M A B O V E
• WHEN DRIVING IN HIGH SPEED, SWITCH TO LOW
BEFORE STOPPING. TRAVEL GRADES IN LOW DRIVE GROUND. ENTER OR EXIT THRU GATE ONLY. PLAT-
FORM MUST BE WITHIN 1 FT (0.3 M) OF ADJACENT -
ONLY. THE HYDRAULIC MOTORS GENERATE MAXI-
SAFE AND SECURE - STRUCTURE.
MUM TORQUE WHEN THE JOYSTICK IS PLACED IN
THE SLOW DRIVE POSITION. MOTORS ALSO ACT AS
SERVICE BRAKES.
• DO NOT USE HIGH SPEED DRIVE IN RESTRICTED
OR CLOSE QUARTERS OR WHEN DRIVING IN
REVERSE.
• BE AWARE OF STOPPING DISTANCES WHEN TRAV-
ELING IN HIGH AND LOW SPEEDS.
• ALWAYS POST A LOOKOUT WHEN DRIVING IN
AREAS WHERE VISION IS OBSTRUCTED.
1-4 – JLG Sizzor – 3120695

• TRANSFERS BETWEEN A STRUCTURE AND THE

PLATFORM EXPOSE OPERATORS TO FALL POTEN-
TIALS. THIS PRACTICE SHOULD BE DISCOURAGED
WHEREVER POSSIBLE. WHERE TRANSFER MUST
BE ACCOMPLISHED TO PERFORM THE JOB, TWO
LANYARDS WILL BE USED. ONE LANYARD SHOULD
BE ATTACHED TO THE PLATFORM, THE OTHER TO
THE STRUCTURE. THE SAFETY LANYARD THAT IS
ATTACHED TO THE PLATFORM SHOULD NOT BE
DISCONNECTED UNTIL SUCH TIME AS THE TRANS-
FER TO THE STRUCTURE IS COMPLETE.
• NEVER POSITION LADDERS, STEPS, OR SIMILAR

ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE. • NEVER EXCEED MANUFACTURERS RATED PLAT-
FORM CAPACITY - REFER TO CAPACITY DECAL ON
• WHEN RIDING IN OR WORKING FROM PLATFORM MACHINE. DISTRIBUTE LOAD EVENLY ON PLAT-
BOTH FEET MUST BE FIRMLY POSITIONED ON FORM FLOOR.
DECK.
• ENSURE MACHINE IS POSITIONED ON A FIRM,
• DO NOT EXTEND REACH LIMITS OF THIS MACHINE LEVEL AND UNIFORM SUPPORTING SURFACE
WITH ADDITIONAL EQUIPMENT SUCH AS PLANKS, BEFORE RAISING PLATFORM.
BOXES, ETC. • DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS
T O P L AT F O R M . A D D I T I O N O F S U C H I T E M S
• DO NOT OPERATE WITHOUT HANDRAILS IN PLACE
INCREASES EXPOSED WIND AREA OF MACHINE.
AND SECURED. IT IS A SAFETY VIOLATION.
• DO NOT ATTACH OVERHANGING LOADS TO THE
• DO NOT STEP OUTSIDE OF HANDRAILS. PLATFORM OR INCREASE THE PLATFORM SIZE
WITH UNAUTHORIZED DECK EXTENSIONS OR
• AVOID ACCUMULATION OF DEBRIS ON PLATFORM
ATTACHMENTS.
WORK AREA. KEEP MUD, OIL, GREASE AND OTHER
SLIPPERY SUBSTANCES FROM FOOTWEAR AND • DO NOT ELEVATE PLATFORM UNLESS MACHINE IS
PLATFORM DECK. LEVEL.
• DO NOT TIE OFF MACHINE TO ANY ADJACENT
STRUCTURE. NEVER ATTACH WIRE, CABLE OR ANY
SIMILAR ITEMS TO PLATFORM.
• CHECK CLEARANCES ABOVE, ON SIDES AND BOT-

TOM OF PLATFORM WHEN RAISING AND LOWERING
PLATFORM. • DURING OPERATION KEEP ALL BODY PARTS INSIDE
PLATFORM RAILINGS.
• EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER- • NEVER ‘SLAM’ A CONTROL SWITCH OR LEVER
FERING WITH OPERATING CONTROLS AND PER- THROUGH NEUTRAL TO OPPOSITE DIRECTION.
SONS IN THE PLATFORM. ALWAYS RETURN SWITCH TO NEUTRAL AND STOP;
THEN MOVE SWITCH TO THE DESIRED POSITION.
• ENSURE THAT OPERATORS OF OTHER OVERHEAD OPERATE LEVERS WITH SLOW, EVEN PRESSURE.
AND FLOOR LEVEL MACHINES ARE AWARE OF THE
• DO NOT CARRY MATERIALS ON PLATFORM RAILING
AERIAL PLATFORM’S PRESENCE. DISCONNECT
POWER TO OVERHEAD CRANES. BARRICADE • NEVER OPERATE A MALFUNCTIONING MACHINE. IF
FLOOR AREA IF NECESSARY. A MALFUNCTION OCCURS, SHUT DOWN THE
3120695 – JLG Sizzor – 1-5

MACHINE , RED TAG IT, AND NOTIFY PROPER Your safety, and that of others, is the first consideration
AUTHORITIES. when engaging in the maintenance of equipment. Always
be conscious of weight.
• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.
Never attempt to move heavy parts without the aid of a
• DO NOT ALLOW PERSONNEL TO TAMPER WITH, mechanical device. Do not allow heavy objects to rest in
SERVICE, OR OPERATE THIS MACHINE FROM THE an unstable position. When raising a portion of the equip-
GROUND WITH PERSONNEL IN PLATFORM EXCEPT ment, ensure that adequate support is provided.
IN AN EMERGENCY.
• ALWAYS DISCONNECT BATTERIES WHEN REPLAC-
• WHEN TWO OR MORE PERSONS ARE IN PLATFORM, ING ELECTRICAL COMPONENTS.
THE OPERATOR SHALL BE RESPONSIBLE FOR ALL
MACHINE OPERATIONS. • REMOVE RINGS, WATCHES AND JEWELRY WHEN
PERFORMING ANY MAINTENANCE.
• ALWAYS ENSURE THAT POWER TOOLS ARE PROP-
ERLY STOWED AND NEVER LEFT HANGING BY • DO NOT WEAR LOOSE FITTING CLOTHING OR LONG
THEIR CORD FROM THE PLATFORM WORK AREA. HAIR UNRESTRAINED, WHICH IS APT TO BECOME
CAUGHT ON, OR ENTANGLED IN EQUIPMENT.
• USE ONLY CLEAN APPROVED NONFLAMMABLE
1.7 TOWING AND HAULING CLEANING SOLVENTS.
• TOW OR PULL MACHINE IN THE EVENT OF AN • SHUT OFF ALL POWER CONTROLS BEFORE MAK-
EMERGENCY ONLY. TO MOVE MACHINE, CARRY ING ADJUSTMENTS, LUBRICATING OR PERFORM-
MACHINE WITH FORKLIFT OF SUITABLE CAPACITY. ING ANY OTHER MAINTENANCE.
• HAVE PLATFORM COMPLETELY EMPTY OF TOOLS

AND DEBRIS BEFORE CARRYING.
• WHEN LIFTING MACHINE, POSITION FORKS ONLY
AT DESIGNATED AREAS AT FRONT OR REAR OF
MACHINE.
• HAVE PLATFORM FULLY RETRACTED WHILE
MACHINE IS BEING CARRIED.
• NEVER ALLOW PERSONNEL IN PLATFORM WHILE
CARRYING.
• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT
1.8 MAINTENANCE WITH SAFETY PROPS, BLOCKING OR OVERHEAD
This section contains the general safety precautions SLING.
which must be observed during maintenance of the aerial
work platform. It is of utmost importance that maintenance
personnel pay strict attention to these warnings and pre-
cautions to avoid possible injury to themselves or others
or damage to the equipment. A maintenance program
must be established by a qualified person and must be
followed to ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY

