JLG 500RTS Operator Manual

Operation & Safety Manual

Model

500RTS

3121100

November 14, 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.

Because the manufacturer has no direct control over machine operation and application, proper safety prac­tices are the responsibility of the owners, users, operators, lessors, and lessees.

All instructions in this manual are based upon the use of the machine under proper operating conditions, with
no deviations from the original design. Any alteration or modification of the machine is strictly forbidden without
written approval from JLG Industries, Inc.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.

Other Publications Available:

Service and Maintenance Manual....................................................... 3121103

Illustrated Parts Manual....................................................................... 3120697

3121100 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the
potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death

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. On the machine, the Safety Signal Words will have either a Red, Orange, or Yellow background as part of a
safety sign or decal. The “DANGER”, “WARNING”, and “CAUTION” Safety Signal Words, definitions, and associated colors
are as follows:

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, WILL
SIGNAL WORD IS USED IN THE MOST EXTREME CASES. WHEN
INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL HAVE A
RED BACKGROUND AS PART OF A DECAL.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.
WHEN INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL
HAVE AN ORANGE BACKGROUND AS PART OF A DECAL.

INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH IF
NOT AVOIDED, MAY
MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.
WHEN INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL
HAVE A YELLOW BACKGROUND AS PART OF A DECAL.

The “IMPORTANT” Safety Signal Word may also appear in this manual or on the machine. This Safety Signal Word typically
will not appear with the Safety Alert Symbol, but contains important information that must be followed for safe and proper
operation, The “IMPORTANT” Safety Signal Word definition and associated color is as follows.

INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION AND
WHICH, IF NOT FOLLOWED, MAY RESULT IN A MACHINE MAL­FUNCTIONED DAMAGE. WHEN INSTALLED IN A MACHINE, THIS
SIGNAL WORD WILL HAVE A GREEN BACKGROUND AS PART OF A
DECAL.

RESULT IN MINOR OR MODERATE INJURY. IT

b – JLG Lift – 3121100

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.

NOTICE

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. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

NOTICE

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL
PROPERTY OR THE JLG PRODUCT.

FOR :

•Accident Reporting

•Product Safety Publications

•Current Owner Updates

•Questions Regarding Product Safety

•Standards and Regulations Compliance Information

•Questions Regarding Special Product Applications

•Questions Regarding Product Modifications

CONTACT :

Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233

Toll Free: 877-JLG-SAFE

877-554-7233

E-mail: [e-mail]

3121100 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - January 3, 2000­Revised (Added Pro 65 page) - April 19, 2000
Revised - April 19, 2002
Revised - August 19, 2002
Revised - December 5, 2002
Revised - April 16, 2004
Added Manual Part Number to Foreword - - August 1, 2004
Revised - - November 14, 2007

d – JLG Lift – 3121100

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

TABLE OF CONTENTS

SECTION - FOREWORD

SECTION 1 - SAFETY PRECAUTIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Pre-operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 Towing, Lifting, and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.5 Additional Hazards / Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SECTION 2 - PREPARATION AND INSPECTION

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery and Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

3121100 – 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

2-3. Walk-Around Inspection Points (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-4. Walk-Around Inspection Points (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

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 , Front and Rear (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 Safe Approach Distances (M.S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

ii – JLG Sizzor – 3121100

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. A maintenance program, using the information
provided in this manual and the Service and Maintenance
Manual, must also be established by a qualified person
and must be followed to ensure that the machine is safe to
operate.

The owner/user/operator/lessor/lessee of the machine
should not accept operating responsibility until this man­ual has been read, training is accomplished, and opera­tion of the machine has been completed under the
supervision of an experienced and qualified operator.

These sections contain the responsibilities of the owner,
user, operator, lessor, and lessee concerning safety, train­ing, inspection, maintenance, application, and operation.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation,
please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED
IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROP­ERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge

• The Operators and Safety Manual must be read in its
entirety before operating the machine. For clarification,
questions, or additional information regarding any por­tions of this manual, contact JLG Industries, Inc.

• Allow only those authorized and qualified personnel to
operate the machine who have demonstrated that they
understand the safe and proper operation and mainte­nance of the unit.

• Read, understand, and obey all DANGERS, WARN­INGS, CAUTIONS, and operating instructions on the
machine and in this manual.

• Ensure that the machine is to be used in a manner
which is within the scope of its intended application as
determined by JLG.

• All operating personnel must be familiar with the emer­gency controls and emergency operation of the
machine as specified in this manual.

• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
your utilization and application of the machine.

Workplace Inspection

• Precautions to avoid all hazards in the work area must
be taken by the user before operation of the machine.

• Do not operate or raise the platform from a position on
trucks, trailers, railway cars, floating vessels, scaffolds
or other equipment unless the application is approved
in writing by JLG.

• Before operation, check work area for overhead haz­ards such as electric lines, bridge cranes, and other
potential overhead obstructions.

• Check floor surfaces for holes, bumps, drop-offs,
obstructions, debris, concealed holes, and other
potential hazards.

• Check the work area for hazardous locations. Do not
operate the machine in hazardous environments
unless approved for that purpose by JLG.

• Ensure that the ground conditions are adequate to
support the maximum tire load indicated on the tire
load decals located on the chassis adjacent to each
wheel.

• Do not operate the machine when wind conditions
exceed 28 mph (12.5 m/s).

• This machine can be operated in nominal ambient tem-

peratures of 0
JLG to optimize operation outside of this temperature
range.

o

F to 104o F (-20o C to 40o C). Consult

• An operator must not accept operating responsibilities
until adequate training has been given by competent
and authorized persons.

Machine Inspection

• Do not operate this machine until the inspections and
functional checks have been performed as specified in
Section 2 of this manual.

3121100 – JLG Sizzor – 1-1

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.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT­FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS­SION FROM THE MANUFACTURER

• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.

• Check the machine for modifications to original com­ponents. Ensure that any modifications have been
approved by JLG.

• Avoid accumulation of debris on platform deck. Keep
mud, oil, grease, and other slippery substances from
footwear and platform deck.

1.3 OPERATION

• When two or more persons are in the platform, the
operator shall be responsible for all machine opera­tions.

• Always ensure that power tools are properly stowed
and never left hanging by their cord from the platform
work area.

• Do not assist a stuck or disabled machine by pushing
or pulling except by pulling at the chassis tie-down
lugs.

• Stow scissor arm assembly and shut off all power
before leaving machine.

Trip a nd Fa ll H a zar ds

• JLG Industries, Inc. recommends that all persons in the
platform wear a full body harness with a lanyard
attached to an authorized lanyard anchorage point
while operating this machine. For further information
regarding fall protection requirements on JLG prod­ucts, contact JLG Industries, Inc.

General

• Do not use the machine for any purpose other than
positioning personnel, their tools, and equipment.

• Before operation, the user must be familiar with the
machine capabilities and operating characteristics of
all functions.

• Never operate a malfunctioning machine. If a malfunc­tion occurs, shut down the machine. Remove the unit
from service and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

• Never slam a control switch or lever through neutral to
an opposite direction. Always return switch to neutral
and stop before moving the switch to the next function.
Operate controls with slow and even pressure.

• Hydraulic cylinders should never be left at end of travel
(fully extended or fully retracted) before shutdown or
for long periods of time. Always “bump” control in
opposite direction slightly when function reaches end
of travel. This applies both to machines in operation or
in the stowed position.

• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the plat­form, except in an emergency.

• Do not carry materials directly on platform railing
unless approved by JLG.

• Prior to operation, ensure all gates are fastened and
secured in their proper position. Identify the desig­nated lanyard anchorage point(s) at the platform and
securely attach the lanyard. Attach only one (1) lanyard
per lanyard anchorage point.

