Operators and Safety Manual Models 100SX 110SXJ 110SX 120SXJ 3121104 June 10, 2003 ANSI
– JLG Lift –
FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. It is important to stress proper machine usage at all times. All information in this manual must be read and understood before any attempt is made to operate the machine.
FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death The Safety Alert Symbol will be used with the appropriate Safety Signal Word of “DANGER” “WARNING” or “CAUTION” to a potential hazard and designate a level of seriousness. The Safety Signal Words are inserted throughout this manual in Black/White.
FOREWORD ALL SAFETY-RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT. JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETYRELATED BULLETINS FOR THIS JLG PRODUCT. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG DEALER FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. IMPORTANT FOR THE PURPOSE OF RECEIVING SAFETY-RELATED BULLETINS, IT IS IMPORTANT THAT THE CURRENT OWNER OF THIS UNIT ENSURES JLG INDUSTRIES, INC. HAS UPDATED OWNERSHIP INFORMATION.
FOREWORD REVISION LOG Original Issue Revised Revised Revised d - April 1, 2000 April 30, 2002 May 30, 2002 June 10, 2003 – JLG Lift – 3121104
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH SECTION PAGE NO. - FOREWORD SECTION 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operator Training and Knowledge . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 PAGE NO. Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Stability . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH 6.4 6.5 PAGE NO. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) This page left blank intentionally.
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection • Do not operate this machine until the inspections and functional checks have been performed as specified in the Preparation and Inspection section of this manual. • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure the footswitch and all other safety devices are operating properly.
SECTION 1 - SAFETY PRECAUTIONS Trip and Fall Hazards JLG Industries, Inc. requires that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc. • Platform-to-structure transfers at elevated positions are discouraged.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1.Minimum Safe Approach Distances (M.S.A.D.) Voltage Range (Phase to Phase) MINIMUM SAFE APPROACH DISTANCE in Feet (Meters) 0 to 300V AVOID CONTACT Over 300V to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) • The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving.
SECTION 1 - SAFETY PRECAUTIONS • Keep the chassis of the machine a minimum distance of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level. • Never push or pull the machine or other objects by telescoping or retracting the boom. • Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.
SECTION 1 - SAFETY PRECAUTIONS 1.5 • Remove all rings, watches, and jewelry when performing any maintenance. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment. MAINTENANCE General This section contains general safety precautions which must be observed during maintenance of this machine.
SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine.
SECTION 2 - PREPARATION AND INSPECTION Turntable 3. Check lift cylinder and cross pins and hydraulic lines for damage, wear, leakage and security. 1. Check turntable and turntable lock for damage, loose or missing parts, and security. Check swing drive hub, hydraulic motor, and brake for damage, loose or missing parts, hydraulic lines and component housings for evidence of leakage; pinion for proper mesh with swing gear. 4. Check boom pivot pins for damage, wear, and security. 5.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-1.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-2.
SECTION 2 - PREPARATION AND INSPECTION Platform 2. Placards. Keep all information and operating placards clean and unobstructed. Cover when spray painting or shot blasting to protect legibility. 1. Check platform and control console for damage, loose or missing parts, and security. 2. Check control switches and levers for damage, loose or missing parts and security. Assure that all levers function properly. 3. Operator’s and Safety Manual. Ensure a copy of this manual and the ANSI A92.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-3.
SECTION 2 - PREPARATION AND INSPECTION GENERAL Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the “Walk-Around Inspection Checklist”. TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DURING WALK-AROUND INSPECTION.
SECTION 2 - PREPARATION AND INSPECTION 25. Cowling and Latches, Right Side - All cowling and latches in working condition, properly secured, no loose or missing part. 26. Turntable Bearing and Pinion - No loose or missing hardware; no visible damage, evidence of proper lubrication. No evidence of loose bolts or looseness between bearing and structure. 27. Engine Air Filter - No loose or missing parts, no visible damage, element clean. 28.
SECTION 2 - PREPARATION AND INSPECTION 2.5 d. Push and hold the Jack/Steer/Axle Select switch in the Axle position. DAILY FUNCTIONAL CHECK e. Position Drive/Steer/Jacks/Axle controller located on platform control console to Extend Axles until axles are fully extended and the Axles Set light is on. THE LOAD MANAGEMENT SYSTEM AND THE AXLES (PROPER EXTENSION AND RETRACTION) MUST BE CHECKED PRIOR TO ANY OTHER SYSTEMS AND/OR FUNCTIONS. f.