A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-
TION.
The specific precautions to be observed during machine • NEVER ALTER, REMOVE OR SUBSTITUTE ANY
maintenance are inserted at the appropriate point in the ITEMS SUCH AS COUNTERWEIGHTS, SOLID TIRES,
manual. These precautions are, for the most part, those BATTERIES, ETC. WHICH WOULD REDUCE THE
that apply when servicing hydraulic and larger machine OVERALL WEIGHT OR BASE STABILITY OF THE
component parts. MACHINE.
1-6 – JLG Sizzor – 3120695

SECTION 2. MACHINE PREPARATION AND INSPECTION
Periodic inspection shall be performed monthly or more

2.1 GENERAL often when required by environment, severity, and fre-
This section provides the necessary information needed quency of usage.
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are Handrail Assemblies
performed prior to use of the machine. It is important that
the information contained in this section be read and Properly installed; no loose or missing parts; no visible
understood before any attempt is made to operate the damage.
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine Platform Assembly
into service. These procedures will aid in obtaining maxi-
mum service life and safe operation. No visible damage; free of dirt and debris.
Sizzor Arms
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- No visible damage, abrasions and/or distortions.
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.
Electrical Cable
No visible damage; properly secured.
2.2 PREPARATION FOR USE
1. Before a new machine is put into operation it must Pivot Pins
be carefully inspected for any evidence of damage No loose or missing retaining hardware; no damage or
resulting from shipment and inspected periodically wear to pin heads which would cause pin to rotate; no evi-
thereafter, as outlined in paragraph 2-3, Delivery and dence of pin or bushing wear.
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
Lift Cylinder
to assure their security. No rust, nicks, scratches or foreign material on piston rod.
2. All preparations necessary to place the machine in No leakage. Evidence of proper lubrication.
operation readiness status are the responsibility of
management personnel. Preparation requires good Frame
common sense, (i.e. lift works smoothly and brakes
operate properly) coupled with a series of visual No visible damage; loose or missing hardware (top and
inspections. The mandatory requirements are given underside).
in paragraph 2-4, Daily Walk Around Inspection.
Drive Hubs
3. It should be assured that the items appearing in the
Delivery and Periodic Inspection and Functional Check oil level in drive hub by removing pipe plug and
Check are complied with prior to putting the feeling for oil level. (Contact service personnel for assis-
machine into service. tance if needed.)
NOTE: Torque Hubs should be one-half full of lubricant.

2.3 DELIVERY AND PERIODIC INSPECTION
Tire and Wheel Assemblies
NOTE: This machine requires periodic safety and mainte-
nance inspections by a JLG Dealer. A decal on the No loose or missing lug nuts; no visible damage
frame provides a place to record (stamp) inspection
dates. Check decal and notify dealer if inspection is Sliding Wear Pad Blocks
overdue.
No excessive wear; adequate lubrication.
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.
3120695 – JLG Sizzor – 2-1

Hydraulic Oil Supply

2.4 DAILY WALK-AROUND INSPECTION
NOTE: Prior to checking the hydraulic oil level, operate the It is the user’s responsibility to inspect the machine before
machine through one complete cycle of the lift func- the start of each workday. It is recommended that each
tion (full up and down). Failure to do so will result in user inspect the machine before operation, even if the
an incorrect oil level reading on the hydraulic tank. machine has already been put into service under another
user. This Daily Walk-Around Inspection is the preferred
Operate hydraulic systems through one complete cycle method of inspection.
before checking oil level in hydraulic oil tank. Oil should
be visible in ADD sight window on hydraulic oil tank. If oil In addition to the Daily Walk-Around Inspection, be sure to
is not visible, add oil until oil is visible in both ADD and include the following as part of the daily inspection:
FULL sight windows on tank. Do not overfill tank.
Overall Cleanliness
Steer Cylinder
Check all standing surfaces for oil, fuel and hydraulic oil
No rust, nicks, scratches or foreign material on piston rod; spillage and foreign objects. Ensure overall cleanliness.
no leakage.
Placards
Steer Linkage
No loose or missing parts; no visible damage. Keep all information and operating placards clean and
unobstructed. Cover when spray painting or shot blasting
to protect legibility.
Steer Spindle Assemblies
No excessive wear; no damage. Operators and Safety Manual
Control Boxes (Console and Ground) Ensure a copy of this manual is enclosed in the manual
storage box.
Switches operable; no visible damage; placards secure
and legible. Hand controller operable; no visible damage.
Machine Log
Battery Ensure a machine operating record or log is kept. Check
Proper electrolyte level; cable connections tight; no visible to see that it is current and that no entries have been left
damage; no corrosion at battery cable connections. uncleared, leaving machine in an unsafe condition for
operation.
Engine
Engine oil level - full mark on dipstick; filler cap secure; air Daily Lubrication
filter secure. For those items pointed out in the Daily Walk-Around
Inspection requiring daily lubrication, refer to Figure 2-5.,
Hydraulic Pump and Valves Lubrication Diagram for specific requirements.
No visible damage; no evidence of leakage; units secure.
Perform the following checks and services before attempt-
ing to operate the machine.
Platform Placards
No visible damage; placards secure and legible.
Lock-Out Cylinders (If Equipped) TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
No rust, nicks, scratches or foreign material on piston rod; TIONING MACHINE IS A SAFETY VIOLATION.
no leakage.
1. Start each day with a full fuel tank.
Leveling Jacks (If Equipped)
No rust, nicks, scratches or foreign material on piston rod; 2. Ensure that all items requiring lubrication are ser-
no leakage. viced in accordance with the Lubrication Chart.
3. Perform functional checks in accordance with para-

Traversing Platform (If Equipped) graph 2-5, Daily Functional Check.
No loose or missing parts; no visible damage; free of dirt
and debris.
2-2 – JLG Sizzor – 3120695

lowered, the scissor arms will press the plunger

2.5 DAILY FUNCTIONAL CHECK in to allow the axles to oscillate.
2. Ensure the machine is on a firm level surface. Check
for proper operation of the leveling jack limit switch
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
first from the ground control station and then from
CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
the platform controls. With all the leveling jacks
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
retracted, check that the platform will not raise
WHEN RELEASED.
above the following limits:
A functional check of all systems must be performed, 400RTS - 8.0m (26ft) Approximate elevation 65%
under no load, in an area free of overhead and ground
level obstructions. Perform the functional check in accor- 500RTS - 6.7m (22ft) Approximate elevation 44%
dance with the following procedure once the walk-around
inspection is complete: 3. Drive forward and reverse, check for proper opera-
tion.
1. From the ground control station, raise and lower the
platform several times and check for the following: 4. Check that drive brakes hold when machine is
driven up a hill, not to exceed rated gradeability, and
a. Smooth elevation and lowering.
stopped.
b. High function speeds cut out as soon as possi-
ble after the platform lifts beyond the stowed 5. Steer left and right. Check for proper operation.
position and begins to elevate. High function 6. Check hydraulic oil reservoir sight gauge. Refer to
speeds must cut out prior to a maximum plat- Lubrication Chart.
form height of 14 ft (4.2 m).
c. If equipped with oscillating axles - Make sure
that the axle lockout valve switch is free of debris
TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL
and the plunger of the switch actuates properly.
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
As shown below, the plunger must extend (out)
TIONING MACHINE IS A SAFETY VIOLATION.
a minimum of 5.6 mm (0.22 in) to lock the axles
when the scissor arms are raised. When fully
Min 5.6 mm (0.22 in.)
3120695 – JLG Sizzor – 2-3

5. Raise the machine platform approximately 2 ft (61

2.6 LOCKOUT CYLINDER CHECK (IF cm); ensure the lockout cylinder cam valve is free of
EQUIPPED) the sizzor arm trip bar.
To be performed quarterly, any time a system component 6. Place the drive controller to the “REVERSE” position
is replaced, or when improper system operation is sus- and carefully drive the machine off of the block and
pected on machines with oscillating axles. ramp.
NOTE: Ensure platform is fully lowered prior to beginning 7. Have an assistant check to see that the left front
lockout cylinder check. wheel remains locked in position off of the ground.
1. Place a 8 in (20 cm) high block with ascension ramp 8. Lower the machine platform; the lockout cylinder
in front of the left front wheel. should then release the wheel and allow it to rest on
the ground.
2. Activate the machine’s hydraulic system from the
platform control station. 9. If the lockout cylinder does not function properly,
have qualified personnel correct the malfunction
3. Place the engine speed and drive speed control prior to any further operation.
switches to their respective “LOW” positions.
4. Place the drive controller to the “FORWARD” posi-
tion and carefully drive the machine up the ascen-
sion ramp until the left front wheel is on top of the
block.
2-4 – JLG Sizzor – 3120695

Figure 2-1. Daily Walk-Around Inspection Diagram
3120695 – JLG Sizzor – 2-5

GENERAL 11. Ladder - No damage, securely attached.