• Keep both feet firmly positioned on the platform floor at
all times. Never position ladders, boxes, steps, planks,
or similar items on unit to provide additional reach for
any purpose.

• Never use the scissor arm assembly to gain access to
or leave the platform.

1-2 – JLG Sizzor – 3121100

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. Where transfer is necessary, enter/exit
through the gate only with the platform within 1 foot
(0.3m) of a safe and secure structure. 100% tie-off is
also required in this situation utilizing two lanyards.
One lanyard must be attached to the platform with the
second lanyard attached to the structure. The lanyard
connected to the platform must not be disconnected
until such time the transfer to the structure is safe and
complete.

• Keep oil, mud, and slippery substances cleaned from
footwear and the platform floor.

Electrocution Hazards

• This machine is not insulated and does not provide
protection from contact with an electrically charged
conductor.

Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations
are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any
part of the machine and its occupants, their tools, and
their equipment from any electrical line or apparatus
carrying up to 50,000 volts. One foot additional clear­ance is required for every additional 30,000 volts or
less.

MINIMUM SAFE APPROACH

DISTANCE

in Feet (Meters)

• Maintain safe clearance from electrical lines, appara­tus, or any energized (exposed or insulated) parts in
accordance with the Minimum Safe Approach Distance
(MSAD) as specified in Table 1-1. Allow for machine
movement and electrical line swaying.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB­ITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND WIR­ING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• Ensure that the ground conditions are adequate to
support the maximum tire load indicated on the tire
load decals located on the chassis adjacent to each
wheel. Do not travel on unsupported surfaces.

• The user should be familiar with the driving surface
before driving. Do not exceed the allowable sideslope
and grade while driving.

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.

3121100 – JLG Sizzor – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• Before driving on floors, bridges, trucks, and other sur­faces, check allowable capacity of the surfaces.

• Never exceed the maximum work load as specified on
the platform. Distribute loads evenly on platform floor.
Keep all loads within the confines of the platform,
unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft.
(0.6m) from holes, bumps, drop-offs, obstructions,
debris, concealed holes, and other potential hazards at
the ground level.

• Never attempt to use the machine as a crane. Do not
tie-off machine to any adjacent structure. Never attach
wire, cable, or any similar items to platform.

• Do not operate the machine when wind conditions
exceed 28 mph (12.5 m/s).Unless otherwise specified
on machine or accessory.

• Do not cover the platform sides or carry large surface­area items in the platform when operating outdoors.
The addition of such items increases the exposed wind
area of the machine.

• Do not increase the platform size with unauthorized
deck extensions or attachments.

• If scissor arm assembly or platform is caught so that
one or more wheels are off the ground, all persons
must be removed before attempting to free the
machine. Use cranes, forklift trucks, or other appropri­ate equipment to stabilize machine and remove per­sonnel.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating
and ground personnel.

• Keep hands and limbs out of the scissor arm assembly
during operation.

• Watch for obstructions around machine and overhead
when driving. Check clearances above, on sides, and
bottom of platform when lifting or lowering platform..

• Keep non-operating personnel at least 6 ft. (1.8m)
away from machine during all driving operations.

• Under all travel conditions, the operator must limit
travel speed according to conditions of ground sur­face, congestion, visibility, slope, location of personnel,
and other factors causing hazards of collision or injury
to personnel.

• Be aware of stopping distances in all drive speeds.
When driving in high speed, switch to low speed
before stopping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quar­ters or when driving in reverse.

• Exercise extreme caution at all times to prevent obsta­cles from striking or interfering with operating controls
and persons in the platform.

• Ensure that operators of other overhead and floor level
machines are aware of the aerial work platform’s pres­ence. Disconnect power to overhead cranes. Barricade
floor area if necessary.

• Avoid operating over ground personnel. Warn person­nel not to work, stand, or walk under a raised platform.
Position barricades on floor as necessary.

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting,
or hauling.

• This machine should not be towed, except in the event
of emergency, malfunction, power failure, or loading/
unloading. Refer to Section 6 for emergency towing
procedures.

• Ensure platform is fully retracted and completely
empty of tools prior to towing, lifting or hauling.

• 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 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations,
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.

• Do not refuel the machine with the engine running

• During operation, keep all body parts inside platform
railing.

• Always post a lookout when driving in areas where
vision is obstructed.

1-4 – JLG Sizzor – 3121100

(where applicable).

• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.

Charge batteries only in a well ventilated area.

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtaining maxi­mum service life and safe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE

1. Before a new machine is put into operation it must
be carefully inspected for any evidence of damage
resulting from shipment and inspected periodically
thereafter, as outlined in paragraph 2-3, Delivery and
Periodic Inspection. The unit should be thoroughly
checked for hydraulic leaks during initial start-up
and run. A check of all components should be made
to assure their security.

2. All preparations necessary to place the machine in
operation readiness status are the responsibility of
management personnel. Preparation requires good
common sense, (i.e. lift works smoothly and brakes
operate properly) coupled with a series of visual
inspections. The mandatory requirements are given
in paragraph 2-4, Daily Walk Around Inspection.

3. It should be assured that the items appearing in the
Delivery and Periodic Inspection and Functional
Check are complied with prior to putting the
machine into service.

Periodic inspection shall be performed monthly or more
often when required by environment, severity, and fre­quency of usage.

Handrail Assemblies

Properly installed; no loose or missing parts; no visible
damage.

Platform Assembly

No visible damage; free of dirt and debris.

Sizzor Arms

No visible damage, abrasions and/or distortions.

Electrical Cable

No visible damage; properly secured.

Pivot Pins

No loose or missing retaining hardware; no damage or
wear to pin heads which would cause pin to rotate; no evi­dence of pin or bushing wear.

Lift Cylinder

No rust, nicks, scratches or foreign material on piston rod.
No leakage. Evidence of proper lubrication.

Frame

No visible damage; loose or missing hardware (top and
underside).

Drive Hubs

Check oil level in drive hub by removing pipe plug and
feeling for oil level. (Contact service personnel for assis­tance if needed.)

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

2.3 DELIVERY AND PERIODIC INSPECTION

NOTE: This machine requires periodic safety and mainte-

nance inspections by a JLG Dealer. A decal on the
frame provides a place to record (stamp) inspection
dates. Check decal and notify dealer if inspection is
overdue.

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.

3121100 – JLG Sizzor – 2-1

Tire and Wheel Assemblies

No loose or missing lug nuts; no visible damage

Sliding Wear Pad Blocks

No excessive wear; adequate lubrication.

SECTION 2 - PREPARATION AND INSPECTION

Hydraulic Oil Supply

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. If oil
is not visible, add oil until oil is visible in both ADD and
FULL sight windows on tank. Do not overfill tank.

Steer Cylinder

No rust, nicks, scratches or foreign material on piston rod;
no leakage.

Steer Linkage

No loose or missing parts; no visible damage.

Steer Spindle Assemblies

No excessive wear; no damage.

Control Boxes (Console and Ground)

Switches operable; no visible damage; placards secure
and legible. Hand controller operable; no visible damage.

Battery

Proper electrolyte level; cable connections tight; no visible
damage; no corrosion at battery cable connections.

Engine

Engine oil level - full mark on dipstick; filler cap secure; air
filter secure.

Hydraulic Pump and Valves

No visible damage; no evidence of leakage; units secure.

Platform Placards

No visible damage; placards secure and legible.

2.4 DAILY WALK-AROUND INSPECTION

It is the user’s responsibility to inspect the machine before
the start of each workday. It is recommended that each
user inspect the machine before operation, even if the
machine has already been put into service under another
user. This Daily Walk-Around Inspection is the preferred
method of inspection.

