JLG 25RTS Use and care manual

Operation & Safety Manual
Model
25RTS
33RTS
40RTS
3120690
May 15, 2003

– JLG Sizzor –

–JLG Sizzor –
This page left blank intentionally.

FOREWORD
3120690 –JLG Lift – 5
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions
and operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.

FOREWORD
6–JLG Lift –3120690
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the
potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. ON
THE MACHINE THIS WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.
ON THE MACHINE THIS WILL HAVE AN ORANGE BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH IF
NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT
MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES. ON
THE MACHINE THIS WILL HAVE A YELLOW BACKGROUND.
IMPORTANT
INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION AND
WHICH, IF NOT FOLLOWED, MAY RESULT IN A MACHINE MAL-
FUNCTIONED DAMAGE. ON THE MACHINE THIS WILL HAVE A
GREEN BACKGROUND.

FOREWORD
3120690 –JLG Lift – 7
FOR :
•Accident Reporting
•Product Safety Publications
•Current Owner Updates
•Questions Regarding Product Safety
•Standards and Regulations Compliance Information
•Questions Regarding Special Product Applications
•Questions Regarding Product Modifications
CONTACT :
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
In USA:
Toll Free: 877-JLG-SAFE
877-554-7233
Outside USA:
717-485-5161
E-mail: [e-mail]
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO-
RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE
MANUFACTURER
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUS-
TRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL
IMPORTANT
IMPORTANT

FOREWORD
8–JLG Lift –3120690
REVISION LOG
Original Issue - March 1, 1993
Revised - May 23, 1999
Revised - July 22, 1999
Revised - September 2, 1999
Revised - October 29, 1999
Revised - May 5, 2000
Revised - October 15, 2001
Revised - May 15, 2003

3120690 –JLG Sizzor –i
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION -
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Pre-operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Towing, Lifting, and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 Additional Hazards / Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
SECTION 2 - PREPARATION AND INSPECTION
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Delivery And Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.4 Daily Walk-around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.6 Lock-out Cylinder Check - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.7 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.8 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.4 Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
SECTION 4 - MACHINE OPERATION
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 Raising and Lowering - (Lifting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.5 Leveling Jacks (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Mechanical Platform Extension (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.8 Traveling - (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.9 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.10 Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.11 Safety Props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.12 Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SECTION 5 - EMERGENCY PROCEDURES
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.4 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION 6 - INSPECTION AND REPAIR LOG

ii –JLG Sizzor –3120690
TABLE OF CONTENTS (Continued)
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Walk-Around Inspection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2-2. Walk-Around Inspection Points (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3. Walk-Around Inspection Points (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-4. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-5. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1 Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4-1 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION 1 - SAFETY PRECAUTIONS
3120690 –JLG Lift –1-1
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. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED
IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROP-
ERTY DAMAGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
•Read and understand this manual before operating the
machine.
•Do not operate this machine until complete training is
performed by authorized persons.
•Only authorized and qualified personnel 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.
•Do not swing turntable or raise the platform while on
trucks, trailers, railway cars, floating vessels, scaffolds
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 0oF
to 104oF (-20oC to 40oC). Consult JLG for operation
outside this range.

SECTION 1 - SAFETY PRECAUTIONS
1-2 –JLG Lift –3120690
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
•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 materials 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
•When operating a boom lift, occupants in the platform
must wear a full body harness with a lanyard attached
to an authorized lanyard anchorage point. When oper-
ating a scissor lift or vertical mast lift, JLG recommends
wearing a full body harness. Attach only one (1) lan-
yard per lanyard anchorage point.
•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, maintain “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.

SECTION 1 - SAFETY PRECAUTIONS
3120690 –JLG Lift –1-3
•Platform-to-structure transfers at elevated positions are
discouraged. Where transfer is necessary, enter/exit
through the gate only with the platform within 1 foot
(0.3m) of a safe and secure structure. 100% tie-off is
also required in this situation using two lanyards. One
lanyard must be attached to the platform with the sec-
ond 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.
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.
Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM SAFE APPROACH
DISTANCE
in Meters (Feet)
0 to 300V AVOID CONTACT
Over 300V to 50 KV 3 (10)
Over 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)

SECTION 1 - SAFETY PRECAUTIONS
1-4 –JLG Lift –3120690
•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.
•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
decrease 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
•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.
•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 driving in reverse.
•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.
1.4 TOWING, LIFTING, AND HAULING
•Never allow personnel in platform while towing, lifting,
or hauling.
•This machine should not be towed, except in the event
of emergency, malfunction, power failure, or loading/
unloading. Refer to 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.
1.5 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.

