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Operators and Safety Manual

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1. 1704135 2046 1704136 2646 1704137 1703822 1703817 1703881 1703817 a 3252630 2033E3 2646E3 3252565 2046E3 2658E3 1704134 1703971 y 1702631 1703998 B 1704127 2646 2658 1703884 1704138 1703883 1704211 2046E3 2646E3 2658E3 1703811 1703811 1703788 1703814 1 TREA Figure 3 12 Decal Installation 1532E3 amp 1932E3 German Sheet 1 of 2 3 16 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1704131 1703773 1704132 1932E3 1704131 1532E3 1704132 1932E3
2. Y B 1703817 Figure 3 15 Decal Installation 1532E3 amp 1932E3 italian Sheet 2 of 2 3120877 JLG Sizzor 3 19 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 20 703819 1702773 ax 7 1703819 gt 1702928 1704131 1532E3 1704131 de DATA 1703841 203532 1932 1703812 1703817 1703817 1703897 5 2012 d 1704982 1703817 0 1703817 1532E3 1124983 p 17 1703814 1703840 1703974 1703788 Figure 3 16 Decal Installation 1532 amp 1932 Spanis
3. e Figure 3 4 Decal Installation 1532E3 amp 1932E3 UK Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120877 1704131 1532E3 1704132 1932E3 1703822 1703773 I 1704131 1932E3 1703817 1703818 1703817 1702631 1703814 1703813 1704982 1704131 1532 1932 3252533 1703969 1532 1704138 1703823 1703698 M ers 1703877 1703788
4. 1703788 1703814 1 03638 Figure 3 30 Decal Installation 2033E3 2046E3 2646E3 amp 2658 Spanish Sheet 1 of 2 3 34 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 203 3252585 2046E3 3252586 2646E3 3252587 1702773 1702928 FWD 1704133 1703819 1704135 2046E3 1704136 1704137 1704133 2658E3 2033E3 1704135 2046E3 1704136 2646 i S 1704137 2658 1703841 1703817 1703812 1703817 m 1703842 1703811 1703817 4 1703811 1703817 1703817 1703840 Figure 3 31 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 Spanish Sheet 2 of 2 3120877 JLG Sizzor 3 35 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL This page left blank intentionally 3 36 JLG Sizzor 3120877 SECTION 4 MACHINE OPERATION 3120877 SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION
5. 1703817 1703817 Figure 3 29 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 italian Sheet 2 of 2 3120877 JLG Sizzor 3 33 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1702928 2046E3 1702773 3252586 2646E3 3252587 2658E3 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 3252584 2033E3 3252585 22 I 1704134 2033 x 1704135 2046E3 1704136 2646E3 1704137 2658E3 3252630 2033E3 2646E3 3252565 2046E3 2658E3 1703794 y 1702631 1 05998 1704127 2646E3 2658E3 1703897 1704138 2033E3 1703842 LESE 1704211 2046E3 2646E3 2658E3 lt 1703811
6. 1704131 1532E3 1704132 1932E3 1703822 1704131 1532E3 p 1703817 1208865 1532E3 1932E3 1702631 1703814 1704982 170498 Pu 1703817 1703864 nt c ee sS 222 1703863 1704132 1932E3 3252533 1703970 S la 1703878 lt 1703788 Figure 3 11 Decal Installation 1532E3 amp 1932E3 French Sheet 2 of 2 JL G Sizzor SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL N 3252584 203 3252585 2046E3 3252586 2646E3 3252587 2658E3 ae 1 1704134 1703819 2033E3 1704135 O 1703882 0 1704136 9 2646 1704137 2658 1702773 1702928
7. 1703865 1703817 1703812 1703817 o 1703866 1703811 1703817 4 1703811 o 1703817 Y B 1703817 1703864 Figure 3 25 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 French Sheet 2 of 2 3120877 JL G Sizzor 3 29 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 2658E3 1702773 1702928 v 1704134 1703819 amp 2033E3 1704135 1703882 2046 1704136 2646E3 1704137 2658E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 1703822 1703817 1703881 1703817 3252630 2033 3 2646 3252565 2046 3 2658 I 1704134 1703971 Y 1702631 1703898 1704127 2646E3 2658E3 1 1703884 1704138 1703883 1704211 2046E3 2646E3 26
8. FWD 1704133 1703819 203 1704135 2046 1704136 2646 OAST pun 1204133 1704135 2046 1704136 2646E3 1704137 2658E3 1703894 1703817 1703812 4703817 170381 1703817 1703817 1703817 1703893 Figure 3 23 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 Dutch Sheet 2 of 2 3120877 JLG Sizzor 3 27 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 2658 eso gn p 1145 1704134 O 1703819 1704135 T 1703865 D o 1704136 1704137 63 2658 i 1704135 2046E3 1704136 2646 1704137 2658E3 1703822 4703817 1703864 1703817 3252630 2033E3
9. 1704131 1532E3 1704132 1932E3 1704131 1532E3 1704132 1932E3 1703822 i 3252534 1703817 1703818 1703817 1704122 1703813 1703969 3252615 1532E3 sees 4 6 1932E3 1702631 1703877 lt 1703788 1703823 1703968 1704123 1703814 Figure 3 7 Decal Installation 1532E3 amp 1932E3 Australian Sheet 2 of 2 3120877 JL G Sizzor 3 11 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 12 703819 1702928 1704131 1532 1704131 17041 3 1703894 12941 1932E3 1703812 1703817 1
10. 1703969 j B TI 1704982 1703817 f u Bc 1532E3 170498 ey 1703886 1932E3 1703788 Figure 3 14 Decal Installation 1532E3 amp 1932 italian Sheet 1 of 2 3 18 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3292587 1702773 1702928 Y FWD lt 1704133 1703819 2033 1704135 2046E3 1704136 2646E3 170413 2658E3 1704133 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658 e ep 7 J D 1703887 1703817 1703812 1703817 1703811 1703817
11. 1703817 1703817 1703881 Figure 3 27 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 German Sheet 2 of 2 3120877 JLG Sizzor 3 31 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 32 1702928 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 So rb 2046E3 3252586 2646E3 3252587 2658 3 1702773 3252585 ih 13252584 2033E3 Q 1703887 t 4 Ups 18 1703822 1703817 1703886 1703817 3252630 2033 3 2646 3252565 2046 3 2658 1703972 1703819 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 1702631 1703898 2033E3 2046E3 1704127 2646 3 2658 1703889 1704138 2033E3 17
12. hydrometer A CAUTION GROUND WHEN ADDING DISTILLED WATER THE BATTERIES NON DEPLOYED METALLIC CONTAINER AND OR FUNNEL MUST BE USED ADD WATER ONLY TO LEVEL INDICATOR OR 0 95 CM 3 8 INCH ABOVE SEPARATORS Figure 2 1 Pothole Protection System Operation NO OPEN FLAMES OR SMOKING WHEN CHARGING BATTERIES 3 Drive forward and reverse check for proper opera CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA tion ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT 4 Check that drive brake holds when machine is WITH SKIN OR CLOTHING driven up a hill not to exceed rated gradeability and stopped NOTE Be sure to disconnect and store any extension cords after charging batteries and before putting machine 5 Steer left and right Check for proper operation into service To avoid electrolyte overflow add distilled water to 6 Check fluid level on hydraulic oil reservoir Refer to batteries after charging the Lubrication Chart 2 6 TORQUE REQUIREMENTS The Torque Chart consists of standard torque values based on bolt diameter and grade also specifying dry and wet torque values in accordance with recommended shop practices This chart is provided as an aid to the operator in the event he she notices a condition that requires prompt attention during the walk around inspec tion or during operation until the proper service personnel can be notified The Service and Maintenance Manual p
13. Figure 3 5 Decal Installation 1532 amp 1932E3 UK Sheet 2 of 2 JLG Sizzor 3 9 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 10 1703969 3252615 1532E3 3252616 1932E3 1532E3 3252582 1702773 3252583 1932E3 y 1704131 1532E3 170413 1932E3 1703877 1703817 d 1703812 1703817 703819 1703819 1704131 1532E3 1704132 1932E3 1704122 1703817 1703817 TE p 1703814 1703813 Figure 3 6 Decal Installation 1532E3 amp 1932E3 Australian Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1704131 1702773 1704132 1932E3
14. 1703811 4 I 1703814 1703698 1703813 1703817 3252534 1703969 1703788 1703819 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 Figure 3 20 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 Australian Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033 3 3252585 2046E3 3252586 2646E3 3252587 1702773 1704433 2033E3 1704135 2046E3 1704136 2646E3 170413 1704133 2658E3 2033E3 1704135 2046E3 1704136 2646E3 m f NZ 1704137 j 2658 1703818 1703817 1703812 1203837 1704122 1703823 1703811 1703817 2 1703811 1703817 1703817 1703813 Figure 3 21 Decal Installation 2033E3 2046E3 2646E3 2658E3 Australian Sheet 2 of 2 3120877 JLG Sizzor 3 25 S
15. 1702928 E 4 1704134 Q O 1703819 2033E3 gt np 1704135 o 1703818 __ 1704136 2646E3 1704137 2658E3 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 1703822 1703817 1703813 1703817 2033E3 2646E3 3252565 2046 3 2658 1703971 1702631 1709858 1704127 2646E3 2658E3 1703877 1704138 1703823 2033E3 1704211 1 2046E3 2646E3 2658E3 1703811 1703811 1703788 1703814 1 Figure 3 18 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 UK Sheet 1 of 2 3 22 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 1702773 1702928 FWD 1704133 N 1703819 2033E3 1704135 2046E
16. 1704132 1932E3 IS 1703822 3252533 1703882 1703817 1703881 1703971 1704982 1532 e T 170498 a 4 roai CE 1 LI lt 1703884 1704138 1703788 1 1703883 1703880 1703814 Figure 3 13 Decal Installation 1532E3 amp 1932E3 German Sheet 2 of 2 3120877 JLG Sizzor 3 17 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 703819 15 1702773 3 1702928 a ME x EUM 10 20 1703819 1 9 LAC 1704131 1532E3 1704131 1704132 1532E3 170413 1703887 SS 7 1703812 1703817 1703817 1703877
17. 1532 8 1932E3 Dutch Sheet 2 of 2 JLG Sizzor 3 13 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 703819 MG t E pe 808 1703819 a RE 1702928 1704131 1532E3 lo 1704131 1704132 1532bE3 170413 gt 1703865 uS 190083 1932bE3 221 Ly 1703812 1703817 1703817 1703878 0 1703866 _ he 1704982 1703817 a 1700617 1532 ST 104983 T 1703814 1703864 1703970 1703788 Figure 3 10 Decal Installation 1532 amp 1932E3 French Sheet 1 of 2 3 14 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120877 1703773 I 1704131 1532E3 1704132 1932E3
18. 2669 0 50 n 86 608 911 8 78 221 786 96160 SBE 99 zoca 79 0 8807 96 68 1900 oz sory 096010042 SLO O sgoe 00420 94 06220 ve pez 6960 22560 8 6 8 9 vz sior 16620 992 0 gr 90 9 EL 6L 8897 2907 52600 12 201 SZ 91 a ZL 9L zec 6 i 916 0800 oz 9 8 8 9 68 80500 ozgp o 3 2 24 v S 809 5700 polis v 66S 7 927 2600 oop o 95 7 S 275 5 807 95600 z 8 2 B 2 ZIZ 95200 IE I 602 eco ea a FU 1 161 8910 0 mE el zi 50109 27820 64 F 222 oe 0 108 se 142 292 z 292 1 0901 3111907 sn ada 3111901 doaa QVOT WO 19 901 dWVv 12 ssayis fee 3215 ES 8 JOYY9 S1108 8 3OYY9 avs Abeba SM3U9S 4 9 KINO 51108 31 14 INIZ 804 SANTWA 3120877 JLG Sizzor 2 8 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 GENERAL A IMPORTANT SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS
19. Figure 4 2 E3 Tie Down front and rear typical A WARNING USE TIE DOWN EYES ONLY TO SECURE THE MACHINE FOR SHIPPING DO NOT USE TIE DOWN EYES TO LIFT THE MACHINE Tie Down When transporting the machine the platform extension must be fully retracted and the platform fully lowered in the stowed mode with the machine securely tied down to the truck or trailer deck A D ring is bolted to both the cen ter front and center rear of the frame for tie down 3120877 JLG Sizzor 4 5 SECTION 4 MACHINE OPERATION Lifting If it becomes necessary to lift the machine it is possible to lift the machine with a forklift On all models forklift pock ets are provided at the rear of the machine In addition all models can be lifted from either side with a forklift provided the forks are placed at the positions indi cated by the decals on the machine It is very important that the forklift operator use only the designated lifting areas to lift the machine Machines may be equipped with optional bolt on lifting lugs which are attached to the four corners of the frame These lugs enable the machine to be lifted using cranes or other suitable lifting devices NOTE If lifting becomes necessary from the optional bolt on lifting lugs JLG Industries Inc recommends the use of a proper spreader bar to avoid damage to the machine NOTE Forklifts cranes or other lifting devices must be capable of handling the followin
20. dL Operators and Safety Manual 2658E3 3120877 July 31 2001 1509001 I REGISTERED COMPANY 015 MG FOREWORD FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose It is important to over stress proper machine usage All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL Keep it with the machine REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAU TION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD
21. 5 4 Manual Descent 4 5 1 5 5 Emergency Operation cisco et eee oat fae 5 1 SECTION 6 INSPECTION AND REPAIR LOG 3120877 JLG Sizzor TABLE OF CONTENTS Continued LIST OF FIGURES FIGURE NO TITLE PAGE NO 2 1 Pothole Protection System Operation 2 3 2 2 Daily Walk Around Inspection Diagram 2 4 2 3 Daily Walk Around Inspection Points Sheet 1 2 2 5 2 4 Daily Walk Around Inspection Points Sheet 2 2 2 6 2 5 Lubrication Diagram Re eg ee eee LERRA UC 2 7 2 6 Torque sc om peeps ewe eh been ste Eripe 2 8 3 1 Ground Control Station Models 1532 1932 3 3 3 2 Ground Control Station Models 2033E3 2046E3 2646E3 2658E3 3 4 3 3 Platform Control Station All 5 3 5 3 4 Decal Location 2 rer ERR E 3 8 3 5 Decal Location right side 1 3 9 4 1 Grade and Sideslope iss u u luu Rede MGR nte gen KIA se add 4 4 4 2 Tie DOWN EE 4 5 4
22. Characteristics and Limitations 1 3 1 3 4 Controls and Indicators 2 Wad Tee eh ae debe 3 2 3 5 Placards and Decals li n lE RARE GRE eee ee Ge 3 7 SECTION 4 MACHINE OPERATION 4 1 Description ooo RD eC e u huuu yu g CMS ROC 4 1 4 2 x n rr Pr ent quide ead e cicer d eed ERR Red 4 1 4 3 Motor Operatii RETE 4 1 4 4 Raising and Lowering Lifting 4 2 4 5 Platform Extensions 3s y RR PEL EVE ee ie e Ea 4 3 4 6 Steering ze Sete aol ee ie he da ieee lect s eas ad 4 3 4 7 Traveling DIVIN z is y u ela ER yee she eaten ded es de dc EO Rub td dius 4 3 4 8 Parking and StoWihng ur s LX 4 4 4 9 Platform Loadirig iR ER RR hala IHR ER a EG RS 4 5 4 10 ee dd e boot ede p VR u aaa a b debe d 4 5 4 11 transporting Tie Down and Lifting 4 5 4 12 TOWING s ziv eek ey bie OS PU A 4 6 SECTION 5 EMERGENCY PROCEDURES 5 1 General zu IE UR EDEN Lees epic ere aad OR ai e 5 1 5 2 Incident Notification uu l ss eee edens e mecs sk Vee aa Su tege edie hae a 5 1 5 8 Emergency Towing 2 5 1
23. IS THE RESPONSI BILITY OF THE USER AND HIS OPERATING PERSONNEL This section provides the necessary information needed to understand control functions Included in this section are the operating characteristics and limitations and func tions and purposes of controls and indicators It is impor tant that the user read and understand the proper procedures before operating the machine These proce dures will aid in obtaining optimum service life and safe operation 3 2 PERSONNEL TRAINING The scissor 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 mainte nance of the machine undergo a thorough training pro gram and check out period in order to become familiar with the characteristics prior to operating the machine Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical con trol 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 mach
24. This machine is a self propelled aerial work platform on top of an elevating scissor mechanism The Scissor Lifts 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 positioned at ground level The JLG Scissor Lift has a primary operator Control Sta tion in the platform From this Control Station the operator can drive and steer the machine in both forward and reverse directions raise and lower the platform and if equipped operate the powered deck extension The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate lift up and down Ground Controls are to be used only in an emergency to lower the platform to the ground should the operator in the platform be unable to do so Vibrations emitted by these machines are not hazardous to an oper ator in the work platform The equivalent continuous A Weighted sound pressure level at the work platform is less than 70 dB A 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 The JLG Scissor Lift is designed to provide efficient and safe operation when maintained and o
25. be increased TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL accordingly MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Operate lift function through one complete cycle before checking oil level Oil level should be at full mark or within 1 5 cm 0 5 in below the full mark 3120877 Sizzor 2 7 SECTION 2 PREPARATION AND INSPECTION g 3avuo avs S 3avuo JYS yeys enbuJoj 79 2 gt si u se pojejd oj Ajdde 93oN 958 80 79792 vere caez 18 66 107 Tooge 2 oere 6 52 O86L 0692 18656 1895 9 seez elec croz 8021 elec ehee zi 79862 8902 call carl 0861 97062 6 9 891 560272 FSZLZ 6192 94 77 vl 99010711 gt zi geor zerei 1 08661 428 08072 166 ese 641 696 eriei 07897 eb O9ccz 516 582 898 60521 8 269 69 60601 gt vi 859 686 561 8 2 96r 96 0 P2P60 pao 075 80r 086 286 LZ 7996 perso ese zz 852 PEEL 20990 8 gc 9c pye bee leze 22
26. is necessary Please use this form to provide JLG with updated information with regard to the current ownership of JLG Products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile 717 485 6573 or mail to address as specified on the back of this form Thank you Product Safety amp Reliability Department JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Telephone 717 485 5161 Fax 717 485 6573 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address City State Zip Telephone 1 1 Date Of Transfer Current Owner Address City _ 5 Zip Telephone Who in your organization should we notify Name Title Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698
27. re cycle the emergency stop switch To activate the drive lift and powered deck functions press the applicable function switch then activate the joystick within three seconds to operate the function If the joystick is not activated within three seconds power is turned off to the function switch and the switch must be pressed again The posi trac and high drive functions are used in conjunction with the drive func tion Do not try to operate the drive lift and powered deck extension functions simultaneously If the drive lift and powered deck extension functions are 3 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 4 Hourmeter Powered Deck Extension Switch If Equipped Circuit Breaker Lift Switch Platform Ground Select Switch Emergency Stop Switch Figure 3 2 Ground Control Station Models 2033E3 2046E3 2646E3 2658E3 selected simultaneously no function will operate If this occurs pause then press only one of the func tion switches to activate the function Refer to the fol lowing paragraphs for more information about the function switches Controller Joystick The joystick controls three functions speed direction and powered deck extension if equipped The joystick is used in con junction with the trigger switch and controls the drive high drive lift and powered deck extension switches to control speed and direction for the selected function The drive high drive and
28. sion when positioned to extend or retract If the machine is equipped with a powered deck extension and the optional fold down rails the rails must be in the upright position before retracting the power deck extension Platform Control Station 3120877 Emergency Stop Switch A two position red mushroom shaped emergency stop switch func tions to provide power to the platform control station and also to turn off power to the platform function controls in the event of an emergency With the power selector switch positioned to platform power is turned on by pulling the switch out on and is turned off by pushing the switch in off Turning the emergency stop switch off and then on again will JLG Sizzor reset the smart system if a system fault has occurred and the machine has shut down Membrane Switch Panel The function switches at the platform control station are an integral part of a membrane switch panel which contains switches for drive high drive lift powered deck extension if equipped and posi trac plus a red tilt indicator light if equipped The drive lift and powered deck extension function switches have a small green light indicator beside them which is illuminated when that function is active The function switch light indicators will flash once or twice then go out when the plat form emergency stop switch is turned on If the light indicators fail to flash or if they fail to stop flashing