In addition to the Daily Walk-Around Inspection, be sure to
include the following as part of the daily inspection:

Overall Cleanliness

Check all standing surfaces for oil, fuel and hydraulic oil
spillage and foreign objects. Ensure overall cleanliness.

Placards

Keep all information and operating placards clean and
unobstructed. Cover when spray painting or shot blasting
to protect legibility.

Operators and Safety Manual

Ensure a copy of this manual is enclosed in the manual
storage box.

Machine Log

Ensure a machine operating record or log is kept. Check
to see that it is current and that no entries have been left
uncleared, leaving machine in an unsafe condition for
operation.

Daily Lubrication

For those items pointed out in the Daily Walk-Around
Inspection requiring daily lubrication, refer to Figure 2-5.,
Lubrication Diagram for specific requirements.

Perform the following checks and services before attempt­ing to operate the machine.

Lock-Out Cylinders (If Equipped)

No rust, nicks, scratches or foreign material on piston rod;
no leakage.

Leveling Jacks (If Equipped)

No rust, nicks, scratches or foreign material on piston rod;
no leakage.

Traversing Platform (If Equipped)

No loose or missing parts; no visible damage; free of dirt
and debris.

TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.

1. Start each day with a full fuel tank.

2. Ensure that all items requiring lubrication are ser­viced in accordance with the Lubrication Chart.

3. Perform functional checks in accordance with para­graph 2-5, Daily Functional Check.

2-2 – JLG Sizzor – 3121100

SECTION 2 - PREPARATION AND INSPECTION

2.5 DAILY FUNCTIONAL CHECK

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
WHEN RELEASED.

A functional check of all systems must be performed,
under no load, in an area free of overhead and ground
level obstructions. Perform the functional check in accor­dance with the following procedure once the walk-around
inspection is complete:

1. From the ground control station, raise and lower the
platform several times and check for the following:

a. Smooth elevation and lowering.

b. High function speeds cut out as soon as possi-

ble after the platform lifts beyond the stowed
position and begins to elevate. High function
speeds must cut out prior to a maximum plat­form 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
and the plunger of the switch actuates properly.
As shown below, the plunger must extend (out)
a minimum of 0.22 in (5.6 mm) to lock the axles

when the scissor arms are raised. When fully
lowered, the scissor arms will press the plunger
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
first from the ground control station and then from
the platform controls. With all the leveling jacks
retracted, check that the platform will not raise
above the following limits:

500RTS - 22 ft (6.7m) Approximate elevation 44%

3. Drive forward and reverse, check for proper opera­tion.

4. Check that drive brakes hold when machine is
driven up a hill, not to exceed rated gradeability, and
stopped.

5. Steer left and right. Check for proper operation.

6. Check hydraulic oil reservoir sight gauge. Refer to
Lubrication Chart.

TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.

Min 5.6 mm (0.22 in.)

3121100 – JLG Sizzor – 2-3

SECTION 2 - 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.

NOTE: Ensure platform is fully lowered prior to beginning

lockout cylinder check.

1. Place a 8 in (20 cm) high block with ascension ramp
in front of the left front wheel.

2. Activate the machine’s hydraulic system from the
platform control station.

3. Place the engine speed and drive speed control
switches to their respective “LOW” positions.

4. Place the drive controller to the “FORWARD” posi­tion and carefully drive the machine up the ascen­sion ramp until the left front wheel is on top of the
block.

5. Raise the machine platform approximately 2 ft (61
cm); ensure the lockout cylinder cam valve is free of
the sizzor arm trip bar.

6. Place the drive controller to the “REVERSE” position
and carefully drive the machine off of the block and
ramp.

7. Have an assistant check to see that the left front
wheel remains locked in position off of the ground.

8. Lower the machine platform; the lockout cylinder
should then release the wheel and allow it to rest on
the ground.

9. If the lockout cylinder does not function properly,
have qualified personnel correct the malfunction
prior to any further operation.

2-4 – JLG Sizzor – 3121100

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Daily Walk-Around Inspection Diagram

3121100 – JLG Sizzor – 2-5

SECTION 2 - PREPARATION AND INSPECTION

GENERAL

Begin the “Walk-Around Inspection” at Item 1, as noted
on the diagram.Continue to the right (counterclockwise
viewed from top) checking each item in sequence for the
conditions listed in the “Walk-Around Inspection Check­list”.

TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL­FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLAT ION. TO AVO ID
POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DUR­ING “WALK-AROUND INSPECTION”.

NOTE: Do not overlook visual inspection of chassis under-

side. Checking this area often results in discovery of
conditions which could cause extensive machine
damage.

1. Steer Cylinder and Tie Rod Ends - No loose or
missing parts, no visible damage. No steer cylinder
leaks or damage.

2. Leveling Jack, Left Front (If Equipped) - No loose or
missing parts, no visible damage. No cylinder leaks
or damage.

3. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured.

4. Steer Spindle, Left Front - No loose or missing
parts, no visible damage, evidence of proper lubri­cation.

5. Steer/Drive Wheel and Tire Assembly, Left Front ­Properly secured, no loose or missing lug nuts, no
visible damage. Refer to inflation psi stenciled on
frame.

6. Drive Motor, Left Front (4 Wheel Drive) - No visible
damage, no evidence of leakage.

7. Drive Brake, Left Front (4 Wheel Drive) - No loose or
missing parts, no visible damage, no evidence of
leakage.

8. Drive Hub, Left Front (4 Wheel Drive) - No visible
damage, no evidence of leakage. Drive hubs
should be one half full of EPGL SAE 90.

9. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
no loose or missing parts, no evidence leakage.

10. Oscillating Axle (If Equipped) - Properly secured,
evidence of proper lubrication. No lockout cylinder
leaks or damage.

11. Ladder - No damage, securely attached.

12. Hydraulic Reservoir - No visible damage or missing
parts. No evidence of leaks. Recommended oil
level in sight glass. Breather cap secure and work­ing.

13. Ground Controls - Switches operable, no visible
damage, placards secure and legible.

14. Tilt Alarm Switch - Properly secured, no loose or
missing parts, no visible damage.

15. Hydraulic Filter - No visible damage, properly
secured, no evidence of leakage.

16. Auxiliary Power Pump - Properly secured, no visible
damage, no evidence of leakage. Hoses and fit­tings properly secured, no visible damage, no evi­dence of leaks.

17. Control Valves - Valves properly secured, no visible
damage, no evidence of leakage. Hoses and fit­tings properly secured, no visible damage, no evi­dence of leaks.

18. Hand Pump Manual Descent - Properly secured, no
loose or missing parts, no visible damage.

19. Fuel Tank (Gasoline or Diesel Engine) - Filler cap
secure, sight gauge visible, no damage or leaks.

20. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
no loose or missing parts, no evidence leakage.

21. Travel/Descent/Motion Alarm - Properly secured, no
loose or missing parts, no visible damage.

22. Safety Prop - Stored securely, no missing parts.

23. Drive Wheel and Tire Assembly, Left Rear - Properly
secured, no loose or missing lug nuts, no visible
damage. Refer to inflation psi stenciled on frame.

24. Drive Motor, Left Rear - No visible damage, no evi­dence of leakage.

25. Drive Brake, Left Rear - No loose or missing parts,
no visible damage, no evidence of leakage.

26. Drive Hub, Left Rear - No visible damage, no evi­dence of leakage. Drive hubs should be one half full
of EPGL SAE 90.

27. Steer Spindle, Left Rear (If Equipped) - No loose or
missing parts, no visible damage, evidence of
proper lubrication.