SECTION 2 - PREPARATION AND INSPECTION
3120690 –JLG Sizzor –2-1
SECTION 2. PREPARATION AND INSPECTION
2.1 GENERAL
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtaining maxi-
mum service life and safe operation.
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
1. Before a new machine is put into operation it must
be carefully inspected for any evidence of damage
resulting from shipment and inspected periodically
thereafter, as outlined in paragraph 2-3, Delivery and
Periodic Inspection. The unit should be thoroughly
checked for hydraulic leaks during initial start-up
and run. A check of all components should be made
to assure their security.
2. All preparations necessary to place the machine in
operation readiness status are the responsibility of
management personnel. Preparation requires good
common sense, (i.e. lift works smoothly and brakes
operate properly) coupled with a series of visual
inspections. The mandatory requirements are given
in paragraph 2-4, Daily Walk Around Inspection.
3. It should be assured that the items appearing in the
Delivery and Periodic Inspection and Functional
Check are complied with prior to putting the
machine into service.
2.3 DELIVERY AND PERIODIC INSPECTION
NOTE: This machine requires periodic safety and mainte-
nance inspections by a JLG Dealer. A decal on the
frame provides a place to record (stamp) inspection
dates. Check decal and notify dealer if inspection is
overdue.
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 every 3 months or
150 hours whichever comes first, or more often when
required by environment, severity, and frequency of
usage.
Handrail Assemblies
Properly installed; no loose or missing parts; no visible
damage.
Platform Assembly
No visible damage; free of dirt and debris.
Sizzor Arms
No visible damage, abrasions and/or distortions.
Electrical Cable
No visible damage; properly secured.
Pivot Pins
No loose or missing retaining hardware; no damage or
wear to pin heads which would cause pin to rotate; no evi-
dence of pin or bushing wear.
Lift Cylinder
No rust, nicks, scratches or foreign material on piston rod.
No leakage. Evidence of proper lubrication.

SECTION 2 - PREPARATION AND INSPECTION
2-2 –JLG Sizzor –3120690
Frame
No visible damage; loose or missing hardware (top and
underside).
Drive Hubs
Check oil level in drive hub by removing pipe plug and
feeling for oil level. (Contact service personnel for assis-
tance if needed.)
NOTE: Torque Hubs should be one-half full of lubricant.
Tire and Wheel Assemblies
No loose or missing lug nuts; no visible damage.
Sliding Wear Pad Blocks
No excessive wear; adequate lubrication.
Hydraulic Oil Supply
Operate hydraulic systems through one complete cycle
before checking oil level in hydraulic oil tank. Oil should
be visible in ADD sight window on hydraulic oil tank. If oil
is not visible, add oil until oil is visible in both ADD and
FULL sight windows on tank. Do not overfill tank.
Steer Cylinder
No rust, nicks, scratches or foreign material on piston rod;
no leakage.
Steer Linkage
No loose or missing parts; no visible damage.
Steer Spindle Assemblies
No excessive wear; no damage.
Control Boxes (Console and Ground)
Switches operable; no visible damage; placards secure
and legible. Hand controller operable; no visible damage.
Battery
Proper electrolyte level; cable connections tight; no visible
damage; no corrosion at battery cable connections.
Engine
Engine oil level - full mark on dipstick; filler cap secure; air
filter secure.
Hydraulic Pump and Valves
No visible damage; no evidence of leakage; units secure.
Platform Placards
No visible damage; placards secure and legible.
Lock-Out Cylinders (If Equipped)
No rust, nicks, scratches or foreign material on piston rod;
no leakage.