Begin the “Walk-Around Inspection” at Item 1, as noted 12. Hydraulic Reservoir - No visible damage or missing
on the diagram.Continue to the right (counterclockwise parts. No evidence of leaks. Recommended oil
viewed from top) checking each item in sequence for the level in sight glass. Breather cap secure and work-
conditions listed in the “Walk-Around Inspection Check- ing.
list”.
13. Ground Controls - Switches operable, no visible
damage, placards secure and legible.
14. Tilt Alarm Switch - Properly secured, no loose or
TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL-
missing parts, no visible damage.
FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
TIONING MACHINE IS A SAFE TY VIO LATIO N. TO AVO ID 15. Hydraulic Filter - No visible damage, properly
POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DUR- secured, no evidence of leakage.
ING “WALK-AROUND INSPECTION”.
16. Auxiliary Power Pump - Properly secured, no visible
damage, no evidence of leakage. Hoses and fit-
NOTE: Do not overlook visual inspection of chassis under-
tings properly secured, no visible damage, no evi-
side. Checking this area often results in discovery of
dence of leaks.
conditions which could cause extensive machine
damage. 17. Control Valves - Valves properly secured, no visible
damage, no evidence of leakage. Hoses and fit-
1. Steer Cylinder and Tie Rod Ends - No loose or tings properly secured, no visible damage, no evi-
missing parts, no visible damage. No steer cylinder dence of leaks.
leaks or damage.
18. Hand Pump Manual Descent - Properly secured, no
2. Leveling Jack, Left Front (If Equipped) - No loose or loose or missing parts, no visible damage.
missing parts, no visible damage. No cylinder leaks
or damage. 19. Fuel Tank (Gasoline or Diesel Engine) - Filler cap
secure, sight gauge visible, no damage or leaks.
3. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured. 20. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
4. Steer Spindle, Left Front - No loose or missing no loose or missing parts, no evidence leakage.
parts, no visible damage, evidence of proper lubri-
cation. 21. Travel/Descent/Motion Alarm - Properly secured, no
loose or missing parts, no visible damage.
5. Steer/Drive Wheel and Tire Assembly, Left Front -
Properly secured, no loose or missing lug nuts, no 22. Safety Prop - Stored securely, no missing parts.
visible damage. Refer to inflation psi stenciled on 23. Drive Wheel and Tire Assembly, Left Rear - Properly
frame. secured, no loose or missing lug nuts, no visible
6. Drive Motor, Left Front (4 Wheel Drive) - No visible damage. Refer to inflation psi stenciled on frame.
damage, no evidence of leakage. 24. Drive Motor, Left Rear - No visible damage, no evi-
7. Drive Brake, Left Front (4 Wheel Drive) - No loose or dence of leakage.
missing parts, no visible damage, no evidence of 25. Drive Brake, Left Rear - No loose or missing parts,
leakage. no visible damage, no evidence of leakage.
8. Drive Hub, Left Front (4 Wheel Drive) - No visible 26. Drive Hub, Left Rear - No visible damage, no evi-
damage, no evidence of leakage. Drive hubs dence of leakage. Drive hubs should be one half full
should be one half full of EPGL SAE 90. of EPGL SAE 90.
9. Traversing Platform Extension Cylinder (If 27. Steer Spindle, Left Rear (If Equipped) - No loose or
Equipped) - Properly secured, no visible damage, missing parts, no visible damage, evidence of
no loose or missing parts, no evidence leakage. proper lubrication.
10. Oscillating Axle (If Equipped) - Properly secured, 28. LP Tank and Bracket (If Equipped) - No loose or
evidence of proper lubrication. No lockout cylinder missing parts, no visible damage. No leaks or dam-
leaks or damage. age.
Figure 2-2. Walk-Around Inspection Points (Sheet 1 of 3)
2-6 – JLG Sizzor – 3120695

29. Leveling Jack, Left Rear (If Equipped) - No loose or 46. Hydraulic Pump - Pump properly secured, no visi-
missing parts, no visible damage. No cylinder leaks ble damage, no evidence of leakage. Hoses and fit-
or damage. tings properly secured, no visible damage, no
evidence of leaks.
visible damage, properly secured. 47. Handrail installation - All railings securely attached,
no damage or missing parts, chains securely
31. Battery Installation (Gasoline or Diesel Engine) -
attached.
Proper electrolyte level, cables secure, no damage
or corrosion. Holddowns secure. 48. Sizzor Arms and Sliding Wear Pads - Properly
secured, no visible damage, evidence of proper
32. Ladder - No damage, securely attached.
lubrication. Inspect sizzor arm guards for damage
33. Traversing Platform (If Equipped) - No loose or and proper installation.
missing parts, no visible damage, platform deck
49. Ladder - No damage, securely attached.
extension operates properly.
50. Lift Cylinder - Properly secured, no visible damage,
34. Leveling Jack, Right Rear (If Equipped) - No loose
no loose or missing parts, no evidence leakage.
or missing parts, no visible damage. No cylinder
leaks or damage. 51. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
no loose or missing parts, no evidence of leakage.
visible damage, properly secured.
52. Steer/Drive Wheel and Tire Assembly, Right Front -
36. Rear Steer Cylinder and Tie Rod Ends (If Equipped)
Properly secured, no loose or missing lug nuts, no
- No loose or missing parts, no visible damage. No
visible damage. Refer to inflation psi stenciled on
steer cylinder leaks or damage.
frame.
37. LP Tank and Bracket (If Equipped) - No loose or
53. Drive Motor, Right Front (4 Wheel Drive) - No visible
missing parts, no visible damage. No leaks or dam-
damage, no evidence of leakage.
age.
54. Drive Brake, Right Front (4 Wheel Drive) - No loose
38. Steer Spindle, Right Rear (If Equipped) - No loose
or missing parts, no visible damage, no evidence of
or missing parts, no visible damage, evidence of
leakage.
proper lubrication.
55. Drive Hub, Right Front (4 Wheel Drive) - No visible
39. Drive Wheel and Tire Assembly, Left Rear - Properly
damage, no evidence of leakage. Drive hubs
secured no loose or missing lug nuts, no visible
should be one half full of EPGL SAE 90.
damage. Refer to inflation psi stenciled on frame.
56. Steer Spindle, Right Front - No loose or missing
40. Drive Motor, Right Rear - No visible damage, no evi-
parts, no visible damage, evidence of proper lubri-
dence of leakage.
cation.
41. Drive Brake, Right Rear - No loose or missing parts,
57. High Speed Limit Switch - No visible damage, prop-
no visible damage, no evidence of leakage.
erly secured.
42. Drive Hub, Right Rear - No visible damage, no evi-
58. Platform Controls - Properly secured, no loose or
dence of leakage. Drive hubs should be one half
missing parts, no visible damage. Placards secure
full of EPGL SAE 90.
and legible, control switches return to neutral. Con-
43. Safety Prop - Stored securely, no missing parts. trol markings legible, manual in manual storage
box.
44. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage, 59. 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.
45. Engine Installation - Engine oil to full mark on dip-
stick, oil fillercap secure. Muffler/exhaust system 60. Drive and Lift Cutout Switches (If Equipped) - No
properly secured, no leakage. Air filter assembly visible damage, properly secured.
secure, no loose or missing parts, element clean.
61. Traversing Platform (If Equipped) - No loose or
Gasoline Engine Only - Radiator cap secure, cool-
missing parts, no visible damage, platform deck
ant to correct level.
extension operates properly.
3120695 – JLG Sizzor – 2-7