28. LP Tank and Bracket (If Equipped) - No loose or
missing parts, no visible damage. No leaks or dam­age.

Figure 2-2. Walk-Around Inspection Points (Sheet 1 of 3)

2-6 – JLG Sizzor – 3121100

29. Leveling Jack, Left Rear (If Equipped) - No loose or
missing parts, no visible damage. No cylinder leaks
or damage.

30. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured.

31. Battery Installation (Gasoline or Diesel Engine) ­Proper electrolyte level, cables secure, no damage
or corrosion. Holddowns secure.

32. Ladder - No damage, securely attached.

33. Traversing Platform (If Equipped) - No loose or
missing parts, no visible damage, platform deck
extension operates properly.

34. Leveling Jack, Right Rear (If Equipped) - No loose
or missing parts, no visible damage. No cylinder
leaks or damage.

35. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured.

36. Rear Steer Cylinder and Tie Rod Ends (If Equipped)

- No loose or missing parts, no visible damage. No
steer cylinder leaks or damage.

37. LP Tank and Bracket (If Equipped) - No loose or
missing parts, no visible damage. No leaks or dam­age.

38. Steer Spindle, Right Rear (If Equipped) - No loose
or missing parts, no visible damage, evidence of
proper lubrication.

39. Drive Wheel and Tire Assembly, Left Rear - Properly
secured no loose or missing lug nuts, no visible
damage. Refer to inflation psi stenciled on frame.

40. Drive Motor, Right Rear - No visible damage, no evi­dence of leakage.

41. Drive Brake, Right Rear - No loose or missing parts,
no visible damage, no evidence of leakage.

42. Drive Hub, Right Rear - No visible damage, no evi­dence of leakage. Drive hubs should be one half
full of EPGL SAE 90.

43. Safety Prop - Stored securely, no missing parts.

44. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
no loose or missing parts, no evidence leakage.

45. Engine Installation - Engine oil to full mark on dip­stick, oil fillercap secure. Muffler/exhaust system
properly secured, no leakage. Air filter assembly
secure, no loose or missing parts, element clean.
Gasoline Engine Only - Radiator cap secure, cool­ant to correct level.

Figure 2-3. Walk-Around Inspection Points (Sheet 2 of 3)

SECTION 2 - PREPARATION AND INSPECTION

46. Hydraulic Pump - Pump properly secured, no visi­ble damage, no evidence of leakage. Hoses and fit­tings properly secured, no visible damage, no
evidence of leaks.

47. Handrail installation - All railings securely attached,
no damage or missing parts, chains securely
attached.

48. Sizzor Arms and Sliding Wear Pads - Properly
secured, no visible damage, evidence of proper
lubrication. Inspect sizzor arm guards for damage
and proper installation.

49. Ladder - No damage, securely attached.

50. Lift Cylinder - Properly secured, no visible damage,
no loose or missing parts, no evidence leakage.

51. Traversing Platform Extension Cylinder (If
Equipped) - Properly secured, no visible damage,
no loose or missing parts, no evidence of leakage.

52. Steer/Drive Wheel and Tire Assembly, Right Front ­Properly secured, no loose or missing lug nuts, no
visible damage. Refer to inflation psi stenciled on
frame.

53. Drive Motor, Right Front (4 Wheel Drive) - No visible
damage, no evidence of leakage.

54. Drive Brake, Right Front (4 Wheel Drive) - No loose
or missing parts, no visible damage, no evidence of
leakage.

55. Drive Hub, Right Front (4 Wheel Drive) - No visible
damage, no evidence of leakage. Drive hubs
should be one half full of EPGL SAE 90.

56. Steer Spindle, Right Front - No loose or missing
parts, no visible damage, evidence of proper lubri­cation.

57. High Speed Limit Switch - No visible damage, prop­erly secured.

58. Platform Controls - Properly secured, no loose or
missing parts, no visible damage. Placards secure
and legible, control switches return to neutral. Con­trol markings legible, manual in manual storage
box.

59. Leveling Jack, Right Front (If Equipped) - No loose
or missing parts, no visible damage. No cylinder
leaks or damage.

60. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured.

61. Traversing Platform (If Equipped) - No loose or
missing parts, no visible damage, platform deck
extension operates properly.

3121100 – JLG Sizzor – 2-7

SECTION 2 - PREPARATION AND INSPECTION

62. Drive Cutout Switch and High Speed Cutout Switch

- No visible damage, properly secured.

63. Leveling Gauge - No visible damage, properly
secured.

Figure 2-4. Walk-Around Inspection Points (Sheet 3 of 3)

2.7 DUAL FUEL SYSTEM

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS
MUST BE FOLLOWED.

Changing from Gasoline to LP Gas

1. Start the engine from the ground control station.

2. Open the hand valve on the LP Gas supply tank by
turning counterclockwise.

BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING
TO LP GAS.

3. While the engine is operating, place the three posi­tion LPG/GAS SELECT switch at the ground control
station to the center OFF position. Allow the engine
to operate, without load, until the engine begins to
‘stumble’ from lack of gasoline.

4. As the engine begins to ‘stumble’ place the switch to
the LPG position, allowing the LP fuel to be sent to
the fuel regulator.

64. Traversing Platform Valve (If Equipped) - No loose
or missing parts, no visible damage, properly
secured, no evidence of leakage.

65. Platform Assembly - No loose or missing parts, no
visible damage, platform deck extension operates
properly.

Changing from LP Gas to Gasoline

1. With engine operating on LP under a no-load condi­tion, position the LPG/GAS SELECT switch at
ground control to the GAS SELECT position.

2. If engine ‘stumbles’ because of lack of gasoline,
place the switch to the LPG position until engine
regains smoothness, then return the switch to the
GAS SELECT position. Repeat as necessary until
engine runs smoothly on gasoline.

3. Close the hand valve on the LP gas supply tank by
turning clockwise.

2.8 TORQUE REQUIREMENTS

The Torque Chart (See Figure 2-6.) consists of standard
torque values based on bolt diameter and grade, also
specifying dry and wet torque values in accordance with
recommended shop practices. This chart is provided as
an aid to the operator in the event he/she notices a condi­tion that requires prompt attention during the walk-around
inspection or during operation until the proper service per­sonnel can be notified. Section 1 of the Service and Main­tenance Manual provides specific torque values and
periodic maintenance procedures with a listing of individ­ual components. Utilizing this Torque Chart in conjunction
with the preventive maintenance section in Section 2 of
the Service and Maintenance Manual, will enhance safety,
reliability and performance of the machine.

2-8 – JLG Sizzor – 3121100

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-5. Lubrication Diagram

3121100 – JLG Sizzor – 2-9

SECTION 2 - PREPARATION AND INSPECTION

Table 2-1. Lubrication Chart

INDEX

NO

1 Oscilla ting 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)

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)/

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)

12 500 RTS Sizzor Arm Pivot Pins 38 Grease Fittings (500RTS) MPG - Pressure Gun 100

13 Rail Slides N/A MPG - Brush 100

14 Platform Extension Slides (Optional) N/A MPG - Brush 100

15 Lift Cy linder 4 Grease Fittings MP G - Pressure Gun 100

16 Engine Crankcase Fill Cap/Drain Plug Check Engine Oil Level 10/100

COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

HO - Change HO

2 Grease Fittings MPG - Pressure Gun 100

(Optional)

INTERVAL

HOURS

10/500

*Torque Hubs should be 1/2 full of lubricant

** JLG Industries recommends replacing the hydraulic
filter after the first 40 hours of operation and every 250
hours thereafter.

KEY TO LUBRICANTS:

MPG - Multi-purpose Grease

EPGL - Extreme Pressure Gear Lube

HO - Hydraulic Oil (Mobil 424)

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL
MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.