29. specified by the manufacturer shall not be exceeded 7 Instruction and warning placards must be legi ble 8 Aerial lifts may be field modified for uses other than those intended by the manufacturer only if certified in writing by the manufacturer to be in conformity to JLG requirements and to be at least as safe as it was prior to modification 9 Aerial lifts shall not be used near electric power lines unless the lines have been de energized or adequate clearance is maintained 10 Employees using aerial lifts shall be instructed on how to recognize and avoid unsafe condi tions and hazards 11 Ground controls shall not be operated unless permission has been obtained from personnel in the platform except in case of an emer gency 12 Regular inspection of the job site and aerial lift shall be performed by competent persons 13 Personnel shall always stand on the floor of the platform not on boxes planks railing or other devices for a work position Applicable Federal OSHA regulations for the United States as of the date of publication of this manual include but are not limited to 29 CFR 1910 67 29 CFR 1926 20 29 CFR 1926 21 29 CFR 1926 28 and 29 CFR 1926 453 JLG Sizzor FOREWORD January 1999 March 12 1999 March 1 2001 July 31 2001 REVISON LOG Original Issue Revised Revised Revised JLG Sizzor 3120877 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT S
30. switch or while operating in the drive forward mode The posi trac switch can also be used in conjunction with drive to evenly divide the oil flow to each drive motor when Sizzor 4 3 SECTION 4 MACHINE OPERATION HORIZONTAL Figure 4 1 Grade and Sideslope traction is a problem Do not try to operate the drive lift and powered deck extension functions simulta neously If the drive lift and powered deck extension functions are selected simultaneously no function will operate If this occurs pause then press only one of the function switches to activate the function A IMPORTANT WHEN TRAVELING A GRADE MAXIMUM TRACTION IS OBTAINED BY TRAVELING IN REVERSE REVERSE TRAVEL SHOULD BE USED WHEN LOADING ON A TRUCK OR WHEN ADEQUATE TRACTION IS NOT ACHIEVED BY TRAVELING FORWARD Traveling in Reverse 1 4 4 Position power selector switch at ground control sta tion to platform Position emergency stop switch at platform control station to on position 2 Press drive switch in conjunction with the trigger 3 Switch and move joystick rearward reverse and hold for duration of travel Drive speed is determined 4 by the distance the joystick is moved from the center off position The drive switch is part of the enable cir cuit which supplies power to the drive switch and 5 the joystick for 3 seconds after the drive switch is pressed If the joystick is not activated within 3 sec onds after the dri
31. the platform Lift is activated by pressing the lift switch and moving the joystick forward lift up or backward lift down Lift up speed is determined by the distance the joystick is moved forward Lift down speed is non adjustable and lift down is attained by moving the joystick fully backward The lift switch is part of the enable circuit which provides power to the joystick and the lift function for 3 seconds when the lift switch is pressed If the joystick is not acti vated within 3 seconds the lift switch must be pressed again before activating the joystick When the joystick is returned to the center off position the operator has 3 seconds to re activate the joystick or select another function before power is removed by the enable circuit Do not try to operate the drive lift and powered deck extension functions simulta neously If the drive lift and powered deck exten sion functions are selected simultaneously no function will operate If this occurs pause then press only one of the function switches to activate the function CAUTION DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION A IMPORTANT DO NOT ATTEMPT TO OPERATE THE LIFT AND DRIVE FUNC TIONS AT THE SAME TIME NO FUNCTION WILL OPERATE AND IT WILL BE NECESSARY TO RE SELECT A SINGLE FUNCTION WHEN OPERATING LIFT DOWN MOVE THE JOYSTICK TO THE FULL DOWN FULLY BACKWARD POSITION 3 6 9 Positive Traction Posi Trac Switch This
32. 04211 2046E3 2646E3 2658E3 1703811 PE 1703814 1 deiude 1703788 Figure 3 28 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 Italian Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 1702773 1702928 1704133 1703819 2033E3 1704135 2046E3 1704136 2646E3 170413 2658E3 J 1704133 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658 e eje e 7 1703887 1703817 1703812 203807 170381 1703817
33. 2646E3 3252565 2046E3 2658E3 1702773 1702928 eje e 1703970 1702631 1 05839 1704127 2646E3 2658E3 1703878 1704138 1703866 1704211 2046E3 2646E3 2658E3 1703811 gt 1703811 LEE 1703788 1703814 1709863 Figure 3 24 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 French Sheet 1 of 2 3 28 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL E 3252584 A 3252585 2046E3 3252586 2644 1702928 3252587 1702773 FWD 1704133 i 1703819 2033E3 1704135 2046E3 1704136 2646E3 2 104137 _ dr 0x 2 1704133 1704135 2046 1704136 2646 1704137 2658E3
34. 3 1704136 2646E3 MR 1704137 A 1704133 B 1704135 2046E3 1704136 2646E3 1704137 2658E3 1703818 1039 1703812 1703817 c 1703823 1703811 1703817 4 1703811 o 1703817 1703817 1703813 Figure 3 19 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 UK Sheet 2 of 2 3120877 JLG Sizzor 3 23 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 24 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 3252584 2033 3252586 1702773 264058 3252587 2658E3 3252585 2046E3 y 2658E3 1703811 1703822 1703817 1704122 1702631 1704129 2646E3 2658E3 1704138 2033E3 1704211 2046E3 2646E3 2658E3
35. 3 Lifting iere fea Sete ere 4 6 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distances 5 1 3 2 1 Lubrication Chart au eL eere de tore sS Sete o dtd de ttu eas 2 7 6 1 Inspection and 00 2 6 1 JLG Sizzor 3120877 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A mainte nance program using the information provided in this manual and the Service and Maintenance Manual must also be established by a qualified person and followed to ensure that the machine is safe to operate The owner user operator lessor lessee of the machine should not operate this machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc ULG A WARNING Do not operate this machine until complete training is performed by authorized persons Only authorized and qualified personn
36. 58E3 1703811 1703788 1703814 1 EET Figure 3 26 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 German Sheet 1 of 2 3 30 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL ups 2 3252585 2046E3 3252586 2646E3 3292587 1702773 1702928 m 3 3 P 9 o 1 1704133 S 1703819 1704135 1704136 2646 M 1704137 1704133 2658 Y 203 1704135 2046E3 1704136 2646 j o 1704137 2658E3 1703882 1409817 1703812 1703817 170381 1703817
37. 703817 1703896 0 1703895 1703973 1703817 8 B 1703817 1532 i 1294983 p V 1703814 1703893 1704982 1703788 Figure 3 8 Decal Installation 1532E3 8 1932E3 Dutch Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120877 1704131 1703773 1704132 1932E3 1704131 1532E3 1704132 1932E3 1704131 1532 1705322 3252533 1703817 1703894 1703817 1703893 1703973 1704982 GT 170498 y SN 1932E3 1702631 4 1703897 1704138 5 1703896 _ 1703895 E 1703892 222 1703814 Figure 3 9 Decal Installation
38. 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska Ul Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
39. ECTION PARAGRAPH PAGE NO SECTION FOREWORD SECTION 1 SAFETY PRECAUTIONS 1 1 General ce I hai ee k scr o aie i ew eoe ure 1 1 1 2 vues da edam eek RT IE dites Ong M eda eps 1 1 1 3 Operation ese see ie ee eed HV PLE PEE e E LEE 1 2 1 4 Towing Lifting and 0 1 4 1 1 4 1 5 Additional Hazards Safety 1 4 SECTION 2 PREPARATION AND INSPECTION 2 1 Gereral inae REI de er Rue E ete date ERE 2 1 2 2 Preparation For Use gt RW a uuu pinu pu Seed ol ek RE OX UAI Pur PRG 2 1 2 3 Delivery and Frequent 2 1 2 4 Daily Walk Around 2 2 2 2 5 Daily Functional 2 2 2 6 Torque 1 2 2 3 2 7 Battery Charging eco duced ex e eee RE YN AR bee ree ee aldea 2 8 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 General us oic tances olt td dus loser te E Det esie et Ruta dep 3 1 3 2 Personnel Training Ve debe ed aed aed td 3 1 3 3 Operating
40. ECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 26 1702928 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 N 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 26583 1702773 2658E3 1703822 1703817 1703893 1703817 3252630 2033E3 2646E3 3252565 2046E3 2658E3 1703973 1702631 1709699 1704127 2646E3 2658E3 1703896 1704138 2033E3 1704211 2046E3 2646E3 2658E3 1703811 1703788 1703814 1703892 Figure 3 22 Decal Installation 2033E3 2046E3 2646E3 amp 2658E3 Dutch Sheet 1 of 2 JLG Sizzor 1703819 1704134 2033E3 1704135 2046E3 1704136 2646E3 1704137 2658E3 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 1702928 3252587 1702773
41. INE CONTROL 3 5 PLACARDS AND DECALS Read and understand all placards and decals Do not operate any machine on which DANGER WARNING CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE Replace placards and decals if damaged missing or illegible Decals are made of Lexan with a Pressure Sensitive Adhe sive on back and a protective film on the front Remove the damaged decal and thoroughly clean the surface before installing a new decal Simply peel off backing paper and press decal on to the surface 3120877 JLG Sizzor NOTE Placards and decals can be ordered by using part number and location found in the Parts Manual See the folowing figures for the location of Danger Warn ing and Caution decals SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1702773 1704131 1532E3 1704132 1703818 1932E3 M 1703812 1703817 1703817 1703877 1703969 1704982 1703817 is 1703817 1532E3 170498 Da 1932 1703813 1703788 703819 1702928 1703819 1704131 1532 1704132 1932