62. Drive Cutout Switch and High Speed Cutout Switch 64. Traversing Platform Valve (If Equipped) - No loose
- No visible damage, properly secured. or missing parts, no visible damage, properly
secured, no evidence of leakage.
63. Leveling Gauge - No visible damage, properly
secured. 65. Platform Assembly - No loose or missing parts, no
visible damage, platform deck extension operates
properly.
Changing from LP Gas to Gasoline

2.7 DUAL FUEL SYSTEM
1. With engine operating on LP under a no-load condi-
tion, position the LPG/GAS SELECT switch at
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE ground control to the GAS SELECT position.
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME 2. If engine ‘stumbles’ because of lack of gasoline,
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS place the switch to the LPG position until engine
MUST BE FOLLOWED. regains smoothness, then return the switch to the
GAS SELECT position. Repeat as necessary until
Changing from Gasoline to LP Gas engine runs smoothly on gasoline.
1. Start the engine from the ground control station. 3. Close the hand valve on the LP gas supply tank by
turning clockwise.
2. Open the hand valve on the LP Gas supply tank by
turning counterclockwise.
2.8 TORQUE REQUIREMENTS
The Torque Chart (See Figure 2-6.) consists of standard
BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING torque values based on bolt diameter and grade, also
TO LP GAS. specifying dry and wet torque values in accordance with
recommended shop practices. This chart is provided as
3. While the engine is operating, place the three posi- an aid to the operator in the event he/she notices a condi-
tion LPG/GAS SELECT switch at the ground control tion that requires prompt attention during the walk-around
station to the center OFF position. Allow the engine inspection or during operation until the proper service per-
to operate, without load, until the engine begins to sonnel can be notified. Section 1 of the Service and Main-
‘stumble’ from lack of gasoline. tenance Manual provides specific torque values and
4. As the engine begins to ‘stumble’ place the switch to periodic maintenance procedures with a listing of individ-
the LPG position, allowing the LP fuel to be sent to ual components. Utilizing this Torque Chart in conjunction
the fuel regulator. with the preventive maintenance section in Section 2 of
the Service and Maintenance Manual, will enhance safety,
reliability and performance of the machine.
2-8 – JLG Sizzor – 3120695

Figure 2-5. Lubrication Diagram
3120695 – JLG Sizzor – 2-9

Table 2-1. Lubrication Chart
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 Hydraulic Oil Reservoir Fill Cap/Drain Plug HO - Check HO Level (See note 4)/ 10/500
HO - Change HO
9 ** Hydraulic Filter Element N/A Initial Change - 40 Hours 250
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)
12 400 RTS Sizzor Arm Pivot Pins 30 Grease Fittings (400 RTS) MPG - Pressure Gun 100
500 RTS Sizzor Arm Pivot Pins 38 Grease Fittings (500RTS) MPG - Pressure Gun
13 Rail Slides N/A MPG - Brush 100
14 Platform Extension Slides (Optional) N/A MPG - Brush 100
15 Lift Cylinder 4 Grease Fittings MPG - Pressure Gun 100
16 Engine Crankcase Fill Cap/Drain Plug Check Engine Oil Level 10/100
*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.
2-10 – JLG Sizzor – 3120695

Figure 2-6. Torque Chart
3120695 – JLG Sizzor – 2-11

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2-12 – JLG Sizzor – 3120695

SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL
3. Knowledge and understanding of all safety work

3.1 GENERAL rules of the employer and of Federal, State and
Local Statutes, including training in the recognition
and avoidance of potential hazards in the work
SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER place; with particular attention to the work to be per-
MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH formed.
GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI-
BILITY OF THE USER AND HIS OPERATING PERSONNEL. 4. Proper use of all required personnel safety equip-
ment.
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-
tant that the user read and understand the proper 6. The safest means to operate near overhead obstruc-
procedures before operating the machine. These proce- tions, other moving equipment, obstacles, depres-
dures will aid in obtaining optimum service life and safe sions, holes, dropoffs, etc. on the supporting
operation. surface.
7. Means to avoid the hazards of unprotected electrical

3.2 PERSONNEL TRAINING conductors.
The sizzor lift is a personnel handling device; therefore, it 8. Any other requirements of a specific job or machine
is essential that it be operated and maintained only by application.
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
assigned to and responsible for the operation and mainte- Training must be done under the supervision of a qualified
nance of the machine undergo a thorough training pro- operator or supervisor in an open area free of obstructions
gram and check out period in order to become familiar until the trainee has developed the ability to safely control
with the characteristics prior to operating the machine. a sizzor lift in congested work locations.
In addition, personnel operating the machine should be
familiar with ANSI standard A92.6-1999 Responsibilities. Operator Responsibility
This standard contains sections outlining the responsibili-
The operator must be instructed that he has the responsi-
ties of the owners, users, operators, lessors and lessees
bility and authority to shut down the machine in case of a
concerning safety, training, inspection, maintenance,
malfunction or other unsafe condition of either the
application and operation.
machine or the job site and to request further information
Persons under the influence of drugs or alcohol or who from his supervisor or JLG Distributor before proceeding.
are subject to seizures, dizziness or loss of physical con-
trol must not be permitted to operate the machine. NOTE: Manufacturer or Distributor will provide qualified per-
sons for training assistance with first unit(s) delivered
and thereafter as requested by user or his person-
Operator Training nel.
Operator training must include instruction in the following:
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.
3120695 – JLG Sizzor – 3-1

Placards Stability
Important points to remember during operation are pro- This machine, as originally manufactured by JLG and
vided at the control stations by DANGER, WARNING, operated within its rated capacity on a smooth, firm and
level supporting surface, provides a stable aerial platform
CAUTION, IMPORTANT and INSTRUCTION placards. This
for all platform positions.
information is placed at various locations for the express
purpose of alerting personnel of potential hazards consti-
tuted by the operating characteristics and load limitations
3.4 CONTROLS AND INDICATORS
of the machine. See foreword for definitions of the above
placards. Machines are equipped with control panels that use sym-
bols instead of words to indicate control functions. Refer
to Figure 3-3., Control Panel Symbols for these symbols
Capacities and their corresponding functions.
Raising platform above stowed position with or without
any load in platform, is based on the following criteria: Ground Control Station
1. Machine is positioned on a smooth, firm and level

surface. DO NOT OPERATE FROM GROUND CONTROL STATION WITH
PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.
2. Load is within manufacturer’s rated capacity.
PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPEC-
3. All machine systems are functioning properly. TIONS FROM THE GROUND CONTROL STATION AS POSSIBLE.
4. Leveling Jacks properly set (If Equipped).
Figure 3-1. Ground Control Station
3-2 – JLG Sizzor – 3120695