NOTE: 1. Be sure to lubricate like items on each side

2. Recommended lubricating intervals are based

on machine operations under normal conditions.
For machines used in multi-shift operations and/or
exposed to hostile environments or conditions,
lubrication frequencies must be increased accord­ingly.

3. Operate hydraulic functions through one com­plete cycle before checking hydraulic oil level in
tank. Oil should be visible in ADD sight window on
hydraulic tank. If oil is not visible, add oil until oil is
visible in both ADD and FULL sight windows on
tank. Do not overfill tank.

4. Any time the pump coupling is removed, coat
splines of coupling with Texaco Code 1912 grease
prior to assembly. (gasoline or diesel engine only).

2-10 – JLG Sizzor – 3121100

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-6. Torque Chart

3121100 – JLG Sizzor – 2-11

SECTION 2 - PREPARATION AND INSPECTION

NOTES:

2-12 – JLG Sizzor – 3121100

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL

3.1 GENERAL

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER
MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH
GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI­BILITY OF THE USER AND HIS OPERATING PERSONNEL.

This section provides the necessary information needed
to understand control functions. Included in this section
are the operating characteristics and limitations, and func­tions and purposes of controls and indicators. It is impor­tant that the user read and understand the proper
procedures before operating the machine. These proce­dures will aid in obtaining optimum service life and safe
operation.

3.2 PERSONNEL TRAINING

The sizzor lift is a personnel handling device; therefore, it
is essential that it be operated and maintained only by
authorized personnel who have demonstrated that they
understand the proper use and maintenance of the
machine. It is important that all personnel who are
assigned to and responsible for the operation and mainte­nance of the machine undergo a thorough training pro­gram and check out period in order to become familiar
with the characteristics prior to operating the machine.

3. Knowledge and understanding of all safety work
rules of the employer and of Federal, State and
Local Statutes, including training in the recognition
and avoidance of potential hazards in the work
place; with particular attention to the work to be per­formed.

4. Proper use of all required personnel safety equip­ment.

5. Sufficient knowledge of the mechanical operation of
the machine to recognize a malfunction or potential
malfunction.

6. The safest means to operate near overhead obstruc­tions, other moving equipment, obstacles, depres­sions, holes, dropoffs, etc. on the supporting
surface.

7. Means to avoid the hazards of unprotected electrical
conductors.

8. Any other requirements of a specific job or machine
application.

Training Supervision

Training must be done under the supervision of a qualified
operator or supervisor in an open area free of obstructions
until the trainee has developed the ability to safely control
a sizzor lift in congested work locations.

In addition, personnel operating the machine should be
familiar with ANSI standard A92.6-1999 Responsibilities.
This standard contains sections outlining the responsibili­ties of the owners, users, operators, lessors and lessees
concerning safety, training, inspection, maintenance,
application and operation.

Persons under the influence of drugs or alcohol or who
are subject to seizures, dizziness or loss of physical con­trol must not be permitted to operate the machine.

Operator Training

Operator training must include instruction in the following:

1. Use and limitations of the platform controls, ground
controls, emergency controls and safety systems.

2. Knowledge and understanding of this manual and of
the control markings, instructions and warnings on
the machine itself.

Operator Responsibility

The operator must be instructed that he has the responsi­bility and authority to shut down the machine in case of a
malfunction or other unsafe condition of either the
machine or the job site and to request further information
from his supervisor or JLG Distributor before proceeding.

NOTE: Manufacturer or Distributor will provide qualified per-

sons for training assistance with first unit(s) delivered
and thereafter as requested by user or his person­nel.

3.3 OPERATING CHARACTERISTICS AND LIMITATIONS

General

A thorough knowledge of the operating characteristics
and limitations of the machine is always the first require­ment for any user, regardless of user’s experience with
similar types of equipment.

3121100 – JLG Sizzor – 3-1

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Placards

Important points to remember during operation are pro­vided at the control stations by DANGER, WARNING,
CAUTION, IMPORTANT and INSTRUCTION placards. This
information is placed at various locations for the express
purpose of alerting personnel of potential hazards consti­tuted by the operating characteristics and load limitations
of the machine. See foreword for definitions of the above
placards.

Capacities

Raising platform above stowed position with or without
any load in platform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level
surface.

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Leveling Jacks properly set.

Stability

This machine, as originally manufactured by JLG and
operated within its rated capacity on a smooth, firm and
level supporting surface, provides a stable aerial platform
for all platform positions.

3.4 CONTROLS AND INDICATORS

Machines are equipped with control panels that use sym­bols instead of words to indicate control functions. Refer
to Figure 3-3., Control Panel Symbols for these symbols
and their corresponding functions.

Ground Control Station

DO NOT OPERATE FROM GROUND CONTROL STATION WITH
PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.

PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPEC­TIONS FROM THE GROUND CONTROL STATION AS POSSIBLE.

Figure 3-1. Ground Control Station

3-2 – JLG Sizzor – 3121100

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.

2. Power Selector Switch - A three position key-oper­ated power selector switch supplies operating
power to the platform or ground controls, as
selected. When positioned to platform, the switch
provides power to the platform controls. When posi­tioned to ground, the switch provides power to the
ground controls. With the power selector switch in
the center off position, power is shut off to both plat­form and ground controls.

NOTE: With the PLATFORM/GROUND SELECT switch

positioned to GROUND, engine speed will stay in
LOW at all times.

3. Start Button - A momentary contact, pushbutton­type switch that supplies electrical power to the
starter solenoid when the IGNITION/EMERGENCY
STOP switch is in the ON position and the START
button is depressed.

retract the rear platform extension as needed for “up
and over” work access.

10. Gasoline/LPG Select Switch (Duel Fuel Only) - A
three position toggle-type switch is used to select
the desired method of powering the unit. Placing the
switch in the gasoline position shuts off the fuel flow
from the lp gas supply tank and allows fuel flow from
the gasoline tank. Moving the switch to the lpg posi­tion shuts off fuel flow from the gasoline tank and
allows lp gas from supply tank to be used to power
the unit. With the switch in the center position, fuel
flow is restricted from both supply tanks.

11. Hourmeter - The hourmeter records engine or elec­tric motor operating time.

12. Voltmeter - With the emergency stop switch in the
up position, and before starting the engine, the volt­meter indicates output voltage of the alternator. Nor­mal reading for the voltmeter will be 12-14 volts with
a properly charged or charging battery.

13. Water Temperature Gauge - The water temperature
gauge provides a visual display of the engine cool­ant temperature.

14. Oil Pressure Gauge - The oil pressure gauge dis­plays the engine lubrication system operating pres­sure.

4. Lift Switch - A three position, momentary contact lift
control switch provides raising and lowering of the
platform when positioned to UP or down.

5. High Engine Circuit Breaker (Diesel Engine) - A
push button reset 3 Amp circuit breaker located on
ground control panel returns interrupted power to
diesel engine throttle when depressed.

6. Start Button - A momentary contact, push-button
type switch supplies electrical power to the starter
solenoid when the IGNITION switch is positioned up
and the START button is depressed.

7. Choke Switch (If Equipped) - A momentary con­tact, push-button type switch supplies power to the
choke solenoid, when depressed, to assist cold start
operation.

8. Platform Traversing Switch (If Equipped) - A dou-
ble throw, momentary contact toggle-type platform
traversing switch permits the operator to hydrauli­cally extend and retract the platform extension as
needed for “up and over” work access.