SECTION 2 - PREPARATION AND INSPECTION
3120690 –JLG Sizzor –2-3
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.
In addition to the Daily Walk-Around Inspection, be sure to
include the following as part of the daily inspection:
Overall Cleanliness
Check all standing surfaces for oil, fuel and hydraulic oil
spillage and foreign objects. Ensure overall cleanliness.
Placards
Keep all information and operating placards clean and
unobstructed. Cover when spray painting or shot blasting
to protect legibility.
Operators and Safety Manual
Ensure a copy of this manual is enclosed in the manual
storage box.
Machine Log
Ensure a machine operating record or log is kept. Check
to see that it is current and that no entries have been left
uncleared, leaving machine in an unsafe condition for
operation.
Daily Lubrication
For those items pointed out in the Daily Walk-Around
Inspection requiring daily lubrication Refer to Table 2-1,
Lubrication Chart, for specific requirements.
Perform the following checks and services before attempt-
ing to operate the machine.
TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
TIONING MACHINE IS A SAFETY VIOLATION.
1. Start each day with a full fuel tank. If operating an
electric machine, start each day with fully charged
batteries.
2. Ensure that all items requiring lubrication are ser-
viced in accordance with the Lubrication Chart.
Refer to Table 2-1, Lubrication Chart.
3. Perform functional checks in accordance with para-
graph 2-5, Daily Functional Check.

SECTION 2 - PREPARATION AND INSPECTION
2-4 –JLG Sizzor –3120690
Figure 2-1. Walk-Around Inspection Diagram

SECTION 2 - PREPARATION AND INSPECTION
3120690 –JLG Sizzor –2-5
GENERAL
Begin the “Walk-Around Inspection”at Item 1, as noted
on the diagram.Continue to the right (counterclockwise
viewed from top) checking each item in sequence for the
conditions listed in the “Walk-Around Inspection Check-
list”.
TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL-
FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-
TIONING MACHINE IS A SAFETY VIOLATION. TO AVOID
POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DUR-
ING “WALK-AROUND INSPECTION”.
NOTE: Do not overlook visual inspection of chassis under-
side. Checking this area often results in discovery of
conditions which could cause extensive machine
damage.
1. Steer Cylinder and Tie Rod Ends - No loose or
missing parts, no visible damage. No steer cylinder
leaks or damage.
2. Leveling Jack, Left Front (If Equipped) - No loose or
missing parts, no visible damage. No cylinder leaks
or damage.
3. Steer Spindle, Left Front - No loose or missing
parts, no visible damage, evidence of proper lubri-
cation.
4. Drive Motor, Left Front (4 Wheel Drive) - No visible
damage, no evidence of leakage.
5. Drive Brake, Left Front (4 Wheel Drive) - No loose or
missing parts, no visible damage, no evidence of
leakage.
6. Drive Hub, Left Front (4 Wheel Drive) - No visible
damage, no evidence of leakage. Drive hubs
should be one half full of EPGL SAE 90.
7. Steer/Drive Wheel and Tire Assembly, Left Front -
Properly secured, no loose or missing lug nuts, no
visible damage. Refer to inflation psi stenciled on
frame.
8. Oscillating Axle (If Equipped) - Properly secured,
evidence of proper lubrication. No lockout cylinder
leaks or damage.
9. Ground Controls - Switches operable, no visible
damage, placards secure and legible.
10. Hydraulic Reservoir - No visible damage or missing
parts. No evidence of leaks. Recommended oil level
in sight glass. Breather cap secure and working.
11. Hydraulic Filter - No visible damage, properly
secured, no evidence of leakage.
12. Control Valves - Valves properly secured, no visible
damage, no evidence of leakage. Hoses and fittings
properly secured, no visible damage, no evidence
of leaks.
13. Tilt Alarm Switch - Properly secured, no loose or
missing parts, no visible damage.
14. Fuel Tank - Filler cap secure, sight gauge visible, no
damage or leaks.
15. Safety Prop - Stored securely, no missing parts.
16. Travel/Descent/Motion Alarm - Properly secured, no
loose or missing parts, no visible damage.
17. Drive Motor, Left Rear - No visible damage, no evi-
dence of leakage.
18. Drive Brake, Left Rear - No loose or missing parts,
no visible damage, no evidence of leakage.
19. Drive Hub, Left Rear - No visible damage, no evi-
dence of leakage. Drive hubs should be one half full
of EPGL SAE 90.
20. Drive Wheel and Tire Assembly, Left Rear - Properly
secured, no loose or missing lug nuts, no visible
damage. Refer to inflation psi stenciled on frame or
wheel rims.
21. Steer Spindle, Left Rear (If Equipped) - No loose or
missing parts, no visible damage, evidence of
proper lubrication.
22. Leveling Jack, Left Rear (If Equipped) - No loose or
missing parts, no visible damage. No cylinder leaks
or damage.
23. Battery Installation (Gasoline or Diesel Engine) -
Proper electrolyte level, cables secure, no damage
or corrosion. Hold-downs secure.
24. Ladder - No damage, securely attached.
25. Leveling Jack, Right Rear (If Equipped) - No loose
or missing parts, no visible damage. No cylinder
leaks or damage.
26. Rear Steer Cylinder and Tie Rod Ends (If Equipped)
- No loose or missing parts, no visible damage. No
steer cylinder leaks or damage.
27. Steer Spindle, Right Rear (If Equipped) - No loose
or missing parts, no visible damage, evidence of
proper lubrication.
Figure 2-2. Walk-Around Inspection Points (Sheet 1 of 2)