1. Ignition/Emergency Stop - A two-position, red retract the rear platform extension as needed for “up
mushroom shaped switch supplies electrical power and over” work access.
to the Start button when positioned up. When posi-
tioned down, the switch shuts off electrical power to 10. Gasoline/LPG Select Switch (Duel Fuel Only) - A
the ignition circuit, acting as an emergency stop three position toggle-type switch is used to select
switch.With the MAIN POWER switch in the OFF the desired method of powering the unit. Placing the
position, the key can be removed in order to inca- switch in the gasoline position shuts off the fuel flow
pacitate the machine on the jobsite to avoid unau- from the lp gas supply tank and allows fuel flow from
thorized use of the machine. the gasoline tank. Moving the switch to the lpg posi-
tion shuts off fuel flow from the gasoline tank and
2. Power Selector Switch - A three position key-oper- allows lp gas from supply tank to be used to power
ated power selector switch supplies operating the unit. With the switch in the center position, fuel
power to the platform or ground controls, as flow is restricted from both supply tanks.
selected. When positioned to platform, the switch
11. Hourmeter - The hourmeter records engine or elec-
provides power to the platform controls. When posi-
tric motor operating time.
tioned to ground, the switch provides power to the
ground controls. With the power selector switch in 12. Voltmeter - With the emergency stop switch in the
the center off position, power is shut off to both plat- up position, and before starting the engine, the volt-
form and ground controls. meter indicates output voltage of the alternator. Nor-
mal reading for the voltmeter will be 12-14 volts with
NOTE: With the PLATFORM/GROUND SELECT switch
a properly charged or charging battery.
positioned to GROUND, engine speed will stay in
LOW at all times. 13. Water Temperature Gauge - The water temperature
gauge provides a visual display of the engine cool-
3. Start Button - A momentary contact, pushbutton- ant temperature.
type switch that supplies electrical power to the
14. Oil Pressure Gauge - The oil pressure gauge dis-
starter solenoid when the IGNITION/EMERGENCY
plays the engine lubrication system operating pres-
STOP switch is in the ON position and the START
sure.
button is depressed.
4. Lift Switch - A three position, momentary contact lift Platform Control Station
control switch provides raising and lowering of the
platform when positioned to UP or down. 1. Enable Switch - These machines are equipped with
an enable switch on the side of the platform control
5. High Engine Circuit Breaker (Diesel Engine) - A console. On machines built with a serial number
push button reset 3 Amp circuit breaker located on before 0200058922, the enable switch must be
ground control panel returns interrupted power to pressed before activating the drive, lift or steer func-
diesel engine throttle when depressed. tions. A built-in timer shuts off power to these func-
tions if they are not activated within 3 seconds after
6. Start Button - A momentary contact, push-button
the enable switch is depressed. In addition, this
type switch supplies electrical power to the starter
timer will shut off power to the drive and lift functions
solenoid when the IGNITION switch is positioned up
3 seconds after they are deactivated, making if nec-
and the START button is depressed.
essary to depress the enable switch before activat-
7. Choke Switch (If Equipped) - A momentary con- ing drive and lift again. The steer function, unless
tact, push-button type switch supplies power to the activated in conjunction with the drive or lift func-
choke solenoid, when depressed, to assist cold start tions, will automatically cut off after 3 seconds of
operation. operation. On machines built from, and including,
serial number 0200058922, the enable switch must
8. Platform Traversing Switch (If Equipped) - A dou- be depressed and held for the duration of lift. The
ble throw, momentary contact toggle-type platform enable switch works in conjunction with the lift
traversing switch permits the operator to hydrauli- switch only.
cally extend and retract the platform extension as
needed for “up and over” work access. 2. Ignition/Emergency Stop Switch - An ignition/
emergency stop red mushroom-type switch is pro-
9. Platform Traversing Select Switch (If Equipped) - vided in order to turn on machine power in the plat-
A full throw, momentary contact toggle-type platform and also to turn off machine power in the event
form traversing select switch that works simulta- of an emergency. Power is turned on by positioning
neously with the platform traversing switch to the switch to the up (on) position, and is turned off
permits the operator to hydraulically extend and by positioning the switch to the down (off) position.
3120695 – JLG Sizzor – 3-3

3. Start Button - A momentary contact, pushbutton- switch is in the on position and the start button is
type switch that supplies electrical power to the depressed.
starter solenoid when the ignition/emergency stop
Figure 3-2. Platform Control Station
4. Tilt Alarm Warning Horn - The Tilt Alarm Warning 6. Lift Switch - The lift toggle switch provides for rais-
Horn is activated by the Tilt Alarm Switch when the ing and lowering the platform when positioned to up
chassis is on a severe slope (over 5 degrees on the or down.
400RTS and 2 degrees on the 500RTS) with the plat-
7. Engine Speed Switch - A two position engine
form raised. speed control switch provides the operator either
high or low engine rpm as required.
8. Pump Speed Switch - A two position pump speed
IF TILT ALARM IS ON WHEN PLATFORM IS RAISED, LOWER control switch allows the operator to select low (one
PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO pump section operating) or high (both pump sec-
THAT IT IS LEVEL BEFORE RAISING PLATFORM. tions operating) speed pump operation.
NOTE: HIGH ENGINE speed, high drive speed (SPEED),

5. Tilt Alarm Warning Light - A warning light on the and HIGH PUMP speed functions will cut-out when
control console that lights when the chassis is on a platform is raised above stowed position, leaving
severe slope (over 5 degrees on the 400RTS and 2 only low function speeds available until platform is
degrees on the 500RTS). lowered completely.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED, HIGH
TOGGLE SWITCHES DO NOT RETURN TO THE CENTER OFF ENGINE SPEED, AND HIGH PUMP SPEED FUNCTIONS OPERATE
POSITION WHEN RELEASED. WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION.
3-4 – JLG Sizzor – 3120695

9. PQ Controller - The PQ Controller performs three 11. Platform Traversing Switch (If Equipped) - This is
functions: Drive, Steer and Drive Speed. On all a double throw, momentary contact toggle-type
machines built before serial number 0200058922, switch which permits the operator to hydraulically
tilting the controller in the direction you want to go extend and retract the platforms as needed for “up
(forward or reverse) activates drive in that direction. and over” work access.
The thumb-operated steer switch on top of the con-
12. Platform Traversing Select Switch (If Equipped) -
troller handle activates the steer wheels in the direc-
In order to select the platform to traverse there is a
tion it is moved. If machine is equipped with four
full throw, momentary contact toggle-type platform
wheel steer, this switch operates only the front steer
traversing select switch, that works in conjunction
wheels. On all machines built after, and including,
with the platform traversing switch to permit the
serial number 0200058922 there is a red trigger
operator to hydraulically extend and retract the plat-
switch on the front of the controller. This switch must
forms as needed for “up and over” work access.
be depressed and held in order to drive the
machine. 13. Travel Warning Horn - A push-button type horn
switch supplies electrical power to an audible warn-
10. Auxiliary Power (If Equipped) - A toggle type auxil-
ing device when pressed.
iary power control switch energizes the electrically-
operated hydraulic pump, when actuated. Switch 14. Choke (If Equipped) - A push-button type switch
must be held ON for the duration of auxiliary pump supplies power, when depressed, to the choke sole-
use. noid for cold start operations.
The auxiliary power pump functions to provide sufficient 15. Leveling Jacks (If Equipped) - The four momentary
oil flow to operate the Traversing Platform Extensions contact type toggle switches correspond to the four
should the main pump or engine fail during operation. leveling jacks, one at each corner of the machine.
It should be noted that the functions will operate at a
slower than normal rate because of the lower GPM deliv-
ered. BE AWARE OF OTHER PERSONNEL AND EQUIPMENT WHEN
EXTENDING OR RETRACTING LEVELING JACKS.
NOTE: Auxiliary power pump only operates the Traversing
Platform Extensions.
16. Engine Distress Light (Gasoline Engine) - The
engine distress light is connected to a sensor on the
engine that detects when coolant temperature rises
above a preset level, illuminating the warning light.
17. Engine Distress Light (Diesel Engine) - The
engine distress light is connected to a sensor on the
engine that detects when oil pressure falls below a
preset level, illuminating the warning light
3120695 – JLG Sizzor – 3-5

Figure 3-3. Control Panel Symbols
3-6 – JLG Sizzor – 3120695

Figure 3-4. Decal Location - Right Side (Sheet 1 of 2)
3120695 – JLG Sizzor – 3-7

Figure 3-5. Decal Location - Left Side (Sheet 2 of 2)
3-8 – JLG Sizzor – 3120695

SECTION 4. MACHINE OPERATION
The JLG Sizzor Lift is powered using hydraulic motors and