9. Platform Traversing Select Switch (If Equipped) -
A full throw, momentary contact toggle-type plat­form traversing select switch that works simulta­neously with the platform traversing switch to
permits the operator to hydraulically extend and

Platform Control Station

1. Enable Switch - These machines are equipped with
an enable switch on the side of the platform control
console. On machines built with a serial number
before 0200058922, the enable switch must be
pressed before activating the drive, lift or steer func­tions. A built-in timer shuts off power to these func­tions if they are not activated within 3 seconds after
the enable switch is depressed. In addition, this
timer will shut off power to the drive and lift functions
3 seconds after they are deactivated, making if nec­essary to depress the enable switch before activat­ing drive and lift again. The steer function, unless
activated in conjunction with the drive or lift func­tions, will automatically cut off after 3 seconds of
operation. On machines built from, and including,
serial number 0200058922, the enable switch must
be depressed and held for the duration of lift. The
enable switch works in conjunction with the lift
switch only.

2. Ignition/Emergency Stop Switch - An ignition/
emergency stop red mushroom-type switch is pro­vided in order to turn on machine power in the plat­form and also to turn off machine power in the event
of an emergency. Power is turned on by positioning
the switch to the up (on) position, and is turned off
by positioning the switch to the down (off) position.

3121100 – JLG Sizzor – 3-3

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-2. Platform Control Station

3. Start Button - A momentary contact, pushbutton­type switch that supplies electrical power to the
starter solenoid when the ignition/emergency stop
switch is in the on position and the start button is
depressed.

4. Tilt Alarm Warning Horn - The Tilt Alarm Warning
Horn is activated by the Tilt Alarm Switch when the
chassis is on a severe slope (over 2° ) 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. Tilt Alarm Warning Light - A warning light on the
control console that lights when the chassis is on a
severe slope (over 2° ).

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF
TOGGLE SWITCHES DO NOT RETURN TO THE CENTER OFF
POSITION WHEN RELEASED.

6. Lift Switch - The lift toggle switch provides for rais­ing and lowering the platform when positioned to up
or down.

7. Engine Speed Switch - A two position engine
speed control switch provides the operator either
high or low engine rpm as required.

8. Pump Speed Switch - A two position pump speed
control switch allows the operator to select low (one
pump section operating) or high (both pump sec­tions operating) speed pump operation.

NOTE: HIGH ENGINE speed, high drive speed (SPEED),

and HIGH PUMP speed functions will cut-out when
platform is raised above stowed position, leaving
only low function speeds available until platform is
lowered completely.

DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED, HIGH
ENGINE SPEED, AND HIGH PUMP SPEED FUNCTIONS OPERATE
WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION.

3-4 – JLG Sizzor – 3121100

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. If machine is equipped with four
wheel steer, this switch operates only the front steer
wheels. On all machines built after, and including,
serial number 0200058922 there is a red trigger
switch on the front of the controller. This switch must
be depressed and held in order to drive the
machine.

10. Auxiliary Power (If Equipped) - A toggle type auxil­iary power control switch energizes the electrically­operated hydraulic pump, when actuated. Switch
must be held ON for the duration of auxiliary pump
use.

The auxiliary power pump functions to provide sufficient
oil flow to operate the Traversing Platform Extensions
should the main pump or engine fail during operation.

It should be noted that the functions will operate at a
slower than normal rate because of the lower GPM deliv­ered.

NOTE: Auxiliary power pump only operates the Traversing

Platform Extensions.

11. Platform Traversing Switch (If Equipped) - This is
a double throw, momentary contact toggle-type
switch which permits the operator to hydraulically
extend and retract the platforms as needed for “up
and over” work access.

12. Platform Traversing Select Switch (If Equipped) -
In order to select the platform to traverse there is a
full throw, momentary contact toggle-type platform
traversing select switch, that works in conjunction
with the platform traversing switch to permit the
operator to hydraulically extend and retract the plat­forms as needed for “up and over” work access.

13. Travel Warni n g H o r n - A push-button type horn
switch supplies electrical power to an audible warn­ing device when pressed.

14. Choke (If Equipped) - A push-button type switch
supplies power, when depressed, to the choke sole­noid for cold start operations.

15. Leveling Jacks - The four momentary contact type
toggle switches correspond to the four leveling
jacks, one at each corner of the machine.

BE AWARE OF OTHER PERSONNEL AND EQUIPMENT WHEN
EXTENDING OR RETRACTING LEVELING JACKS.

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

3121100 – JLG Sizzor – 3-5

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-3. Control Panel Symbols

3-6 – JLG Sizzor – 3121100

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-4. Decal Location - Right Side (Sheet 1 of 2)

3121100 – JLG Sizzor – 3-7

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-5. Decal Location - Left Side , Front and Rear (Sheet 2 of 2)

3-8 – JLG Sizzor – 3121100

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. From this Control Station, the operator can
drive and steer the machine in both forward and reverse
directions as well as raise and lower the platform. The
machine has a Ground Control Station which will override
the Platform Control Station. Ground Controls operate Lift
Up, Lift Down, and Platform Traversing, (If Equipped). The
controls are to be used only for daily check or in an emer­gency to lower the platform to the ground should the
operator in the platform be unable to do so.

Instructions and hazard warnings are posted adjacent to
both operator control stations and at other places on the
machine. It is extremely important that operators know
what instructions and warnings are placed on the
machine, and review these periodically so that they are
fresh in their minds. Vibrations emitted by these machines
are not hazardous to an operator in the work platform.

The JLG Sizzor Lift is designed to provide efficient and
safe operation when maintained and operated in accor­dance with warnings on the machine, the Operators &
Safety, Service and Specification Manual and all jobsite
and government rules and regulations. As with any type of
machinery, the operator is very important to efficient and
safe operation. Owner/user/operator 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 concerning safety, training,
inspection, maintenance, application and operation. It is
absolutely necessary that the JLG Lift be regularly main­tained in accordance with this section and the Service and
Specifications section, and that any evidence of lack of
maintenance, malfunction, excessive wear, damage or
modification to the machine be reported immediately to
the machine owner or the jobsite supervisor or safety
manager and that the machine be taken out of service
until all discrepancies are corrected.

The JLG Sizzor Lift is not intended to be used to lift mate­rial other than supplies which personnel in the platform
require to do their job. Supplies or tools which extend out­side the platform are prohibited. It must not be used as a
forklift, crane, support for overhead structure, or to push
or pull another object.

The JLG Sizzor Lift is powered using hydraulic motors and
cylinders for the various machine motions. The hydraulic
components are controlled by electrically activated
hydraulic valves using switches and the joystick controller.
The machine is equipped with a Enable Switch which
must be pressed before activating the drive, lift or steer
functions. The Enable Switch has a built-in timer which
shuts off power to these functions if they are not activated
within 3 seconds after Enable Switch is depressed. The
speeds of functions controlled by the joystick controller
are variable from zero to maximum speed depending
upon the position of the controller. Functions controlled by
toggle switches are either on or off. Higher or lower speed
is possible only when the applicable high function speed
control switch at the Platform Control Station is used in
conjunction with the drive function. All switches at the plat­form are guarded to prevent inadvertent operation by indi­vidual switch guards.

The JLG Sizzor is a two or four wheel drive machine with
drive power being supplied by a hydraulic motor for each
drive wheel. Each drive wheel is supplied with a hydrauli­cally released, spring applied brake. The brakes are auto­matically applied anytime the Drive controller is returned
to the neutral position.

The capacity of the 500RTS is found on the capacity
decals located on the machine. These capacities are
based on a load uniformly distributed in the center of the
platform. This means that the total combined weight of
personnel, tools and supplies must not exceed the given
capacity for a particular model.

The platform may be raised only when positioned on firm,
level and uniform surfaces. Leveling jacks, if provided, are
to assist in leveling the Sizzor Lift. The Sizzor Lift must be
level when operating on leveling jacks.

4.2 GENERAL

This section provides the necessary information needed
to operate the machine. Included in this section are the
procedures for starting, stopping, traveling, steering, park­ing, platform loading and transporting. It is important that
the user read and understand the proper procedures
before operating the machine.