42. Incomplete Charge Charger On Abnormal Cycle 3 2 JLG Sizzor A WARNING DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY PERFORM AS MANY PRE OPERATIONAL CHECKS AND INSPEC TIONS FROM THE GROUND CONTROL STATION AS POSSIBLE REFER TO SECTION 2 FOR PRE OPERATIONAL CHECKS AND INSPECTIONS 1 Power Selector Switch A three position key oper ated Power Selector Switch supplies operating power to the platform or ground controls as selected When positioned to platform the switch provides power to the emergency stop switch at the platform controls When positioned to ground the Switch provides power to the emergency stop switch at 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 Power Selector 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 With the Power Selector Switch positioned to ground ground functions will operate at low speed at all times Low speed is the default speed for all functions When the platform is elevated all functions operate in creep speed only 2 Emergency Stop Switch A two position red mushroom shaped Emergency Stop Switch when positioned to on with the Power Selector Switch positioned to Ground furnishes operating power to the ground control
43. ON 2 6 Motor Pump Unit Properly secured no visible damage no evidence of hydraulic leakage Hydraulic Filter No visible damage properly secured no evidence of leakage Tilt Switch Properly secured no loose or miss ing parts no visible damage no loose or broken wires Hydraulic Reservoir No visible damage no loose or missing parts no evidence of leakage Recommended hydraulic fluid level on side of tank Breather cap secure and working Powered Deck Extension Cylinder If Equipped Properly secured no visible damage no loose or missing parts no evidence of leakage Steer Drive Wheel and Tire Assembly Right Front Properly secured no loose or missing lug nuts no visible damage check drive hoses Drive Motor Right Front Properly secured no visible damage no evidence of leakage Safety Prop Properly secured no loose or miss ing parts no visible damage Handrail Installation All railings attached no visible damage no missing parts chain improper working order If equipped access gate properly secured and in good work ing order Platform Assembly No loose or missing visible damage platform deck extension oper ates properly Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing parts Not Shown on Illustration Valves Valve Fittings Hosing and Tubing Properly secured no loose or missing parts no v
44. Placards secure and legible control markings legible manual in manual storage box Steer Cylinder and Linkage Properly secured no loose or missing parts no visible damage no evidence of steer cylinder leakage Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or miss ing parts High Drive Limit Switch Properly secured no visible damage no loose or missing parts Steer Drive Wheel and Tire Assembly Left Front Properly secured no loose or missing lug nuts no visible damage check drive hoses Drive Motor Left Front Properly secured no visible damage no evidence of leakage Manual Descent Cable and Pull Handle Prop erly secured no loose or missing parts no visi ble damage Powered Deck Extension Cylinder If Equipped Properly secured no visible damage no loose or missing parts no evidence of leakage Pothole Protection System Support bar roll ers limit switches springs and links properly secured no visible damage no loose or miss ing parts Compartment Cover and Latches Cover and latches in working condition properly secured no loose or missing parts Machine Controller 1532E3 and 1932E3 Properly secured no visible damage no loose or broken wiring Battery Installation Proper electrolyte level cables secure no damage or corrosion Hold downs secure Machine Controller 2033E3 2046E3 2646E3 and 2658E3 Properly secured no visi
45. SPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS 5 3 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited However provisions for moving the machine have been incorporated The fol lowing procedures are to be used ONLY for emergency 1 Chock wheels securely 2 Engage the brake release on both drive hubs by loosening the bolts completely reversing hub caps and retightening the bolts 3 Connect towing equipment and remove chocks After towing machine complete the following procedure 1 Position machine on a firm level surface 2 Chock wheels securely 3 Disengage the brake release on both drive hubs by loosening the bolts completely reversing hub caps and retightening the bolts 4 Remove chocks 3120877 5 4 MANUAL DESCENT SYSTEM The manual descent system is used in the event of total power failure to lower the platform using gravity Pull the handle located at the left front of the machine just above the tire 5 5 EMERGENCY OPERATION Operator Unable to Control Machine NOTE IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CON TROL MACHINE 1 Other personnel should operate the machine from ground controls only as required 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERA TION IF CONTROLS DO NOT FUNCTION PROP ERLY 3 Cranes forklift trucks or other e
46. TAINED BY TRAVELING IN REVERSE ALWAYS USE REVERSE TRAVEL WITH LOW SPEED AND POSI TRAC ENGAGED WHEN LOADING ON A TRUCK OR WHEN ADEQUATE TRACTION IS NOT OBTAINED TRAVELING FORWARD NOTE The machine is equipped with a Pothole Protection System which lowers automatically when the plat form is raised If the pothole protection does not fully lower the drive function is cut out until the platform is completely lowered Traveling Forward 1 Place power selector switch at ground control sta tion to platform 2 Position emergency stop switch at Platform Control Station to on position 3 Press drive switch in conjunction with the trigger switch and move joystick forward and hold for duration of travel Drive speed is determined by the distance the joystick is moved from the center off position The drive switch is part of the enable cir cuit which supplies power to the drive switch and the joystick for 3 seconds after the drive switch is pressed If the joystick is not activated within 3 sec onds after the drive switch is pressed power is removed from the switch and joystick and the switch must be pressed again before activating the joystick When the joystick is returned to the center off posi tion the operator has 3 seconds to re activate the joystick or select another function before power is removed by the enable circuit For additional drive speed press the high drive speed switch simulta neously when depressing the drive
47. TO SERIOUS INJURY OR DEATH IF IGNORED A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH CAUTION CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH A IMPORTANT IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOL LOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE A IMPORTANT JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM PLETED ON THE AFFECTED JLG PRODUCT Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notifica tion Contact JLG Industries Inc for updated information 3120877 JLG Sizzor a FOREWORD This page left blank intentionally JLG Sizzor 3120877 FOREWORD 3120877 All procedures herein are based on the use of the machine under proper operating conditions with no devia
48. WHEN THE MACHINE IS NOT IN USE A IMPORTANT E3 SERIES SCISSOR LIFTS ARE EQUIPPED WITH A PQ CON TROLLER WHICH FEATURES A TRIGGER SWITCH ON THE FRONT OF THE JOYSTICK THIS SWITCH MUST BE DEPRESSED TO OPERATE THE JOYSTICK SELECT DESIRED FUNCTION SQUEEZE THE TRIGGER THEN POSITION THE JOYSTICK TO FORWARD OR REVERSE AS DESIRED 4 4 RAISING AND LOWERING LIFTING A WARNING DO NOT RAISE THE PLATFORM EXCEPT ON A HARD LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES Raising 1 If the machine is shut down place the power selec tor switch to the desired position platform or ground 2 Position the applicable emergency stop switch to the on position 3 If operating from the ground controls position the lift Switch to up and hold until the desired elevation is 4 2 JLG Sizzor achieved If operating from the platform controls press the lift switch and move the controller joy stick forward and hold until the desired elevation is reached The lift switch is part of the enable circuit which supplies power to the lift switch and the joy stick for 3 seconds after the lift switch is pressed If the joystick is not activated within 3 seconds after the lift switch is pressed power is removed from the switch and the joystick and the switch must be pressed again before activating the joystick When the joystick is returned to the center off position the operator has 3 seconds to re activate the joystick or select anot
49. aintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Check orientation of directional arrows on chassis before driving The direction of drive and steer may be opposite from normal operation based upon orienta tion of chassis 3120877 SECTION 1 SAFETY PRECAUTIONS Platform to structure transfers at elevated positions are discouraged Where transfer is necessary enter exit through the gate only with the platform within 0 3m 1 ft of a safe and secure structure 100 tie off is also required in this situation using two lanyards One lan yard must be attached to the platform with the second lanyard attached to the structure The lanyard con nected to the platform must not be disconnected until the transfer to the structure is safe and complete Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical cur rent Maintain safe distance from electrical lines apparatus or any energized exposed or insulated parts accord ing to the Minimum Safe Approach Distance MSAD as shown in Table 1 1 Allow for machine movement and electrical line sway ing 3120877 Table 1 1 Minimum Safe Approach Distances M S A D MINIMUM SAFE APPROACH Voltage Range Phase to Phase DISTANCE in Meters Feet 010 300V AVOID CONTACT Over 300V to 50 KV 3 10 Ov
50. and powered deck extension functions are selected simulta neously no function will operate If this occurs pause then press only one of the function switches to activate the function A WARNING DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION 3120877 SECTION 4 MACHINE OPERATION 4 5 PLATFORM EXTENSION Manual Platform Extension The machine is equipped with a mechanically extendible deck which adds 0 9 meters to the front of the platform giving the operator better access to worksites To extend the deck squeeze the release lever on the handle on the right side of the platform to release the lock pin then use the handle and handrail to push the extendible deck out To retract the deck squeeze the release lever to release the lock pin and use the handle and handrail to pull and retract the deck Be sure the lock pin is locked in place after the deck is retracted Maximum capacity of the deck extension is 113 kg 1 person A IMPORTANT IF THE MACHINE IS EQUIPPED WITH THE OPTIONAL PIPE RACKS THE PLATFORM EXTENSION MUST BE IN THE RETRACTED POSITION WHEN THE PIPE RACKS ARE LOADED FAILURE TO RETRACT THE PLATFORM EXTENSION COULD RESULT IN DAMAGE TO THE PLATFORM EXTENSION A IMPORTANT IF THE MACHINE IS EQUIPPED WITH A POWERED DECK EXTEN SION AND THE OPTIONAL FOLD DOWN RAILS THE RAILS MUST BE IN THE UPRIGHT POSITION BEFORE RETRACTING THE POWER DECK EXTENSION 4 6 STEERING To steer the ma
