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Oshkosh Corporation JLG 400RTS Operation & Safety Manual

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Operation & Safety Manual
Models
400RTS
500RTS
3120695
November 9, 2007

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  • Page 1 Operation & Safety Manual Models 400RTS 500RTS 3120695 November 9, 2007...
  • Page 2 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.
  • Page 3 FOREWORD JLG requirements and to be at least as safe as it was All procedures herein are based on the use of the machine prior to modification. under proper operating conditions, with no deviations from original design intent... as per OSHA regulations. 9.
  • Page 4 FOREWORD REVISION LOG June 1, 1993 Original Issue May 6, 1999 Revised October 29, 1999 - Revised Pro 65 page added - Updated 4-19-00 Revised - Updated 4-19-00 Revised August 20, 2002 Revised December 5, 2002 Revised September 26, 2007 Revised November 9, 2007 3120695...
  • Page 5 FOREWORD This page left blank intentionally. – JLG Sizzor – 3120695...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. TABLE OF CONTENTS SECTION SECTION - FOREWORD SECTION 1 - SAFETY PRECAUTIONS General ..............1-1 Driving/Towing/Carrying .
  • Page 7 TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 2-1. Daily Walk-Around Inspection Diagram ..........2-5 2-2.

  • Page 8: Section 1 - Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 DRIVING/TOWING/CARRYING This section prescribes the proper and safe practices for Before driving the machine the user must be familiar with major areas of machine usage which have been divided the drive, steer and stopping characteristics.

  • Page 9: Electrocution Hazard

    SECTION 1 - SAFETY PRECAUTIONS 1.3 ELECTROCUTION HAZARD NOTE: MAINTAIN M.A.D. FROM ALL OTHER CHARGED LINES AND PARTS AS WELL AS THOSE SHOWN. DO NOT MANEUVER MACHINE OR PERSONEL INSIDE PROHIB- M.A.D. = MINIMUM APPROACH DISTANCE ITED ZONE. ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

  • Page 10: Pre-Operational

    SECTION 1 - SAFETY PRECAUTIONS 1.4 PRE-OPERATIONAL • READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE • DO NOT OPERATE MACHINE WHEN WIND CONDI- READ - THEN BEGIN OPERATIONS. TIONS EXCEED 30 MPH. • ALLOW ONLY THOSE AUTHORIZED AND QUALIFIED • NEVER OPERATE OR RAISE PLATFORM WHEN MACHINE IS ON A TRUCK OR OTHER VEHICLE.

  • Page 11: Driving

    SECTION 1 - SAFETY PRECAUTIONS • KEEP NON-OPERATING PERSONNEL AT LEAST 6 1.5 DRIVING FEET (1.8 M) AWAY FROM MACHINE DURING DRIV- ING OPERATIONS. 1.6 OPERATION • WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING. • READ YOUR MANUAL, UNDERSTAND WHAT YOU’VE READ - THEN BEGIN OPERATIONS.
  • Page 12 SECTION 1 - SAFETY PRECAUTIONS • TRANSFERS BETWEEN A STRUCTURE AND THE PLATFORM EXPOSE OPERATORS TO FALL POTEN- TIALS. THIS PRACTICE SHOULD BE DISCOURAGED WHEREVER POSSIBLE. WHERE TRANSFER MUST BE ACCOMPLISHED TO PERFORM THE JOB, TWO LANYARDS WILL BE USED. ONE LANYARD SHOULD BE ATTACHED TO THE PLATFORM, THE OTHER TO THE STRUCTURE.

  • Page 13: Towing And Hauling

    SECTION 1 - SAFETY PRECAUTIONS MACHINE , RED TAG IT, AND NOTIFY PROPER Your safety, and that of others, is the first consideration AUTHORITIES. when engaging in the maintenance of equipment. Always be conscious of weight. • NO STUNT DRIVING OR HORSEPLAY IS PERMITTED. Never attempt to move heavy parts without the aid of a •...

  • Page 14: Section 2. Machine Preparation And Inspection

    SECTION 2 - MACHINE PREPARATION AND INSPECTION SECTION 2. MACHINE PREPARATION AND INSPECTION Periodic inspection shall be performed monthly or more 2.1 GENERAL often when required by environment, severity, and fre- quency of usage. This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are Handrail Assemblies...