4.1 DESCRIPTION cylinders for the various machine motions. The hydraulic
This machine is a self-propelled elevating ‘sizzor’ aerial components are controlled by electrically activated
work platform. The Sizzor Lift’s intended purpose is to hydraulic valves using switches and the joystick controller.
position personnel with their tools and supplies at posi- The machine is equipped with a Enable Switch which
tions above ground level. The machine can be used to
must be pressed before activating the DRIVE, LIFT or
reach work areas located above machinery or equipment.
STEER functions. The Enable Switch has a built-in timer
The JLG Sizzor Lift has a primary operator Control Station which shuts off power to these functions if they are not
in the platform. From this Control Station, the operator can activated within 3 seconds after Enable Switch is
drive and steer the machine in both forward and reverse depressed. The speeds of functions controlled by the joy-
directions as well as raise and lower the platform. The stick controller are variable from zero to maximum speed
machine has a Ground Control Station which will override
depending upon the position of the controller. Functions
the Platform Control Station. Ground Controls operate Lift
controlled by toggle switches are either on or off. Higher
Up, Lift Down, and Platform Traversing, (If Equipped). The
controls are to be used only for daily check or in an emer- or lower speed is possible only when the applicable high
gency to lower the platform to the ground should the function speed control switch at the Platform Control Sta-
operator in the platform be unable to do so. tion is used in conjunction with the drive function. All
switches at the platform are guarded to prevent inadvert-
Instructions and hazard warnings are posted adjacent to
ant operation by individual switch guards.
both operator control stations and at other places on the
machine. It is extremely important that operators know
The JLG Sizzor is a two or four wheel drive machine with
what instructions and warnings are placed on the
drive power being supplied by a hydraulic motor for each
machine, and review these periodically so that they are
fresh in their minds. Vibrations emitted by these machines drive wheel. Each drive wheel is supplied with a hydrauli-
are not hazardous to an operator in the work platform. cally released, spring applied brake. The brakes are auto-
matically applied anytime the Drive controller is returned
The JLG Sizzor Lift is designed to provide efficient and to the neutral position.
safe operation when maintained and operated in accor-
dance with warnings on the machine, the Operators & The capacities of model 400RTS and 500RTS are found
Safety, Service and Specification Manual and all jobsite on the capacity decals located on the machine. These
and government rules and regulations. As with any type of
capacities are based on a load uniformly distributed in the
machinery, the operator is very important to efficient and
center of the platform. This means that the total combined
safe operation. Owner/user/operator must be familiar with
Sections 6, 7, 8, 9, and 10 of ANSI A92.6-1999. These sec- weight of personnel, tools and supplies must not exceed
tions contain the responsibilities of the owner, users, oper- the given capacity for a particular model.
ators, lessors and lessees concerning safety, training,
inspection, maintenance, application and operation. It is The platform may be raised only when positioned on firm,
absolutely necessary that the JLG Lift be regularly main- level and uniform surfaces. Leveling jacks, if provided, are
tained in accordance with this section and the Service and to assist in leveling the Sizzor Lift. The Sizzor Lift must be
Specifications section, and that any evidence of lack of level when operating on leveling jacks.
maintenance, malfunction, excessive wear, damage or
modification to the machine be reported immediately to
the machine owner or the jobsite supervisor or safety
4.2 GENERAL
manager and that the machine be taken out of service
until all discrepancies are corrected. This section provides the necessary information needed
The JLG Sizzor Lift is not intended to be used to lift mate- to operate the machine. Included in this section are the
rial other than supplies which personnel in the platform procedures for starting, stopping, traveling, steering, park-
require to do their job. Supplies or tools which extend out- ing, platform loading and transporting. It is important that
side the platform are prohibited. It must not be used as a the user read and understand the proper procedures
forklift, crane, support for overhead structure, or to push before operating the machine.
or pull another object.
The machine has a manual descent system which will
allow the platform to lowered without power from the
engine/motor powered pump.
Updated 4/19/00
3120695 – JLG Sizzor – 4-1
6. Check engine voltmeter when starting engine and

4.3 ENGINE OPERATION monitor gauge periodically during operation.
RTS SERIES SCISSOR LIFTS MANUFACTURED AFTER AUGUST

26, 1996 ARE EQUIPPED WITH A HYDRAULIC OIL TEMPERATURE ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW
SWITCH THAT SHUTS DOWN THE ENGINE WHEN THE HYDRAU- SPEED BEFORE APPLYING ANY LOAD.
LIC OIL REACHES A TEMPERATURE OF APPROXIMATELY 230˚ F
(111˚ C). THIS SHUT DOWN IS INTENDED TO PROTECT THE 7. After engine has had sufficient time to warm up, pro-
HYDRAULIC SYSTEM AND ITS COMPONENTS FROM DAMAGE ceed with operation of unit.
DUE TO EXCESSIVE HEAT. HEAT MAY BUILD UP DUE TO
EXTENDED DRIVING, IN CONJUNCTION WITH HIGH AMBIENT
TEMPERATURES, ACTIVATING THIS SWITCH AND SHUTTING
4.4 RAISING AND LOWERING (LIFTING)
DOWN THE MACHINE. IF THE MACHINE SHUTS DOWN, ALLOW
THE HYDRAULIC OIL TO COOL, THEN RESUME NORMAL OPERA-
TION.
DO NOT RAISE PLATFORM EXCEPT ON A FIRM, LEVEL SURFACE
NOTE: Initial starting should always be performed from the FREE OF OBSTRUCTIONS AND HOLES.
Ground Control Station.
NOTE: This machine is equipped with a Enable Switch on

Starting Procedure
the side of the platform control console. This switch
must be depressed before activating DRIVE, LIFT, or
1. Check engine oil before attempting to start engine; if
STEER functions from the platform control console.
necessary, add oil in accordance with Engine Manu-
facturers Manual.
Raising
2. Pull the red mushroom-type Ignition/Emergency
Stop switch at the Ground Control Station to the UP
position (ON). NOTE: On machines equipped with leveling jacks, leveling
jacks must be in contacted with the ground for lift
3. Place the PLATFORM/GROUND SELECT switch to system to raise above 22 ft. (6.7 m).
the applicable position for desired control station
operation.
1. Position MAIN POWER switch to desired position
4. If operating a dual fuel machine, place the LP/GAS- and position POWER ON (platform) or EMERGENCY
OLINE SELECT switch to the desired position. STOP (ground) switch, as applicable, to ON. If
machine has been shut down, start engine and
NOTE: If LPG system is selected, ensure that the hand allow warm-up period before beginning any lifting.
valve on the LPG supply tank is opened prior to
attempting to start the engine. 2. Pull LIFT toggle switch, then move it to UP and hold
until desired elevation is achieved.
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN

Lowering
EXTENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE
AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2 TO 3 MINUTES.
IF ENGINE FAILS TO START AFTER SEVERAL ATTEMPTS, REFER ENSURE SIZZOR ARM AREA IS FREE OF PERSONNEL PRIOR TO
TO ENGINE MAINTENANCE MANUAL.
LOWERING PLATFORM.
DO NOT ‘LIFT DOWN’ WITHOUT COMPLETELY RETRACTING THE
NOTE: If starting machine from the platform control station,
OPTIONAL TRAVERSING DECK.
place the engine speed control switch to the LOW
position prior to starting the engine.
Pull LIFT toggle switch, then move it to DOWN and hold
5. If starting machine from ground controls, position until desired elevation is achieved or until platform is fully
IGNITION/EMERGENCY STOP switch to ON and lowered.
depress START button and hold until engine starts.
If starting from platform controls, position POWER
ON switch to ON and depress START button and
hold until engine starts.
4-2 – JLG Sizzor – 3120695

the switch must be activated in the opposite direction until

4.5 TRAVERSING PLATFORM (OPTIONAL) the wheels are centered.
The machine may be equipped with hydraulically oper-
ated traversing platforms that moves 4 ft. (1.2 meters) at
each end of the machine to give the operator “up and 4.7 TRAVELING (DRIVING)
over” access to worksites. The traversing platform is oper-
ated by either the TRAVERSE toggle switches at platform
control console or the TRAVERSE toggle switch at the ALWAYS RAISE LEVELING JACKS, IF EQUIPPED, BEFORE TRAV-
ground control switches. ELING TO AVOID INJURY TO PERSONNEL OR DAMAGE TO
MACHINE.
IF EQUIPPED WITH LEVELING JACKS, DRIVE FUNCTION IS CUT