The machine has a manual descent system which will
allow the platform to lowered without power from the
engine/motor powered pump.

3121100 – JLG Sizzor – 4-1

SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

RTS SERIES SCISSOR LIFTS MANUFACTURED AFTER AUGUST
26, 1996 ARE EQUIPPED WITH A HYDRAULIC OIL TEMPERATURE
SWITCH THAT SHUTS DOWN THE ENGINE WHEN THE HYDRAU­LIC OIL REACHES A TEMPERATURE OF APPROXIMATELY 230
DEGREES F (111 DEGREES C). THIS SHUT DOWN IS INTENDED
TO PROTECT THE HYDRAULIC SYSTEM AND ITS COMPONENTS
FROM DAMAGE DUE TO EXCESSIVE HEAT. HEAT MAY BUILD UP
DUE TO EXTENDED DRIVING, IN CONJUNCTION WITH HIGH
AMBIENT TEMPERATURES, ACTIVATING THIS SWITCH AND
SHUTTING DOWN THE MACHINE. IF THE MACHINE SHUTS
DOWN, ALLOW THE HYDRAULIC OIL TO COOL, THEN RESUME
NORMAL OPERATION.

NOTE: Initial starting should always be performed from the

Ground Control Station.

Starting Procedure

1. Check engine oil before attempting to start engine; if
necessary, add oil in accordance with Engine Manu­facturers Manual.

2. Pull the red mushroom-type Ignition/Emergency
Stop switch at the ground control station to the up
position (on).

3. Place the platform/ground select switch to the appli­cable position for desired control station operation.

4. If operating a dual fuel machine, place the LP/Gaso­line select switch to the desired position.

NOTE: If LPG system is selected, ensure that the hand

valve on the LPG supply tank is opened prior to
attempting to start the engine.

6. Check engine voltmeter when starting engine and
monitor gauge periodically during operation.

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW
SPEED BEFORE APPLYING ANY LOAD.

7. After engine has had sufficient time to warm up, pro­ceed with operation of unit.

4.4 RAISING AND LOWERING (LIFTING)

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.

Raising

NOTE: On machines equipped with leveling jacks, leveling

jacks must be in contacted with the ground for lift
system to raise above 22 ft. (6.7 m).

1. Position main power switch to desired position and
position power on (platform) or emergency stop
(ground) switch, as applicable, to on. If machine has
been shut down, start engine and allow warm-up
period before beginning any lifting.

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
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
TO ENGINE MAINTENANCE MANUAL.

NOTE: If starting machine from the platform control station,

place the engine speed control switch to the low
position prior to starting the engine.

5. If starting machine from ground controls, position
ignition/emergency stop switch to on and 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.

Lowering

ENSURE SIZZOR ARM AREA IS FREE OF PERSONNEL PRIOR TO
LOWERING PLATFORM.
DO NOT ‘LIFT DOWN’ WITHOUT COMPLETELY RETRACTING THE
OPTIONAL TRAVERSING DECK.

Pull lift toggle switch, then move it to down and hold until
desired elevation is achieved or until platform is fully low­ered.

4-2 – JLG Sizzor – 3121100

SECTION 4 - MACHINE OPERATION

4.5 TRAVERSING PLATFORM (OPTIONAL)

The machine may be equipped with hydraulically oper­ated traversing platforms that moves 4 ft. (1.2 meters) at
each end of the machine to give the operator “up and
over” access to worksites. The traversing platform is oper­ated by either the TRAVERSE toggle switches at platform
control console or the TRAVERSE toggle switch at the
ground control switches.

TO AVOID INJURY TO GROUND PERSONNEL, RETRACT TRA­VERSING PLATFORM COMPLETELY BEFORE LOWERING PLAT­FORM.

4.6 STEERING

To steer the machine, the thumb operated steer control
switch on the controller handle is positioned to the right
for traveling right, or to the left for traveling left.

To steer the machine with the optional 4 wheel steer, posi­tion steer control switch to right for traveling right, or to left
for traveling left.

When released, the switch will return to the center-off posi­tion and the wheels will remain in the previously selected
position. To return the wheels to the straightened position,

the switch must be activated in the opposite direction until
the wheels are centered.

4.7 TRAVELING (DRIVING)

ALWAYS RAISE LEVELING JACKS, IF EQUIPPED, BEFORE TRAV­ELING TO AVOID INJURY TO PERSONNEL OR DAMAGE TO
MACHINE.

IF EQUIPPED WITH LEVELING JACKS, DRIVE FUNCTION IS CUT
OUT WHEN LEVELING JACKS ARE IN THE SET POSITION.

IF MACHINE BECOMES STUCK DURING TRAVEL, DO NOT
“ROCK” MACHINE IN AN ATTEMPT TO REGAIN TRACTION, AS
DAMAGE TO DRIVE HUBS MAY RESULT.

DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A
SMOOTH, FIRM, AND LEVEL SURFACE FREE OF OBSTRUCTIONS
AND HOLES.

TO AVOID LOSS OF CONTROL OR UPSET ON GRADES AND
SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDES­LOPES EXCEEDING THOSE SPECIFIED FOR THE MACHINE.
TRAVEL GRADES AND SIDESLOPES WITH PLATFORM COM­PLETELY LOWERED.

Figure 4-1. Grade and Sideslope

3121100 – JLG Sizzor – 4-3

SECTION 4 - MACHINE OPERATION

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 6 FEET (2 M) OF
AN OBSTRUCTION.

3. Position controller to forward, squeeze red trigger
switch on the front of the controller, and hold con­troller in position for duration of travel. The red trig­ger switch must be depressed for the duration of
travel. Drive speed is determined by the distance the
controller is moved from the center off position.

HIGH DRIVE SPEED IS CUT OUT WHEN PLATFORM IS RAISED
ABOVE STOWED POSITION. IF LIMIT SWITCH MALFUNCTIONS,
SHUT DOWN MACHINE AND HAVE AUTHORIZED SERVICE PER­SONNEL REPAIR OR REPLACE LIMIT SWITCH PRIOR TO RESUM­ING OPERATION.

THE 500RTS IS EQUIPPED WITH A 2 DEGREES TILT SWITCH
THAT ILLUMINATES A LIGHT ON THE PLATFORM CONTROL
CONSOLE AND SOUNDS AN AUDIBLE ALARM WHEN THE
MACHINE IS ON A SLOPE (OVER 2 DEGREES) WITH THE PLAT­FORM RAISED. WHEN MACHINE IS ON A SLOPE (OVER 2
DEGREES) WITH THE PLATFORM COMPLETELY LOWERED,
ONLY THE WARNING LIGHT IS ILLUMINATED.

Traveling Forward

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. Position controller to forward, squeeze red trigger
switch on the front of the controller, and hold con­troller in position for duration of travel. The red trig­ger switch must be depressed for the duration of
travel. Drive speed is determined by the distance the
controller is moved from the center off position.

4.8 PARKING AND STOWING

Park and stow machine as follows:

1. Drive machine to a reasonably well-protected and
well-ventilated area.

2. Ensure platform is fully lowered.

3. Position emergency stop switch to off position.

4. If necessary, cover the instruction placards, caution
and warning decals so that they will be protected
from hostile environment.

5. Chock at least two wheels when parking machine for
an extended period of time.

6. Turn ignition/emergency stop switch to off and turn
the Power selector switch to the center position and
remove key to disable machine from unauthorized
use.

4.9 PLATFORM LOADING

The platform maximum rated load capacity is shown on a
placard located on the platform and is based upon the fol­lowing criteria.

1. Machine is positioned on a smooth, firm and level
surface.

2. All braking devices are engaged.

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. Refer to Section 3 for platform capacities.