  • Page 15: Daily Walk-Around Inspection

    SECTION 2 - MACHINE PREPARATION AND INSPECTION Hydraulic Oil Supply 2.4 DAILY WALK-AROUND INSPECTION NOTE: Prior to checking the hydraulic oil level, operate the It is the user’s responsibility to inspect the machine before machine through one complete cycle of the lift func- the start of each workday.

  • Page 16: Daily Functional Check

    SECTION 2 - MACHINE PREPARATION AND INSPECTION lowered, the scissor arms will press the plunger 2.5 DAILY FUNCTIONAL CHECK in to allow the axles to oscillate. 2. Ensure the machine is on a firm level surface. Check for proper operation of the leveling jack limit switch TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY first from the ground control station and then from CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING...

  • Page 17: Lockout Cylinder Check (If Equipped)

    SECTION 2 - MACHINE PREPARATION AND INSPECTION 5. Raise the machine platform approximately 2 ft (61 2.6 LOCKOUT CYLINDER CHECK (IF cm); ensure the lockout cylinder cam valve is free of EQUIPPED) the sizzor arm trip bar. To be performed quarterly, any time a system component 6.

  • Page 18: Daily Walk-Around Inspection Diagram

    SECTION 2 - MACHINE PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection Diagram 3120695 – JLG Sizzor –...

  • Page 19: Walk-Around Inspection Points (Sheet 1 Of 3)

    SECTION 2 - MACHINE PREPARATION AND INSPECTION GENERAL 11. Ladder - No damage, securely attached. 12. Hydraulic Reservoir - No visible damage or missing Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram.Continue to the right (counterclockwise parts.

  • Page 20: Walk-Around Inspection Points (Sheet 2 Of 3)

    SECTION 2 - MACHINE PREPARATION AND INSPECTION 29. Leveling Jack, Left Rear (If Equipped) - No loose or 46. Hydraulic Pump - Pump properly secured, no visi- missing parts, no visible damage. No cylinder leaks ble damage, no evidence of leakage. Hoses and fit- or damage.

  • Page 21: Dual Fuel System

    SECTION 2 - MACHINE PREPARATION AND INSPECTION 62. Drive Cutout Switch and High Speed Cutout Switch 64. Traversing Platform Valve (If Equipped) - No loose - No visible damage, properly secured. or missing parts, no visible damage, properly secured, no evidence of leakage. 63.
  • Page 22 SECTION 2 - MACHINE PREPARATION AND INSPECTION 3120695 – JLG Sizzor –...
  • Page 23 SECTION 2 - MACHINE PREPARATION AND INSPECTION Table 2-1. Lubrication Chart INDEX INTERVAL COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD HOURS Oscillating Axle Pivot Point (Optional) 1 Grease Fitting MPG - Pressure Gun Lockout Cylinders (Optional) 2 Grease Fittings (1 each cylinder) MPG - Pressure Gun Front Steering Spindles (2-W/D) 2 Grease Fittings...
  • Page 24 SECTION 2 - MACHINE PREPARATION AND INSPECTION 3120695 – JLG Sizzor – 2-11...
  • Page 25 SECTION 2 - MACHINE PREPARATION AND INSPECTION This page intentionally left blank. 2-12 – JLG Sizzor – 3120695...

  • Page 26: Section 3. User Responsibilities And Machine Control

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3. Knowledge and understanding of all safety work 3.1 GENERAL rules of the employer and of Federal, State and Local Statutes, including training in the recognition and avoidance of potential hazards in the work place;...

  • Page 27: Controls And Indicators

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Placards Stability This machine, as originally manufactured by JLG and Important points to remember during operation are pro- operated within its rated capacity on a smooth, firm and vided at the control stations by DANGER, WARNING, level supporting surface, provides a stable aerial platform CAUTION, IMPORTANT and INSTRUCTION placards.

  • Page 28: Platform Control Station

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 1. Ignition/Emergency Stop - A two-position, red retract the rear platform extension as needed for “up mushroom shaped switch supplies electrical power and over” work access. to the Start button when positioned up. When posi- 10.
  • Page 29 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3. Start Button - A momentary contact, pushbutton- switch is in the on position and the start button is depressed. type switch that supplies electrical power to the starter solenoid when the ignition/emergency stop Figure 3-2.
  • Page 30 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 9. PQ Controller - The PQ Controller performs three 11. Platform Traversing Switch (If Equipped) - This is functions: Drive, Steer and Drive Speed. On all a double throw, momentary contact toggle-type machines built before serial number 0200058922, switch which permits the operator to hydraulically tilting the controller in the direction you want to go...