51. ble damage no loose or broken wiring Ground Controls Properly secured no visible damage switches operable placards secure and legible Wheel and Tire Assembly Left Rear Properly secured no loose or missing lug nuts no visi ble damage Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or miss ing parts Parking Brake No loose or missing parts no visible damage no cylinder leakage Ladder Properly secured no visible damage no loose or missing hardware Battery Charger No visible damage properly secured Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or miss ing parts Wheel and Tire Assembly Right Rear Properly secured no loose or missing lug nuts no visi ble damage Pothole Protection System Support bar roll ers limit switches and links properly secured no visible damage no loose or missing parts Compartment Cover and Latches Cover and latches in working condition properly secured no visible damage no loose or missing parts Control Valve Installation No loose or missing parts no evidence of leakage No unsupported wires or hoses no damaged or broken wires Lift Cylinder Properly secured no visible dam age no loose or missing parts no evidence of leakage Figure 2 3 Daily Walk Around Inspection Points Sheet 1 of 2 3120877 JLG Sizzor 2 5 SECTION 2 PREPARATION AND INSPECTI
52. chine 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 When released the switch will return to the center off position and the wheels will remain in the previously selected posi tion 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 A WARNING DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED FOR THE MACHINE 3120877 A WARNING 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 1 8 METERS OF AN OBSTRUCTION SELECTION OF MULTIPLE FUNCTIONS WHEN TRAVELING UP A GRADE CAN CAUSE AN OVERCURRENT SHUTDOWN TO OCCUR IF THIS SHOULD HAPPEN LET THE CONTROL HANDLE RETURN TO NEUTRAL THEN PAUSE FOR 3 5 SECONDS TO ALLOW THE SYSTEM TO RESET BEFORE RE SELECTING A FUNCTION TO GO BACK DOWN THE GRADE IF TRAVELING FORWARD UP THE GRADE BUMP THE CONTROL HANDLE FORWARD SLIGHTLY TO ENSURE THE BRAKES ARE RELEASED BEFORE DESCENDING THE GRADE A IMPORTANT WHEN TRAVELING ON A GRADE MAXIMUM TRACTION IS OB
53. ck before attempting to operate the machine A WARNING TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION A functional check of all systems should be performed under no load once the walk around inspection is com plete in an area free of overhead and ground level obstructions Perform pre load functional check in accor dance with the following procedure 1 Ensure batteries are fully charged 2 Raise and lower platform several times Check for smooth elevation and lowering Check for High Drive cut out as platform begins to raise Check that pothole protection system is deployed when plat form is raised and that actuating rollers are in con tact with the connecting bar JLG Sizzor 3120877 SECTION 2 PREPARATION AND INSPECTION 2 7 BATTERY CHARGING At the end of the work day the batteries should be charged for the next days work Position the Emergency Stop switch to OFF Prior to charging be sure electrolyte covers plates Connect the battery charger to a properly grounded receptacle using a suitable extension cord Set the battery charger timer switch if equipped for the desired charging time After charging check the electro lyte level of the batteries and adjust accordingly Add dis tilled water only to batteries A fully charged battery will have a specific gravity of between 1 260 1 275 ona
54. ecrease stability Do not increase the platform size with unauthorized deck extensions or attachments If elevating assembly or platform is in a position that one or more wheels are off the ground all persons must be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropri ate equipment to stabilize machine and remove per sonnel Crushing and Collision Hazards 1 4 Approved head gear must be worn by all operating and ground personnel Keep hands and limbs out of the elevating assembly during operation Check work area for clearances overhead on sides and bottom of platform when lifting or lowering plat form and driving 4 During operation keep all body parts inside platform railing Use elevating assembly functions not the drive func tion to position the platform close to obstacles Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 1 8m 6 ft away from machine during all driving operations Limit travel speed according to conditions of ground surface congestion visibility slope location of per sonnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quar ters or when driv
55. el can operate the machine Read understand and obey all DANGERS WARN INGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by JLG All operating personnel must be familiar with the emer gency controls and emergency operation of the machine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all hazards in the work area prior to machine operation FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROP ERTY DAMAGE PERSONAL INJURY OR DEATH Do not swing turntable or raise the platform while on trucks trailers railway cars floating vessels scaffolds 1 2 PRE OPERATION Operator Training and Knowledge 3120877 Read and understand this manual before operating the machine or other equipment unless approved in writing by JLG Do not operate the machine in hazardous environ ments unless approved for that purpose by JLG Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine This machine can be operated in temperatures of 20 C to 40 C 0 F to 104 F Consult JLG for operation outs
56. emer gency stop switch at the ground control station When the switch is in the platform position battery power is sup plied to the emergency stop switch at the platform control station The Power Selector Switch should be in the off position when recharging the batteries and or parking the machine overnight JLG Sizzor 4 1 SECTION 4 MACHINE OPERATION Emergency Stop Switch This switch when in the on out position provides battery power to the ground controls or platform controls as applicable In addition the switch can be used to turn off power push the switch in to the function controls in the event of an emergency If the machine shuts down due to a trouble fault turning the Emergency Stop Switch off and then on again will reset the JLG SMART system Motor Activation With the power selector switch in the appropriate position platform or ground and the applicable emergency stop switch in the on position and a function switch or control ler is operated and held the motor becomes activated and operates the desired function When operating the platform controls the applicable function switch must be pressed before activating the controller to operate the function CAUTION IF A MOTOR MALFUNCTION NECESSITATES AN UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT THE CAUSE BEFORE RESUMING ANY OPERATION A IMPORTANT ALWAYS POSITION THE POWER SELECTOR AND EMERGENCY STOP SWITCHES TO THE OFF POSITION
57. er 50KV to 200 KV 5 15 Over 200 KV to 350 KV 6 20 Over 350 KV to 500 KV 8 25 Over 500 KV to 750 KV 11 35 Over 750 KV to 1000 KV 14 45 A DANGER DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB ITED ZONE MSAD ASSUME ALL ELECTRICAL PARTS AND WIR ING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping Hazards The user should be familiar with the surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform elevated while on a sloping uneven or soft surface Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distrib ute loads evenly on platform floor Do not raise the platform or drive from an elevated position unless the machine is on firm level surfaces and evenly supported Keep the chassis of the machine at least 2 ft 0 6m from holes bumps drop offs obstructions debris concealed holes and other potential hazards on the floor surface unless approved by JLG Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure JLG Lift 1 3 SECTION 1 SAFETY PRECAUTIONS Do not operate the machine when wind conditions exceed the maximum allowable wind speed Do not increase the surface area of the platform or the load Increase of the area exposed to the wind will d
58. ff In some instances a function switch can be used in conjunc tion with the joystick to give the machine a higher function speed range The JLG Scissor Lift is a two wheel drive machine with drive power being supplied by a hydraulic motor for each drive wheel The rear wheels are supplied with spring applied hydraulically released brakes These brakes are automatically applied any time the drive joystick is returned to the neutral position The platform capacity of each scissor lift model is as fol lows Model 1532E3 270 kg Model 1932E3 230 kg Models 2033E3 2646E3 340 kg Models 2046E3 2658E3 450 kg The weight in the platform should be uniformly distributed in the center of the platform The total combined weight of personnel tools and supplies must not exceed the above figures The platform may be raised only when positioned on firm level and uniform surfaces 42 GENERAL This section provides the necessary information needed to operate the machine Included in this section are the procedures for starting stopping traveling steering park ing platform loading and transporting the machine It is important that the user read and understand the proper procedures before operating the machine 4 3 MOTOR OPERATION Power Selector Switch The Power Selector switch functions to direct battery power to the desired control station With the switch in the ground position battery power is supplied to the