TO AVOID INJURY TO GROUND PERSONNEL, RETRACT TRA-
OUT WHEN LEVELING JACKS ARE IN THE SET POSITION.
VERSING PLATFORM COMPLETELY BEFORE LOWERING PLAT-
FORM.
IF MACHINE BECOMES STUCK DURING TRAVEL, DO NOT
“ROCK” MACHINE IN AN ATTEMPT TO REGAIN TRACTION, AS
DAMAGE TO DRIVE HUBS MAY RESULT.
4.6 STEERING
To steer the machine, the thumb operated steer control
switch on the controller handle is positioned to the right
D O N O T D R I V E W I T H P L AT FO R M R A I S E D E X C EP T O N A
for traveling right, or to the left for traveling left.
SMOOTH, FIRM, AND LEVEL SURFACE FREE OF OBSTRUCTIONS
To steer the machine with the optional 4 wheel steer, posi- AND HOLES.
tion steer control switch to right for traveling right, or to left
for traveling left. TO AVOID LOSS OF CONTROL OR UPSET ON GRADES AND
SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDES-
When released, the switch will return to the center-off posi- LOPES EXCEEDING THOSE SPECIFIED FOR THE MACHINE.
tion and the wheels will remain in the previously selected TRAVEL GRADES AND SIDESLOPES WITH PLATFORM COM-
position. To return the wheels to the straightened position, PLETELY LOWERED.
Figure 4-1. Grade and Sideslope
3120695 – JLG Sizzor – 4-3

2. Position pump and engine control switches to

desired positions (high or low) and position drive
TRAVEL GRADES IN “LOW” DRIVE SPEED ONLY. USE EXTREME control switch to desired position (torque or speed).
CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN
DRIVING WITH PLATFORM ELEVATED AND ESPECIALLY WHEN 3. Position controller to forward, pull up on safety lock,
DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET (2 M) OF and hold controller in position for duration of travel.
AN OBSTRUCTION. Once drive is initiated, the safety lock can be
HIGH DRIVE SPEED IS CUT OUT WHEN PLATFORM IS RAISED released and drive will continue to function until con-
ABOVE STOWED POSITION. IF LIMIT SWITCH MALFUNCTIONS, troller is returned to the center off position. Drive
SHUT DOWN MACHINE AND HAVE AUTHORIZED SERVICE PER-
speed is determined by the distance the controller is
SONNEL REPAIR OR REPLACE LIMIT SWITCH PRIOR TO RESUM-
moved from the center off position.
ING OPERATION.
THE 400RTS MAY BE EQUIPPED WITH A 5 DEGREES TILT
SWITCH THAT ILLUMINATES A LIGHT ON THE PLATFORM CON-
TROL CONSOLE AND SOUNDS AN AUDIBLE ALARM WHEN THE 4.8 PARKING AND STOWING
MACHINE IS ON A SLOPE (OVER 5 DEGREES) WITH THE PLAT-
FORM RAISED. Park and stow machine as follows:
THE 500RTS IS EQUIPPED WITH A 2 DEGREES TILT SWITCH
THAT ILLUMINATES A LIGHT ON THE PLATFORM CONTROL 1. Drive machine to a reasonably well-protected and
CONSOLE AND SOUNDS AN AUDIBLE ALARM WHEN THE well-ventilated area.
MACHINE IS ON A SLOPE (OVER 2 DEGREES) WITH THE PLAT-
FORM RAISED. WHEN MACHINE IS ON A SLOPE (OVER 2 2. Ensure platform is fully lowered.
DEGREES) WITH THE PLATFORM COMPLETELY LOWERED,
ONLY THE WARNING LIGHT IS ILLUMINATED. 3. Position emergency stop switch to off position.
4. If necessary, cover the instruction placards, caution

Traveling Forward and warning decals so that they will be protected
from hostile environment.
NOTE: On machines equipped with leveling jacks, leveling
jacks must be in the stowed position before opera- 5. Chock at least two wheels when parking machine for
tion of the drive system. an extended period of time.
6. Turn ignition/emergency stop switch to off and turn

1. Position ignition/emergency stop switch to on. If the Power selctor switch to the center position and
remove key to disable machine from unauthorized
allow warm-up period before beginning any lifting.
use.
2. Position pump and engine control switches to
desired positions (high or low) and position drive
control switch to desired position (torque or speed). 4.9 PLATFORM LOADING
3. Position controller to forward, pull up on safety lock, The platform maximum rated load capacity is shown on a
and hold controller in position for duration of travel. placard located on the platform and is based upon the fol-
Once drive is initiated, the safety lock can be lowing criteria.
released and drive will continue to function until con-
troller is returned to the center off position. Drive 1. Machine is positioned on a smooth, firm and level
speed is determined by the distance the controller is surface.
moved from the center off position.
2. All braking devices are engaged.
Traveling in Reverse
3. Refer to Section 3 for platform capacities.
NOTE: On machines equipped with leveling jacks, leveling 4. Leveling Jacks properly set (If Equipped).
jacks must be in the stowed position before opera-
tion of the drive system. It is important to remember that the load should be evenly
distributed on the platform. The load should be placed
1. Position ignition/emergency stop switch to on. If near the center of the platform when possible.
allow warm-up period before beginning any lifting.
4-4 – JLG Sizzor – 3120695

4.10 SAFETY PROPS 4.11 MACHINE TIE DOWN

When transporting machine, platform must be fully
retracted in the stowed mode with machine securely tied
SAFETY PROPS MUST BE USED WHEN MAINTENANCE PER- down to truck or trailer deck. Four tie down lugs are pro-
FORMED ON MACHINE REQUIRES SIZZOR ARMS TO BE RAISED. vided, one at each corner of the machine frame.
To engage safety props, raise platform so that both props

can be disconnected from locking arms and lowered to a USE TIE DOWN LUGS ONLY TO SECURE THE MACHINE FOR
vertical position. Lower the platform until the safety props SHIPPING. DO NOT USE TIE DOWN LUGS TO LIFT MACHINE.
rest on the pads provided on the frame. Maintenance can
now begin.
To store safety props, raise platform so that props can be 4.12 TOWING
pivoted up and secured by their locking arms. The machine should not be towed, except in the event of
an emergency such as a machine malfunction or a total
machine power failure. Refer to Section 6 for emergency
towing procedures.
3120695 – JLG Sizzor – 4-5

NOTES:
4-6 – JLG Sizzor – 3120695

SECTION 5. EMERGENCY PROCEDURES
3. Return disconnect caps to normal (engaged) posi-

5.1 GENERAL tion.
This section provides information on the procedures to be
followed and on the systems and controls to be used in
the event an emergency situation is encountered during
machine operation. Prior to operation of the machine and
periodically thereafter, the entire operating manual, includ-
ing this section, should be reviewed by all personnel
whose responsibilities include any work or contact with
the machine.
5.2 EMERGENCY TOWING PROCEDURES

Although towing the machine is prohibited, when not
equipped with a tow package, provisions for moving the
machine, in case of a malfunction or power failure, have Figure 5-2. Drive Hub Connect
been incorporated. The following procedures are to be
used ONLY for emergency movement to a suitable main- 4. Remove chocks from wheels.
tenance area.
1. Chock wheels securely.

5.3 EMERGENCY CONTROLS AND THEIR
2. Disengage (reverse) the disconnect cap on each LOCATIONS
drive torque hub by removing the two attaching cap-
screws, turning the cap around, and reinstalling and Emergency Stop Switch
tightening the capscrews.
At platform controls, push red Ignition/Emergency stop
switch this will immediately stop the machine.
Ground Control Station

The Ground Control Station is located on the left side of
the machine frame. The controls on this panel provide the
means for overriding the platform controls and for control-
ling the platform lift up and down and ignition functions
from the ground. Position the Ignition/Emergency Stop
switch to ON, position the PLATFORM/ GROUND SELECT
switch to the GROUND position and operate the the
appropriate switch, LIFT or IGNITION.
IF MACHINE IS EQUIPPED WITH PLATFORM EXTENSION OR TRA-

Figure 5-1. Drive Hub Disconnect VERSING DECK, RETRACT DECK BEFORE LOWERING PLAT-
FORM.
3. Remove chocks and move the machine to an appro- Manual Descent (Engine/Pump Failure -
priate maintenance area, using suitable equipment Platform Controls)
for assistance.
In the event of engine/pump failure while operating the
After moving machine, complete the following proce- machine from the platform console, the following proce-
dures: dure should be followed to lower the platform. Turn the
power on switch to on. Place the lift control switch to
1. Position machine on a firm, level surface. down. When platform is completely down, return lift con-
trol switch to center off and position power on switch to
2. Chock wheels securely. off.
3120695 – JLG Sizzor – 5-1