  • Page 31: Control Panel Symbols

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-3. Control Panel Symbols – JLG Sizzor – 3120695...

  • Page 32: Decal Location - Right Side (Sheet 1 Of 2)

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-4. Decal Location - Right Side (Sheet 1 of 2) 3120695 – JLG Sizzor –...

  • Page 33: Decal Location - Left Side (Sheet 2 Of 2)

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-5. Decal Location - Left Side (Sheet 2 of 2) – JLG Sizzor – 3120695...

  • Page 34: Section 4. Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION The JLG Sizzor Lift is powered using hydraulic motors and 4.1 DESCRIPTION cylinders for the various machine motions. The hydraulic This machine is a self-propelled elevating ‘sizzor’ aerial components are controlled by electrically activated work platform.

  • Page 35: Engine Operation

    SECTION 4 - MACHINE OPERATION 6. Check engine voltmeter when starting engine and 4.3 ENGINE OPERATION monitor gauge periodically during operation. RTS SERIES SCISSOR LIFTS MANUFACTURED AFTER AUGUST ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW 26, 1996 ARE EQUIPPED WITH A HYDRAULIC OIL TEMPERATURE SPEED BEFORE APPLYING ANY LOAD.

  • Page 36: Traversing Platform (Optional)

    SECTION 4 - MACHINE OPERATION the switch must be activated in the opposite direction until 4.5 TRAVERSING PLATFORM (OPTIONAL) the wheels are centered. The machine may be equipped with hydraulically oper- ated traversing platforms that moves 4 ft. (1.2 meters) at 4.7 TRAVELING (DRIVING) each end of the machine to give the operator “up and over”...

  • Page 37: Parking And Stowing

    SECTION 4 - MACHINE OPERATION 2. Position pump and engine control switches to desired positions (high or low) and position drive TRAVEL GRADES IN “LOW” DRIVE SPEED ONLY. USE EXTREME control switch to desired position (torque or speed). CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND ESPECIALLY WHEN 3.

  • Page 38: Safety Props

    SECTION 4 - MACHINE OPERATION 4.10 SAFETY PROPS 4.11 MACHINE TIE DOWN When transporting machine, platform must be fully retracted in the stowed mode with machine securely tied down to truck or trailer deck. Four tie down lugs are pro- SAFETY PROPS MUST BE USED WHEN MAINTENANCE PER- vided, one at each corner of the machine frame.
  • Page 39 SECTION 4 - MACHINE OPERATION NOTES: – JLG Sizzor – 3120695...

  • Page 40: Section 5. Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 3. Return disconnect caps to normal (engaged) posi- 5.1 GENERAL tion. This section provides information on the procedures to be followed and on the systems and controls to be used in the event an emergency situation is encountered during machine operation.

  • Page 41: Emergency Operation

    SECTION 5 - EMERGENCY PROCEDURES Manual Descent (Engine/Pump Failure - 5.4 EMERGENCY OPERATION Ground Controls) Use of Ground Controls The following procedure should be used to lower the plat- form from the ground controls in the event of engine/ pump failure. Turn main power switch to on and platform/ ground select switch to ground.

  • Page 42: Incident Notification

    SECTION 5 - EMERGENCY PROCEDURES Righting of Tipped Machine 5.5 INCIDENT NOTIFICATION A forktruck of suitable capacity or equivalent equipment It is imperative that JLG Industries, Inc. be notified imme- should be placed under the elevated side of the chassis, diately of any incident involving a JLG product.
  • Page 43 SECTION 5 - EMERGENCY PROCEDURES NOTES: – JLG Sizzor – 3120695...

  • Page 44: Section 6 - Inspection And Repair Log

    SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Table 6-1.Inspection and Repair Log Date Comments 3120695 – JLG Sizzor –...
  • Page 45 SECTION 6 - INSPECTION AND REPAIR LOG Table 6-1.Inspection and Repair Log Date Comments – JLG Sizzor – 3120695...
  • Page 46 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!

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