SECTION 2 - PREPARATION AND INSPECTION
2-6 –JLG Sizzor –3120690
28. Drive Motor, Right Rear - No visible damage, no evi-
dence of leakage.
29. Drive Brake, Right Rear - No loose or missing parts,
no visible damage, no evidence of leakage.
30. Drive Hub, Right Rear - No visible damage, no evi-
dence of leakage. Drive hubs should be one half full
of EPGL SAE 90.
31. Drive Wheel and Tire Assembly, Left Rear - Properly
secured no loose or missing lug nuts, no visible
damage. Refer to inflation psi stenciled on frame or
wheel rims.
32. Sizzor Arms and Sliding Wear Pads - Properly
secured, no visible damage, evidence of proper
lubrication. Inspect sizzor arm guards for damage
and proper installation.
33. Lift Cylinder - Properly secured, no visible damage,
no loose or missing parts, no evidence leakage.
34. Safety Prop - Stored securely, no missing parts.
35. Hydraulic Pump - Pump properly secured, no visi-
ble damage, no evidence of leakage. Hoses and fit-
tings properly secured, no visible damage, no
evidence of leaks.
36. Engine Installation - Engine oil to full mark on dip-
stick, oil fillercap secure. Muffler/exhaust system
properly secured, no leakage. Air filter assembly
secure, no loose or missing parts, element clean.
Gasoline Engine Only - Radiator cap secure, cool-
ant to correct level.
37. Handrail installation - All railings securely attached,
no damage or missing parts, chains securely
attached.
38. Steer/Drive Wheel and Tire Assembly, Right Front -
Properly secured, no loose or missing lug nuts, no
visible damage. Refer to inflation psi stenciled on
frame or wheel rims.
39. Drive Motor, Right Front (4 Wheel Drive) - No visible
damage, no evidence of leakage.
40. Drive Brake, Right Front (4 Wheel Drive) - No loose
or missing parts, no visible damage, no evidence of
leakage.
41. Drive Hub, Right Front (4 Wheel Drive) - No visible
damage, no evidence of leakage. Drive hubs
should be one half full of EPGL SAE 90.
42. Steer Spindle, Right Front - No loose or missing
parts, no visible damage, evidence of proper lubri-
cation.
43. Leveling Jack, Right Front (If Equipped) - No loose
or missing parts, no visible damage. No cylinder
leaks or damage.
44. Drive and Lift Cutout Switches (If Equipped) - No
visible damage, properly secured.
45. Platform Controls - Properly secured, no loose or
missing parts, no visible damage. Placards secure
and legible, control switches return to neutral. Con-
trol markings legible, manual in manual storage
box.
46. Manual Descent Cable - Properly secured, no loose
or missing parts, no visible damage.
Figure 2-3. Walk-Around Inspection Points (Sheet 2 of 2)