59. fter as requested by user or his person nel 3 3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first require ment for any user regardless of users experience with similar types of equipment Placards Important points to remember during operation are pro vided 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 consti tuted by the operating characteristics and load limitations of the machine See foreword for definitions of the above placards 3120877 JLG Sizzor 3 1 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Capacities Ground Control Station Raising platform above horizontal with or without any load in platform is based on the following criteria 1 Machine is positioned on a smooth firm and level surface 2 Loadis within manufacturers rated capacity 3 All machine systems are functioning properly Stability This machine as originally manufactured by JLG and operated within its rated capacity on a smooth firm and level supporting surface provides a stable aerial platform for all platform positions 3 4 CONTROLS AND INDICATORS The machine is equipped with control panels that use symbols instead of words to indica
60. g weights 1532E3 1 315 kg 1932 1 383 kg 2033E3 2 032 kg 2046E3 1 878 kg 2646E3 2 073kg 2658E3 2 236 kg 4 12 TOWING It is not recommended that this machine be towed except in the event of an emergency such as a machine malfunc tion or a total machine power failure Refer to Section 6 for emergency towing procedures kg FRONT REAR AXLE GVW WHEELBASE kg cm 1532E3 557 599 1932E3 635 680 2033E3 853 2046E3 853 1383 127 2032 185 1878 185 1315 127 2646E3 953 2073 185 2658E3 1016 2236 185 Figure 4 3 Lifting Chart JLG Sizzor 3120877 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating 5 2 INCIDENT NOTIFICATION JLG Industries Inc must be notified immediately of any incident involving a JLG product Even if no injury or prop erty damage is evident the factory should be contacted by telephone and provided with all necessary details JLG Phone 717 485 5161 Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occur rence may void any warranty consideration on that partic ular machine IMPORTANT FOLLOWING ANY ACCIDENT THOROUGHLY IN
61. h Sheet 1 of 2 JLG Sizzor 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120877 Y 1704131 1532E3 1703773 1704132 1932 1704131 1532E3 1704132 1932E3 1704131 1532 1704132 1932 3252533 1703822 1703841 1703817 1703840 1703817 1703974 1704982 gt lt 4 1702631 4 1703897 1704138 1703788 r pant o 703842 ej ail Li iJ aue 1703814 Figure 3 17 Decal Installation 1532E3 amp 1932E3 Spanish Sheet 2 of 2 JLG Sizzor 3 21 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3252584 2033E3 3252585 2046E3 3252586 2646E3 3252587 2658E3 1702773
62. he drive switch must be pressed again before activating the joystick When the joy Stick is returned to the center off position the opera tor has 3 seconds to re activate the joystick or select another function before power is removed by the enable circuit In addition the posi trac switch can be engaged while operating the drive function to give a more evenly distributed oil flow to each drive 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Emergency Stop Switch Powered Deck Extension Switch If Equipped Posi Trac Switch Battery Discharge Indicator Drive Switch High Drive Speed Switch Lift Switch Figure 3 3 Platform Control Station All Models motor Do not try to operate the drive lift and pow ered deck extension functions simultaneously If the drive lift and powered deck extension functions are selected simultaneously no function will operate If this occurs pause then press only one of the func tion switches to activate the function NOTE If the machine is equipped with the optional powered deck extension the drive function is cut out when the deck is extended with the platform raised above the stowed position As an option Models 2033E3 and 2646E3 may be equipped for 450 kg platform capacity When equipped for 450 kg platform capacity Model 2033E3 cuts out the drive function at a platform height of 5 2 m and Model 2646E3 cuts out the drive function at a platform heig
63. her function before power is removed by the enable circuit Do not try to operate the drive lift and powered deck extension functions simulta neously If the drive lift and powered deck exten sion functions are selected simultaneously no function will operate If this occurs pause then press only one of the function switches to activate the function Lowering A WARNING ENSURE THE SCISSOR ARM AREA IS FREE OF PERSONNEL PRIOR TO LOWERING THE PLATFORM If operating from the ground controls position the lift switch to down and hold until the desired elevation is achieved or until the platform is fully lowered If operating from the platform controls press the lift switch and move the joystick backward and hold until the desired elevation is reached or until the platform is fully lowered The lift switch is part of the enable circuit which supplies power to the lift switch and the joystick for 3 seconds after the lift switch is pressed If the joystick is not activated within 3 seconds after the lift switch is pressed power is removed from the switch and the joystick and the switch must be pressed again before activating the joystick When the joy stick is returned to the center off position the operator has 3 seconds to re activate the joystick or select another function before power is removed by the enable circuit Do not try to operate the drive lift and powered deck extension functions simultaneously If the drive lift
64. ht of 5 8 m The machine is equipped with a Pothole Protection System which lowers automatically when the plat form is raised If the Pothole Protection System does not fully lower the drive function is cut out until the platform is completely lowered 7 High Drive Speed Switch The high drive speed Switch when used in conjunction with the joystick being operated in the drive mode provides addi tional oil flow to the drive circuit for increased travel speed To operate high drive depress the high drive 3120877 speed switch either simultaneously with the drive Switch or while operating the drive function A CAUTION DO NOT USE HIGH DRIVE SPEED WHEN DRIVING IN CLOSE QUARTERS OR WHEN DRIVING IN REVERSE A CAUTION IF HIGH DRIVE IS SELECTED WHEN OIL TEMPERATURE IS VERY COLD BELOW 4 4 DEGREES C HIGH DRIVE WILL NOT ENGAGE IMMEDIATELY AS OIL WARMS ABOVE 4 4 DEGREES C IF HIGH DRIVE IS SELECTED IT WILL ENGAGE AUTOMATICALLY WHILE DRIVING NOTE The High Drive Speed switch will cut out when the platform is raised above the stowed position return ing drive speed to low until the platform is lowered completely A CAUTION DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION JLG Sizzor 3 5 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Lift Switch The lift switch when used in conjunc tion with the joystick provides for raising and lower ing
65. ide this range JLG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Machine Inspection Before machine operation perform inspections and functional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual Be sure all safety devices are operating properly Mod ification of these devices is a safety violation Do not operate any machine on which safety or instruction placards or decals are missing or illegible Avoid any buildup of debris on the platform floor Keep mud oil grease and other slippery substances from footwear and platform floor 1 3 OPERATION General 1 2 Do not use the machine for any purpose other than positioning personnel their tools and equipment Never operate a machine that is not working properly If a malfunctions occurs shut down the machine Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Operate controls with slow and even pressure Hydraulic cylinders should never be left fully extended or fully retracted before shutdown or for long periods of time Do not allow personnel to tamper with or operate the machine from the ground with personnel in the plat form except in an emergency Do not carry ma
66. ine itself 3 Knowledge and understanding of all safety work rules of the employer and of Federal State and Local Statutes including training in the recognition and avoidance of potential hazards in the work place with particular attention to the work to be per formed 4 Proper use of all required personnel safety equip ment 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 obstruc tions other moving equipment obstacles depres sions 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 scissor lift in congested work locations Operator Responsibility The operator must be instructed that he has the responsi bility 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 therea
67. ing in reverse 1 4 1 5 JLG Lift Exercise extreme caution at all times to prevent obsta cles from striking or interfering with operating controls and persons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised platform Position barricades on floor if neces sary TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unloading Refer to the Emergency Procedures section of this manual for emergency towing procedures The platform must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift with lifting equipment of adequate capacity Refer to the Machine Operation section of this manual for lifting information ADDITIONAL HAZARDS SAFETY Do not use machine as a ground for welding Do not refuel the machine with the engine running Battery fluid is highly corrosive Avoid contact with skin and clothing at all times Charge batteries only in a well ventilated area 3120877 SECTION 2 PREPARATION AND INSPECTION SECTION 2 PREPARATION AND INSPECTION 2 1 GENERAL This section provides the necessary information needed by th
68. iodic Inspection and Functional Check are complied with prior to putting the machine into service 2 3 DELIVERY AND FREQUENT INSPECTION NOTE This machine requires periodic safety and mainte nance inspections by a JLG distributor or certified JLG mechanic NOTE An annual inspection shall be performed on the aerial platform no later than thirteen 13 months from the date of the prior annual inspection The inspection shall be performed by person s certified as a mechanic on the specific make and model of the aerial platform The following checklist provides a systematic inspection to assist in detecting defective damaged or improperly installed parts The checklist denotes the items to be inspected and conditions to examine Frequent inspection shall be performed monthly or more often when required by environment severity and frequency of usage This checklist is also applicable and must be followed for all machines that have been in storage or for all machines that will be exposed to harsh or changing climates These check are also to be performed after maintenance has been performed on the machine 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 missi