4. Leveling Jacks properly set.

It is important to remember that the load should be evenly
distributed on the platform. The load should be placed
near the center of the platform when possible.

4-4 – JLG Sizzor – 3121100

SECTION 4 - MACHINE OPERATION

4.10 SAFETY PROPS

SAFETY PROPS MUST BE USED WHEN MAINTENANCE PER­FORMED ON MACHINE REQUIRES SIZZOR ARMS TO BE RAISED.

To engage safety props, raise platform so that both props
can be disconnected from locking arms and lowered to a
vertical position. Lower the platform until the safety props
rest on the pads provided on the frame. Maintenance can
now begin.

To store safety props, raise platform so that props can be
pivoted up and secured by their locking arms.

4.11 MACHINE TIE DOWN

When transporting machine, platform must be fully
retracted in the stowed position with machine securely
tied down to truck or trailer deck. Four tie down lugs are
provided, one at each corner of the machine frame.

USE TIE DOWN LUGS ONLY TO SECURE THE MACHINE FOR
SHIPPING. DO NOT USE TIE DOWN LUGS TO LIFT MACHINE.

4.12 TOWING

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.

3121100 – JLG Sizzor – 4-5

SECTION 4 - MACHINE OPERATION

NOTES:

4-6 – JLG Sizzor – 3121100

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 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. Prior to operation of the machine and
periodically thereafter, the entire operating manual,
including 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
been incorporated. The following procedures are to be
used ONLY for emergency movement to a suitable main­tenance area.

1. Chock wheels securely.

2. Disengage (reverse) the disconnect cap on each
drive torque hub by removing the two attaching cap­screws, turning the cap around, and reinstalling and
tightening the capscrews.

3. Return disconnect caps to normal (engaged) posi­tion.

Figure 5-2. Drive Hub Connect

4. Remove chocks from wheels.

5.3 EMERGENCY CONTROLS AND THEIR LOCATIONS

Emergency Stop Switch

At platform controls, push red Ignition/Emergency stop
switch this will immediately stop the machine.

Figure 5-1. Drive Hub Disconnect

3. Remove chocks and move the machine to an appro­priate maintenance area, using suitable equipment
for assistance.

After moving machine, complete the following proce­dures:

1. Position machine on a firm, level surface.

2. Chock wheels securely.

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 control­ling 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
TRAVERSING DECK, RETRACT DECK BEFORE LOWERING PLAT­FORM.

Manual Descent (Engine/Pump Failure ­Platform Controls)

In the event of engine/pump failure while operating the
machine from the platform console, the following proce­dure should be followed to lower the platform. Turn the
power on switch to on. Place the lift control switch to
down. When platform is completely down, return lift con­trol switch to center off and position power on switch to
off.

3121100 – JLG Sizzor – 5-1

SECTION 5 - EMERGENCY PROCEDURES

Manual Descent (Engine/Pump Failure ­Ground Controls)

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.

Manual Descent (Complete Loss of Power)

The manual descent valve is used, in the event of total
power failure, to lower the platform using gravity. The
manual descent handle is located on the inside of the
valve compartment on the left side of the machine. Turn
the release valve on the side of the pump to the closed
position and pump the handle. This will release the hold­ing valve, lowering the platform. After the platform reaches
the stowed position, open the release valve on the pump.

Auxiliary Power (If Equipped) (Engine/Pump Failure - Platform Controls)

A toggle type auxiliary power control switch is located on
the platform control station. Operation of switch turns on
the electrically driven auxiliary hydraulic pump. This
should be used in the case of failure of the main power
plant. The auxiliary pump will operate “only” the traversing
platforms. To activate auxiliary power:

1. Position IGNITION switch to off.

2. Operate appropriate control switch for desired func­tion and hold.

3. Position AUXILIARY POWER switch to ON and hold.

4. Release AUXILIARY POWER switch and selected
control switch.

Auxiliary Power (If Equipped) (Engine/Pump Failure - Ground Controls)

The toggle type traversing platform control switches are
located on the ground control station. Operation of switch
turns on the electrically driven auxiliary hydraulic pump.

1. Position IGNITION switch to off.

5.4 EMERGENCY OPERATION

Use of Ground Controls

KNOW HOW TO USE THE GROUND CONTROLS IN AN EMER­GENCY SITUATION.

Ground personnel must be thoroughly familiar with the
machine operating characteristics and the ground control
functions. Training should include operation of the
machine, review and understanding of this section and
hands-on operation of the controls in simulated emergen­cies.

Operator Unable to Control Machine

If the platform operator is pinned, trapped or unable to
operate or control the machine.

1. USE THE MANUAL DESCENT SYSTEM AS FIRST
CHOICE for bringing the platform and operator
down, particularly IF THERE IS INDICATION OF
CONTROL MALFUNCTION. Further use of hydraulic
power may cause severe injury or death.

2. Operate the machine from ground controls ONLY
with the assistance of other personnel and equip­ment (cranes, overhead hoists, etc.) as may be
required to safely remove the danger or emergency
condition.

3. Other qualified personnel on the platform may use
the platform controls. DO NOT CONTINUE OPERA­TION IF CONTROLS DO NOT FUNCTION NOR­MALLY.

4. Cranes, forklift trucks or other equipment which may
be available are to be used to remove platform
occupants and stabilize motion of the machine in
case machine controls are inadequate or malfunc­tion when used.

Platform Caught Overhead

If the platform becomes jammed or snagged in overhead
structures or equipment, do not continue operation of the
machine from either the platform or the ground until the
operator and all personnel are safely moved to a secure
location. Only then should an attempt be made to free the
platform using any necessary equipment and personnel.
Do not operate controls to cause one or more wheels to
leave the ground.

2. Operate appropriate control switch for desired tra­versing platform function and hold.

5-2 – JLG Sizzor – 3121100

SECTION 5 - EMERGENCY PROCEDURES

Righting of Tipped Machine

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. Do not lift above 10 ft (3
meters) until you are secure that all damage has been
repaired, if required, and that all controls are operating
correctly.

5.5 INCIDENT NOTIFICATION

It is imperative that JLG Industries, Inc. be notified imme­diately of any incident involving a JLG product. Even if no
injury or property damage is evident, the factory should
be contacted by telephone and provided with all neces­sary details.

Contact at 1-877-JLG-SAFE (554-7223) between the hours
of 8:00 AM - 4:45 PM Eastern Standard time.

It should be noted that failure to notify the Manufacturer of
an incident involving a JLG Industries product within 48
hours of such an occurrence may void any warranty con­sideration on that particular machine.

3121100 – JLG Sizzor – 5-3

SECTION 5 - EMERGENCY PROCEDURES

NOTES:

5-4 – JLG Sizzor – 3121100

SECTION 6 - INSPECTION AND REPAIR LOG

SECTION 6. INSPECTION AND REPAIR LOG

Table 6-1.Inspection and Repair Log

Date Comments

3121100 – JLG Sizzor – 6-1

SECTION 6 - INSPECTION AND REPAIR LOG

Table 6-1.Inspection and Repair Log

Date Comments

6-2 – JLG Sizzor – 3121100

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!

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA
[phone]
[phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Por t M acquarie
N.S.W. 2444
Australia

[phone]

[phone]

JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany

[phone]

[phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland

[phone]

[phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil

[phone]

[phone]

JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Scotland)
Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland

[phone]

[phone]

www.jlg.com

JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England

[phone]

[phone]

JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy

[phone]

[phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain

[phone]

[phone]

JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France

[phone]

[phone]

JLG Europe B.V.
Polaris Avenue 63
2132 JH Hoofddorp
The Netherlands

[phone]

[phone]

JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden

[phone]

[phone]