Operation & Safety Manual Models 400RTS 500RTS 3120828 November 9, 2007
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. It is important to stress proper machine usage at all times. All information in this manual must be read and understood before any attempt is made to operate the machine.
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 The Safety Alert Symbol will be used with the appropriate Safety Signal Word of “DANGER” “WARNING” or “CAUTION” to a potential hazard and designate a level of seriousness. The Safety Signal Words are inserted throughout this manual in Black/White.
FOREWORD ALL SAFETY-RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT. JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETYRELATED BULLETINS FOR THIS JLG PRODUCT. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG DEALER FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. FOR THE PURPOSE OF RECEIVING SAFETY-RELATED BULLETINS, IT IS IMPORTANT THAT THE CURRENT OWNER OF THIS UNIT ENSURES JLG INDUSTRIES, INC. HAS UPDATED OWNERSHIP INFORMATION.
FOREWORD REVISION LOG Original Issue Revised Revised Revised Revised Added Manual Part Number to Foreword Revised Revised Revised d - March 1 1993 - August 24, 1999 - August 20, 2002 - December 5, 2002 - March 19, 2004 - August 1, 2004 - August 19, 2004 - September 26, 2007 - November 9, 2007 – JLG Sizzor – 3120828
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. TABLE OF CONTENTS SECTION - FOREWORD SECTION 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operation. . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. 2-1. 2-2. 2-3. 2-4. 2-5. 3-1. 3-2. 3-3. 4-1. 5-1. 5-2. TITLE PAGE NO. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Walk-Around Inspection Points (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Walk-Around Inspection Points (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual.
SECTION 1 - SAFETY PRECAUTIONS • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • Use extreme caution when entering or leaving platform. Ensure that the scissor arm assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. • Platform-to-structure transfers at elevated positions are discouraged.
SECTION 1 - SAFETY PRECAUTIONS • Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and uniformly supported surface before elevating platform or driving with the platform in the elevated position. • Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.
SECTION 1 - SAFETY PRECAUTIONS • When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity. • Refer to Section 4 for lifting information. 1.5 MAINTENANCE items that may reduce or affect the overall weight or stability of the machine. • Reference the Service and Maintenance Manual for the weights of critical stability items.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-6 – JLG Lift – 3120828
SECTION 2 - MACHINE PREPARATION AND INSPECTION SECTION 2. MACHINE 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.
SECTION 2 - MACHINE PREPARATION AND INSPECTION Hydraulic Oil Supply 2.4 NOTE: Prior to checking the hydraulic oil level, operate the machine through one complete cycle of the lift function (full up and down). Failure to do so will result in an incorrect oil level reading on the hydraulic tank. 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.
SECTION 2 - MACHINE PREPARATION AND INSPECTION 2.5 lowered, the scissor arms will press the plunger in to allow the axles to oscillate. DAILY FUNCTIONAL CHECK 2. Ensure the machine is on a firm level surface. Check for proper operation of the leveling jack limit switch first from the ground control station and then from the platform controls.
SECTION 2 - MACHINE PREPARATION AND INSPECTION Figure 2-1.
SECTION 2 - MACHINE 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”. 12. Hydraulic Reservoir - Recommended oil level in sight glass. Breather cap secure and working. See Inspection Note. 13. Ground Controls - Switches operable, no visible damage, placards secure and legible. 14.
SECTION 2 - MACHINE PREPARATION AND INSPECTION 37. LP Tank and Bracket (If Equipped) - See Inspection Note. 51. Traversing Platform Extension Equipped) - See Inspection Note. 38. Steer Spindle, Right Rear (If Equipped) - Evidence of proper lubrication. See Inspection Note. 52. Steer/Drive Wheel and Tire Assembly, Right Front Refer to inflation psi stenciled on frame. See Inspection Note. 39. Drive Wheel and Tire Assembly, Right Rear - Refer to inflation psi stenciled on frame. See Inspection Note. 40.
SECTION 2 - MACHINE PREPARATION AND INSPECTION 2.6 LOCKOUT 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. 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.
Figure 2-4.