69. isible damage no evidence of leakage Figure 2 4 Daily Walk Around Inspection Points Sheet 2 of 2 JLG Sizzor 3120877 SECTION 2 PREPARATION AND INSPECTION Note 100 Hrs 3 months 200 Hrs 6 months 400 Hrs 1 Year 800 Hrs 2 Years od T 9 O H H 4 1 2 Figure 2 5 Lubrication Diagram Table 2 1 Lubrication Chart INDEX NO TYPE LUBE INTERVAL NUMBER COMPONENT TYPE LUBE METHOD HOURS COMMENTS 1 Hydraulic Oil Fill Cap Drain Plug HO Check HO Level 8 800 Check oil level every 8 hours HO Change HO Change oil every 800 hours 2 Hydraulic Filter N A N A 50 400 Change filter after first 50 hours of operation Element then every 400 hours thereafter 1 year 3 Kingpin Housing Grease Fittings MPG Pressure Gun 100 months 4 Wheel Bearings Rear Wheels MPG Repack 800 2 years Key To Lubricants NOTE 1 Be sure to lubricate like items on each side of machine MPG Multi Purpose Grease 2 Recommended lubricating intervals are based HO Hydraulic Oil Mobilfluid 424 on machine operations under normal conditions For machines used in multi shift operations and or A WARNING exposed to hostile environments or condi tions lubricating frequencies must
70. n its standard configuration is as follows 1532E3 270 kg 1932E3 230 kg 2033E3 2646E3 340 kg 2046E3 2658E3 450 kg 4 Maximum capacity of the manual platform extension is 120 kg 1 person NOTE 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 pos sible 4 10 SAFETY PROP A CAUTION THE SAFETY PROP MUST BE USED WHENEVER MAINTENANCE PERFORMED ON THE MACHINE REQUIRES THE SCISSOR ARMS TO BE RAISED To engage the safety prop raise the platform then rotate the prop clockwise until it hangs vertically Lower the plat form until the safety prop rests on the point provided on the frame Maintenance can now begin To store the safety prop raise the platform so that the prop can be rotated counterclockwise until it rests on the stop provided on the scissor arms 4 11 TRANSPORTING TIE DOWN AND LIFTING Transporting Loading Unloading It is recommended the machine be winched when load ing unloading on a tilt rollback type truck or trailer Due to a potential loss of traction winch using the frame mounted D rings To winch be sure the machines brakes are released Refer to the Emergency Towing Procedures in Section 6 or the Emergency Towing Decal affixed to the machine A CAUTION BE SURE THE MACHINE IS ON A LEVEL SURFACE OR PROP ERLY SECURE BEFORE RELEASING THE BRAKES
71. ng retaining hardware no visible dam age no evidence of pin or bushing wear Lift Cylinder No rust nicks scratches or foreign material on piston rod no leakage Frame No visible damage loose or missing hardware top and underside Tire and Wheel Assemblies No loose or missing lug nuts no visible damage check drive hoses for damage Sliding Wear Pad Blocks No excessive wear 3120877 Sizzor 2 1 SECTION 2 PREPARATION AND INSPECTION Hydraulic Oil Supply Overall Cleanliness Operate lift function through one complete cycle before checking oil level Oil level should be at full mark or within 1 5 cm 0 5 in below full mark on side of hydraulic tank all systems shut down machine in stowed position No visible oil leaks on the ground Steer Cylinder No rust nicks scratches or foreign material on piston rod no leakage Steer Linkage No loose or missing parts no visible damage Front Spindle Assemblies No excessive wear no damage evidence of proper lubri cation Control Boxes Platform and Ground Switches operable no visible damage placards secure and legible controller operable no visible damage Batteries Proper electrolyte level cable connections tight no visible damage no corrosion at battery cable connections Ensure batteries are fully charged Motor Pump Unit and Valves No leakage units secure Platform Placard
72. ose 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 maxi mum service life and safe operation A IMPORTANT SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IS THE RESPONSIBILITY OF THE OWNER OPERATOR 2 2 PREPARATION FOR USE Before a new machine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter as outlined in the Delivery and Frequent Inspection The unit should be thoroughly checked for hydraulic leaks during initial start up and run A check of all components should be made to assure their security All preparations necessary to place the machine in opera tion readiness status are the responsibility of manage ment personnel Preparation requires good common sense i e lift works smoothly and brakes operate prop erly coupled with a series of visual inspections The man datory requirements are given in the Daily Walk Around Inspection It should be assured that the items appearing in the Deliv ery and Per
73. perated in accor dance with warnings on the machine the Operating and Safety Manual the Service and Maintenance 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 It is absolutely necessary that the JLG Lift be regularly maintained in accordance with this manual and the machine Service and Maintenance Manual 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 Scissor Lift is not intended to be used to lift mate rial other than supplies which personnel in the platform require to do their job Supplies or tools which extend out side 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 Scissor Lift is powered using hydraulic motors and cylinders for the various machine motions The hydraulic components are controlled by electrically acti vated hydraulic valves using switches and control levers The speeds of functions controlled by control levers are variable from zero to maximum speed depending upon the position of the control lever Functions controlled by toggle or push button switches are either on or o
74. posi trac functions may be operated simultaneously but the drive lift and powered deck extension functions must be operated independently of each other If the drive lift and powered deck extension functions are selected simultaneously no function will operate If this occurs pause then press only one of the func tion switches to activate the function To operate the joystick squeeze the red trigger switch then posi tion the joystick to forward or reverse as desired Steer Switch The thumb operated steer switch located on top of the joystick works in conjunction JLG Sizzor with the trigger switch and activates the steer wheels in the direction the switch is moved left or right Drive Switch The drive switch when used in con junction with the joystick provides for driving the machine in forward or reverse Drive is activated by pressing the drive switch in conjunction with the trigger switch and moving the joystick forward for ward or backward reverse Drive speed is deter mined by the distance the joystick is moved forward or backward Increased drive speed is possible when the high drive speed switch is pressed either simultaneously with the drive switch or while operat ing the drive function The drive switch is part of the enable circuit which provides power to the joystick and the drive function for 3 seconds when the drive Switch is pressed If the joystick is not activated within 3 seconds t
75. quipment which may be available are to be used to remove platform occupants and stabilize motion of the machine Platform Caught Overhead If the platform or boom becomes jammed or snagged in overhead structures or equipment rescue platform occu pants prior to freeing the machine JLG Lift 5 1 SECTION 5 EMERGENCY PROCEDURES This page left blank intentionally 5 2 JLG Lift 3120877 SECTION 6 INSPECTION AND REPAIR LOG SECTION 6 INSPECTION AND REPAIR LOG Table 6 1 Inspection and Repair Log Date Comments 3120877 JLG Sizzor 6 1 SECTION 6 INSPECTION AND REPAIR LOG Table 6 1 Inspection and Repair Log Date Comments 6 2 JLG Sizzor 3120877 Please cut on the dotted line and fax to 717 485 6573 Q e JLG Industries Inc TRANSFER OF OWNERSHIP To JLG Gradall Lull and Sky Trak product owner If you now own but ARE NOT the original purchaser of the product covered by this manual we would like to know who you are For the purpose of receiving safety related bulletins it is very important to keep JLG Industries Inc updated with the current ownership of all JLG products JLG maintains owner information for each JLG product and uses this information in cases where owner notification
76. r select another function before power is removed by the enable circuit Do not try to operate the powered deck extension drive and lift functions simulta neously If the powered deck extension drive and lift functions are selected simultaneously no func tion will operate If this occurs pause then press only one of the function switches to activate the function 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 1 5 or 2 0 depending on which tilt is equipped with the machine When the machine is equipped with a powered deck extension the horn is activated when the deck extension is being extended or retracted A CAUTION IF TILT ALARM IS ON WHEN PLATFORM IS RAISED LOWER PLATFORM COMPLETELY THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM 12 13 14 JLG Sizzor Tilt Alarm Warning Light A red warning light on the membrane switch panel that illuminates when the chassis is a severe slope over 1 5 or 2 0 depending on which tilt is equipped with the machine Horn This push button switch when activated per mits the operator to warn jobsite personnel when the machine is operating in the area Battery Discharge Indicator The battery dis charge indicator is a gauge that provides a visual indication of the condition of the batteries 3120877 SECTION 3 USER RESPONSIBILITIES AND MACH