Manual Descent (Engine/Pump Failure -

5.4 EMERGENCY OPERATION
Ground Controls)
The following procedure should be used to lower the plat- Use of Ground Controls
form from the ground controls in the event of engine/
pump failure. Turn main power switch to on and platform/
ground select switch to ground. For battery powered
KNOW HOW TO USE THE GROUND CONTROLS IN AN EMER-
machines, position main power switch to ground. Place lift GENCY SITUATION.
control switch to down. When platform is completely
down, return lift control switch to center off and position Ground personnel must be thoroughly familiar with the
main power switch to off. machine operating characteristics and the ground control
functions. Training should include operation of the
Manual Descent (Complete Loss of Power) machine, review and understanding of this section and
hands-on operation of the controls in simulated emergen-
The manual descent valve is used, in the event of total cies.
power failure, to lower the platform using gravity. The
manual descent handle is located on the inside of the Operator Unable to Control Machine
valve compartment on the left side of the machine. Turn
If the platform operator is pinned, trapped or unable to
the release valve on the side of the pump to the closed
operate or control the machine.
position and pump the handle. This will release the hold-
ing valve, lowering the platform. After the platform reaches 1. USE THE MANUAL DESCENT SYSTEM AS FIRST
the stowed position, open the release valve on the pump. CHOICE for bringing the platform and operator
down, particularly IF THERE IS INDICATION OF
Auxiliary Power (If Equipped) (Engine/Pump CONTROL MALFUNCTION. Further use of hydraulic
power may cause severe injury or death.
Failure - Platform Controls)
2. Operate the machine from ground controls ONLY
A toggle type auxiliary power control switch is located on with the assistance of other personnel and equip-
the platform control station. Operation of switch turns on ment (cranes, overhead hoists, etc.) as may be
the electrically driven auxiliary hydraulic pump. This required to safely remove the danger or emergency
should be used in the case of failure of the main power condition.
plant. The auxiliary pump will operate “only” the traversing
platforms. To activate auxiliary power: 3. Other qualified personnel on the platform may use
the platform controls. DO NOT CONTINUE OPERA-
1. Position IGNITION switch to off. TION IF CONTROLS DO NOT FUNCTION NOR-
MALLY.
2. Operate appropriate control switch for desired func-
4. Cranes, forklift trucks or other equipment which may
tion and hold.
be available are to be used to remove platform
3. Position AUXILIARY POWER switch to ON and hold. occupants and stabilize motion of the machine in
case machine controls are inadequate or malfunc-
4. Release AUXILIARY POWER switch and selected tion when used.
control switch.
Platform Caught Overhead
Auxiliary Power (If Equipped) (Engine/Pump If the platform becomes jammed or snagged in overhead
Failure - Ground Controls) structures or equipment, do not continue operation of the
machine from either the platform or the ground until the
The toggle type traversing platform control switches are operator and all personnel are safely moved to a secure
located on the ground control station. Operation of switch location. Only then should an attempt be made to free the
turns on the electrically driven auxiliary hydraulic pump. platform using any necessary equipment and personnel.
Do not operate controls to cause one or more wheels to
1. Position IGNITION switch to off. leave the ground.
2. Operate appropriate control switch for desired tra-

versing platform function and hold.
5-2 – JLG Sizzor – 3120695

Righting of Tipped Machine

5.5 INCIDENT NOTIFICATION
A forktruck of suitable capacity or equivalent equipment
It is imperative that JLG Industries, Inc. be notified imme-
should be placed under the elevated side of the chassis,
diately of any incident involving a JLG product. Even if no
with a crane or other suitable lifting equipment used to lift
injury or property damage is evident, the factory should
the platform while the chassis is lowered by the forklift or
be contacted by telephone and provided with all neces-
other equipment.
sary details. Contact at 1-877-JLG-SAFE (554-7223)
between the hours of 8:00 AM - 4:45 PM Eastern Standard
Post-Incident Inspection time.
Following any accident, thoroughly inspect the machine
It should be noted that failure to notify the Manufacturer of
and test all functions first from the ground controls, then
an incident involving a JLG Industries product within 48
from the platform controls. Do not lift above 10 ft (3
hours of such an occurrence may void any warranty con-
meters) until you are secure that all damage has been
sideration on that particular machine.
repaired, if required, and that all controls are operating
correctly.
3120695 – JLG Sizzor – 5-3

NOTES:
5-4 – JLG Sizzor – 3120695

SECTION 6. INSPECTION AND REPAIR LOG
Table 6-1.Inspection and Repair Log
Date Comments
3120695 – JLG Sizzor – 6-1

Table 6-1.Inspection and Repair Log
Date Comments
6-2 – JLG Sizzor – 3120695

CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of Califormia
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N. T. Italy The Netherlands
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 +31 (0)23 565 5665
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +31 (0)23 557 2493
(852) 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Sverige AB

UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
+48 (0)914 320 245 Scotland 08755 Castellbisbal, Barcelona Sweden
+48 (0)914 358 200 Spain +46 (0)850 659 500
+44 (0)141 781 6700
+34 93 772 4700 +46 (0)850 659 534
+44 (0)141 773 1907
+34 93 771 1762
www.jlg.com

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Operation & Safety Manual

IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES

3120695 – JLG Sizzor – a

The listing of these requirements shall not relieve the

1. Only trained and authorized operators shall be per-

b – JLG Sizzor – 3120695

3120695 – JLG Sizzor – c

This page left blank intentionally.

d – JLG Sizzor – 3120695

3120695 – JLG Sizzor – i

ii – JLG Sizzor – 3120695

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL 1.2 DRIVING/TOWING/CARRYING

Carrying or loading the unit should be accomplished

3120695 – JLG Sizzor – 1-1

1.3 ELECTROCUTION HAZARD

NOTE: MAINTAIN M.A.D. FROM ALL OTHER CHARGED

VOLTAGE RANGE MINIMUM APPROACH DISTANCE

0 to 300V AVOID CONTACT

Over 300V to 50KV 10 (3)

Over 50KV to 200KV 15 (5)

Over 200KV to 350KV 20 (6)

Over 350KV to 500KV 25 (8)

Over 500KV to 750KV 35 (11)

Over 750KV to 1000KV 45 (14)

1-2 – JLG Sizzor – 3120695

BEEN GIVEN BY COMPETENT AND AUTHORIZED

• READ AND OBEY ALL WARNINGS, CAUTIONS AND

• BE FAMILIAR WITH LOCATION AND OPERATION OF

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS

3120695 – JLG Sizzor – 1-3

• KEEP NON-OPERATING PERSONNEL AT LEAST 6

• WATCH FOR OBSTRUCTIONS AROUND MACHINE

• CHECK TRAVEL PATH FOR PERSONS, HOLES,

1-4 – JLG Sizzor – 3120695

• TRANSFERS BETWEEN A STRUCTURE AND THE

• NEVER POSITION LADDERS, STEPS, OR SIMILAR

• CHECK CLEARANCES ABOVE, ON SIDES AND BOT-

3120695 – JLG Sizzor – 1-5

• HAVE PLATFORM COMPLETELY EMPTY OF TOOLS

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY

1-6 – JLG Sizzor – 3120695

SECTION 2. MACHINE PREPARATION AND INSPECTION

Periodic inspection shall be performed monthly or more

NOTE: Torque Hubs should be one-half full of lubricant.

3120695 – JLG Sizzor – 2-1

Hydraulic Oil Supply

3. Perform functional checks in accordance with para-

2-2 – JLG Sizzor – 3120695

lowered, the scissor arms will press the plunger

Min 5.6 mm (0.22 in.)

3120695 – JLG Sizzor – 2-3

5. Raise the machine platform approximately 2 ft (61

2-4 – JLG Sizzor – 3120695

Figure 2-1. Daily Walk-Around Inspection Diagram

3120695 – JLG Sizzor – 2-5

GENERAL 11. Ladder - No damage, securely attached.