SECTION 2 - MACHINE PREPARATION AND INSPECTION Table 2-1.
Figure 2-5.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 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.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Placards Stability 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.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 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.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.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-2. Platform Control Station 4. Tilt Alarm Warning Horn (Optional on 400 RTS) The Tilt Alarm Warning Horn is activated by the Tilt Alarm Switch when the chassis is on a severe slope (over 5° on the 400RTS and 2° on the 500RTS) with the platform raised. IF TILT ALARM IS ON WHEN PLATFORM IS RAISED, LOWER PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM. 5.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 9. PQ Controller - The PQ Controller performs three functions: Drive, Steer and Drive Speed. On all machines built before serial number 0200058922, tilting the controller in the direction you want to go (forward or reverse) activates drive in that direction. The thumb-operated steer switch on top of the controller handle activates the steer wheels in the direction it is moved.
3-6 – JLG Lift – 12 26 13 11 1 14 2 16 3 4 21 20 19 5 14 7 A-A 19 10 13 12 11 4 Figure 3-3.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Table 3-1.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Table 3-1.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION This machine is a self-propelled elevating ‘sizzor’ aerial work platform. The Sizzor Lift’s intended purpose is to position personnel with their tools and supplies at positions above ground level. The machine can be used to reach work areas located above machinery or equipment. The JLG Sizzor Lift has a primary operator Control Station in the platform.
SECTION 4 - MACHINE OPERATION Starting Procedure Table 4-1. Operating Specifications Model 500RTS 4 4 680 kg 900 kg 2. Pull the red mushroom-type Ignition/Emergency Stop switch at the Ground Control Station to the UP position (ON). 35% 45% 35% 45% 2 degreess 2 degreess 3. Place the PLATFORM/GROUND SELECT switch to the applicable position for desired control station operation. 12.1m 15.
SECTION 4 - MACHINE OPERATION 4.4 RAISING AND LOWERING (LIFTING) 4.6 DO NOT RAISE PLATFORM EXCEPT ON A FIRM, LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES. NOTE: This machine is equipped with a Enable Switch on the side of the platform control console. This switch must be depressed before activating DRIVE, LIFT, or STEER functions from the platform control console.
SECTION 4 - MACHINE OPERATION . Figure 4-1. Grade and Sideslope Traveling Forward TRAVEL GRADES IN “LOW” DRIVE SPEED ONLY. USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND ESPECIALLY WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 2 M (6 FT) OF AN OBSTRUCTION. NOTE: On machines equipped with leveling jacks, leveling jacks must be in the stowed position before operation of the drive system.
SECTION 4 - MACHINE OPERATION Traveling in Reverse NOTE: On machines equipped with leveling jacks, leveling jacks must be in the stowed position before operation of the drive system. 1. Position ignition/emergency stop switch to on. If machine has been shut down, start engine and allow warm-up period before beginning any lifting. 2. Position pump and engine control switches to desired positions (high or low) and position drive control switch to desired position (torque or speed). 3.
SECTION 4 - MACHINE OPERATION NOTES: 4-6 – JLG Lift – 3120828
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 3. Return disconnect caps to normal (engaged) position. GENERAL 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.
SECTION 5 - EMERGENCY PROCEDURES Manual Descent (Engine/Pump Failure Ground Controls) 5.4 The following procedure should be used to lower the platform 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 machines, position main power switch to ground. Place lift control switch to down. When platform is completely down, return lift control switch to center off and position main power switch to off.
SECTION 5 - EMERGENCY PROCEDURES Righting of Tipped Machine 5.5 A forktruck of suitable capacity or equivalent equipment should be placed under the elevated side of the chassis, with a crane or other suitable lifting equipment used to lift the platform while the chassis is lowered by the forklift or other equipment. Post-Incident Inspection Following any accident, thoroughly inspect the machine and test all functions first from the ground controls, then from the platform controls.
SECTION 5 - EMERGENCY PROCEDURES NOTES: 5-4 – JLG Lift – 3120828
SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Table 6-1.
SECTION 6 - INSPECTION AND REPAIR LOG Table 6-1.
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) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.