77. rovides specific torque values and periodic maintenance procedures with a listing of individual components Utiliz ing this Torque Chart in conjunction with the preventive maintenance procedures in the Service and Maintenance Manual will enhance safety reliability and performance of the machine 3120877 JLG Sizzor 2 8 SECTION 2 PREPARATION AND INSPECTION 35 36 34 uMp e S 1 cS I lI CS 1 L oF 2 Figure 2 2 Daily Walk Around Inspection Diagram 3120877 JLG Sizzor 2 4 SECTION 2 PREPARATION AND INSPECTION General Begin the Walk Around Inspection at Item 1 as noted on the diagram Continue to the right counter clockwise viewed from top checking each item in sequence for the conditions listed in the Walk Around inspection Checklist A WARNING TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MAL FUNCTIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Do not overlook visual inspection of chassis underside Checking this area often results in discovery of conditions which could cause extensive machine damage Platform Controls Properly secured no loose or missing parts no visible damage to control box or controller joystick
78. s No visible damage placards secure and legible 2 4 DAILY WALK AROUND INSPECTION It is the users responsibility to inspect the machine before the start of each workday It is recommended that each user inspect the machine before operation even if the machine has already been put into service under another user This Daily Walk Around Inspection is the preferred method of inspection These checks are also to be performed after maintenance has been performed on the machine In addition to the Daily Walk Around Inspection be sure to include the following as part of the daily inspection 2 2 Check all standing surfaces for oil fuel and hydraulic oil spillage and foreign objects Ensure overall cleanliness Placards Keep all information and operating placards clean and unobstructed Cover when spray painting or shot blasting to protect legibility Operators and Safety Manual Ensure a copy of this manual is enclosed in the manual storage box Machine Log Ensure a machine operating record or log is kept Check to see that it is current and that no entries have been left uncleared leaving machine in an unsafe condition for operation Daily Lubrication For those items pointed out in the Daily Walk Around Inspection requiring daily lubrication refer to the Lubrica tion Chart for specific requirements 2 5 DAILY FUNCTIONAL CHECK Perform functional checks in accordance with the Daily Functional Che
79. station In addition the switch can be used to turn off power to the function con trols in the event of an emergency Power is turned on by pulling the switch out on and is turned off by pushing the switch in off Turning the Emergency Stop Switch off and then on again will reset the Smart System if a system fault has occurred and the machine has shut down 3 Lift Switch A three position momentary contact Lift control toggle switch provides raising and lower ing of the platform when positioned to up or down 4 Circuit Breaker A push button reset 15 Amp circuit breaker located at the ground control panel returns interrupted power to the machine functions when depressed 5 Hourmeter The machine is equipped with an hour meter to indicate the number of hours the machine has been operated The hourmeter operates only when a machine function is operating 3120877 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Hourmeter If Equipped Emergency Stop Switch Lift Switch Platform Ground Select Switch Circuit Breaker 6 NOTE Figure 3 1 Ground Control Station Models 1532E3 1932E3 Powered Deck Extension Switch If Equipped Models 2033E3 2046E3 2646E3 and 2658E3 Only If the machine is equipped with either the 1 2 m or 1 8 m hydraulically powered deck extension this three position momentary contact toggle switch provides extension or retraction of the deck exten
80. switch when pressed activates a solenoid on the main con trol valve forcing oil through a flow divider in the drive circuit maintaining hydraulic oil flow to both drive motors for improved traction The positive trac tion Posi trac switch activates the positive traction solenoid for a preset time when the positive traction Posi trac switch is pressed Positive traction is automatically de activated after the preset time is out This function will only operate when the drive function is activated 10 11 Powered Deck Extension Switch If Equipped Models 2033E3 2046E3 2646E3 and 2658E3 Only If the machine is equipped with either the 1 2 m or 1 8 m hydraulically powered deck exten sion this switch is used in conjunction with the joy Stick to provide extension or retraction of the powered deck extension Powered deck extension or retraction is activated by pressing the powered deck extension switch and moving the joystick for ward extend or backward retract The powered deck extension switch is part of the enable circuit which provides power to the joystick and the pow ered deck extension function for 3 seconds when the powered deck extension switch is pressed If the joystick is not activated within 3 seconds the pow ered deck extension switch must be pressed again before activating the joystick When the joystick is returned to the center off position the operator has 3 seconds to re activate the joystick o
81. te control functions Refer to Symbols figure for these symbols and their corre sponding functions JLG SMART System The machine is controlled by the JLG SMART System a 24 volt multiplex motor controller which works in conjunc tion with a joystick and several switches to operate all machine functions Special operating characteristics of the JLG SMART System are noted where applicable Special attention should be paid to these operating characteristics as they may be somewhat different from those on previous JLG machines A IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 52 BAR AT A MINIMUM DISTANCE OF 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERI ODS TO AVOID HEAVY SATURATION Battery Charger The battery charger is located at the rear of the machine behind the ladder The charger is a 24 volt DC charger with an output of 25 Amps A built in automatic timer shuts down charger operation when the batteries are fully charged A rocker switch circuit breaker is included to reset the charger in the event of a loss of power LEDs on the front panel of the charger indicate the status of charger operation Charge Complete 80 Charge
82. terials directly on platform railing unless approved by JLG When two or more persons are in the platform the operator shall be responsible for all machine opera tions Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area Supplies or tools which extend outside the platform are prohibited unless approved by JLG Do not assist a stuck or disabled machine by pushing pulling or by using machine functions Only pull the unit from the tie down lugs on the chassis Stow elevating assembly and shut off all power before leaving machine Trip and Fall Hazards JLG Lift When operating a boom lift or vertical mast lift occu pants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point When operating a scissor lift or verti cal mast lift JLG recommends wearing a full body har ness Attach only one 1 lanyard per lanyard anchorage point d Before operating the machine make sure all gates are closed and fastened or in their proper position Keep both feet firmly positioned on the platform floor at all times Never use ladders boxes steps planks or similar items on platform to provide additional reach Never use the elevating assembly to enter or leave the platform Use extreme caution when entering or leaving plat form Be sure that the platform is fully lowered Face the machine m
83. tions from original design intent as per OSHA regulations and applicable ANSI standards READ amp HEED The ownership use service and or maintenance of this machine is subject to various governmental and local laws and regulations It is the responsibility of the owner user to be knowledgeable of these laws and regulations and to comply with them The most prevalent regulations of this type in the United States are the Federal OSHA Safety Regulations Listed below in abbreviated form are some of the require ments of Federal OSHA regulations in effect as of the date of publication of this handbook The listing of these requirements shall not relieve the owner user of the responsibility and obligation to determine all applicable laws and regulations and their exact wording and requirements and to com ply with the requirements Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Indus tries Inc 1 Only trained and authorized operators shall be permitted to operate the aerial lift 2 A malfunctioning lift shall be shut down until repaired 3 The controls shall be plainly marked as to their function 4 The controls shall be tested each day prior to use to determine that they are in safe operating condition 5 All personnel in the platform shall at all times wear approved fall protection devices and other safety gear as required 6 Load limits
84. ve switch is pressed power is 6 removed from the switch and joystick and the switch JLG Sizzor must be pressed again before activating the joystick When the joystick is returned to the center off posi tion the operator has 3 seconds to re activate the joystick or select another function before power is removed by the enable circuit DO NOT activate the high drive speed switch when traveling in reverse 4 8 PARKING AND STOWING NOTE When parking battery powered units overnight bat teries should be charged in accordance with instruc tions in Section 2 to ensure readiness for the following workday Park and stow machine as follows 1 Drive machine to a reasonably well protected and well ventilated area Ensure platform is fully lowered Position emergency stop switch to off position If necessary cover the instruction placards caution and warning decals so that they will be protected from hostile environment Chock at least two wheels when parking machine for an extended period of time Turn switch to OFF and remove key to disable machine from unauthorized use 3120877 SECTION 4 MACHINE OPERATION 4 9 PLATFORM LOADING The platform maximum rated load capacity is shown ona placard located on the platform and is based upon the fol lowing criteria 1 Machine is positioned on a smooth firm and level surface 2 All braking devices are engaged 3 Maximum platform capacity for each model i

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