SECTION 2 - PREPARATION AND INSPECTION d. Retract the boom until tele out will function. The system is now reset. e. Position the toggle switch to the M position and hold. f. Extend the boom until it stops. The boom must stop on the white band on the mid boom section. 13. With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform control console, manually activate the indicator light by compressing any one of the three tilt indicator mounting springs.
SECTION 2 - PREPARATION AND INSPECTION Load Management System Daily Check 2.7 At the beginning of each days’ use, perform check with no load (persons or material) in platform from ground control station. 1. Extend all axles fully. 2. With boom fully retracted, raise boom to horizontal. 3. Position toggle switch located on the right side of the ground control station in the “P” position and hold. 4. Extend boom until it stops. Boom must stop on white tape on mid boom. Release toggle switch.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-6.
SECTION 2 - PREPARATION AND INSPECTION Table 2-1.
Figure 2-7.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 3. Knowledge and understanding of all safety work rules of the employer and of Federal, State and local statutes, including training in the recognition and avoidance of potential hazards in the work place; with particular attention to the work to be performed.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3.3 h. Position the POWER/EMERGENCY SWITCH to off. CONTROLS AND INDICATORS 3. Control Station Selector Ground Controls A three position, center off, key activated Platform/ Ground Select switch supplies power to the platform control console when positioned to Platform. With the switch in Ground position, power is shut off to the platform control console, and only the controls on the ground control panel are operable. 1.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-1.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-2. Ground Control Indicator Panel 7. Hourmeter 11. Load Management Test Switch An hourmeter, installed in the right side of the Ground Control box, registers the amount of time the machine has been in use, with engine running. By connecting into the alternator charging circuit of the engine, only engine run hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 25. Broken Fan Belt Indicator 15. Transmission Pump Oil Filter Indicator (Optional) When illuminated indicates that charge pump filter is too restrictive and needs to be replaced. This indicator has an integral temperature sensor (70 degrees F.) so that false signals are not generated when the hydraulic oil is below normal operating temperature. 16.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-3.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Platform Station IMPORTANT NOTE: For engine starting, the footswitch must be in the released (up) position. Footswitch must be actuated in order for controls to function. 1. Footswitch This feature makes it necessary to depress the footswitch to allow operation of the controls. WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-4.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL NOTE: LIFT, SWING, and DRIVE control levers or switches are spring-loaded and will automatically return to the neutral (OFF) position when released. NOTE: When the boom is above horizontal, high speed functions are automatically cut out and the machine continues to operate at a lower speed. 10. Drive Speed/Torque Select The Drive Speed/Torque Select switch is a three position switch.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 13. Platform Level 21. Engine Distress Indicator Light The PLATFORM LEVEL control switch allows the operator to compensate for any difference in the automatic self-leveling system by positioning the switch up or down. The light turns on and an alarm sounds when machine’s power system requires immediate service.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL NOTE: One of the capacity indicator lights should be illuminated at all times during operation. If no capacity lights are on, a bulb could be burned out. Operation of the machine must be halted until the lights are working properly. Check the capacity decal in the platform and at the ground control station for the machines operating capacity(s). 27.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-5.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-6.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1703797 A 3-14 – JLG Lift – 3121104
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1703798 B P/N 1703804 B 3121104 – JLG Lift – 3-15
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1703805 B P/N 1703804 B 3-16 – JLG Lift – 3121104
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1704606 A P/N 1704755 A 3121104 – JLG Lift – 3-17
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-7.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-8.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-9.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION This machine is a self-propelled aerial work platform on the end of an elevating, telescoping and rotating boom. The JLG Lift’s intended purpose is to position personnel with their tools and supplies at positions above ground level. The machine can be used to reach work areas located above and over machinery or equipment. The JLG Lift has a primary operator Control Station in the platform.
SECTION 4 - MACHINE OPERATION Table 4-1. Operating Specifications - 100SX, 110SX & 110SXJ Maximum Work Load (Capacity) Restricted (110SX Only): Unrestricted: 1000 lb (455 kg) 500 lb (230 kg) 45% Maximum Travel Grade (Gradeablility Maximum Travel Grade (Side Slope) 5° Max Vertical Platform Height, 100SX: 100 ft. (30.5 m) Max Vertical Platform Height 110SX, 110SXJ: 110 ft. (33.5 m) Maximum Horizontal Platform Reach 60 ft. (18.3 m) Turning Radius (inside) - 4WS Axles Retracted Axles Extended 9.
SECTION 4 - MACHINE OPERATION Figure 4-1.
SECTION 4 - MACHINE OPERATION Figure 4-2.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION 4.3 Shutdown Procedure GENERAL This section provides the necessary information needed to operate the machine. Included in this section are the procedures for starting, stopping, traveling, steering, parking, platform loading and transporting. It is important that the user read and understand the proper procedures before operating the machine. 4.4 IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION. 1.
SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Side Slope Traveling Forward or Reverse 4.6 4. With engine running, depress footswitch and position DRIVE control to FORWARD and hold for the duration of forward travel desired. 5. Depress footswitch and position DRIVE control to REVERSE and hold for duration of reverse travel desired. 6. Depress footswitch and position STEER control to RIGHT for traveling right and LEFT for traveling left. 7.
SECTION 4 - MACHINE OPERATION 4.8 PLATFORM 4.9 Loading From Ground Level AXLES, EXTENDING AND RETRACTING Machines without Jacks 1. Position chassis on a smooth, firm and level surface. 1. From the platform controls, activate the machine hydraulic system and position the boom over the drive wheel end of the machine. 2. If total load (personnel, tools and supplies) is less then rated capacity, distribute load uniformly on platform floor and proceed to work position. 2.
SECTION 4 - MACHINE OPERATION 2. Position the Steer Select switch to the Front Steer position. The boom must be retracted within the limits of the 10 foot cutout switch and below horizontal. 3. Position the Axle/Jack Select switch to the desired jack. 5. Position Drive/Steer/Jacks/Axle controller located on platform control console to Extend Axles until axles are fully extended and the Axles Set light is on. 6.
SECTION 4 - MACHINE OPERATION NOTE: If no function is selected and the power is still on, the jack will automatically retract after a period of 7 seconds. 9. Push and hold the Jack/Steer/Axle Select switch in the Jack position. 6. Push and hold the Jack/Steer/Axle Select switch in the Axle position. 10. Position Drive/Steer/Jacks/Axle controller located on platform control console to Retract Jack position until the jack is fully retracted. 11. Repeat steps 1 thru 10 for the opposite axle. 4.
SECTION 4 - MACHINE OPERATION . 4. Push and hold the Jack/Steer/Axle Select switch in the Jack position. 6. Push and hold the Jack/Steer/Axle Select switch in the Axle position. 5. Position the Front Steer/Jacks/Axle switch to the Extend Jack position until the jack is fully extended. 7. Position Front Steer/Jacks/Axle switch to the Extend Axle position until axles are fully extended and the Axles Set light is on. 8.
SECTION 4 - MACHINE OPERATION NOTE: If no function is selected and the power is still on, the jack will automatically retract after a period of 7 seconds. 9. Push and hold the Jack/Steer/Axle Select switch in the Jack position. 10. Position the Front Steer/Jacks/Axle switch to the Retract Jack position until the jack is fully retracted. 11. Repeat steps 1 thru 10 for the opposite axle.
Figure 4-6.
Figure 4-7.
Figure 4-8.
SECTION 4 - MACHINE OPERATION Raising and Lowering the Main Boom 4.11 BOOM A RED TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE (5 DEGREES OR GREATER). DO NOT SWING, EXTEND OR RAISE BOOM ABOVE HORIZONTAL WHEN LIT. DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5 DEGREES OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM ABOVE HORIZONTAL.
SECTION 4 - MACHINE OPERATION 4.13 TIE DOWN AND LIFTING 4.15 TOWING (IF EQUIPPED) When transporting machine, boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck. Four tie down eyes are provided in the frame slab, one at each corner of the machine.
SECTION 4 - MACHINE OPERATION After towing the machine, complete the following: 4.16 SWING-AWAY JIB (120SXJ ONLY) 1. Actuate steer/tow selector valve for steering; push valve knob IN to the actuated position. To Erect the Jib 1. Remove the lockpin from the jib plates. 2. Reconnect drive hubs by inverting disconnect cap. (See Figure 4-9., Drive Disconnect Hub.) 2. With the aid of an assistant, swing the jib until straight with the boom and the holes in the jib plates align. 3.
SECTION 4 - MACHINE OPERATION Figure 4-10.
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SECTION 5 - OPTIONAL EQUIPMENT SECTION 5. OPTIONAL EQUIPMENT 5.1 Changing From LP Gas to Gasoline DUAL FUEL SYSTEM (GAS ENGINE ONLY) Description 1. With engine operating on LP under a no-load condition, position DUAL FUEL switch at Ground Control Station to GASOLINE position. The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas.
SECTION 5 - OPTIONAL EQUIPMENT 5.6 BOOM WIPERS 5.9 A one piece U-shaped neoprene strip, be attached to the front of the base boom section, wipes the top and both sides of the fly section. The bottom side of the fly section is protected by a straight neoprene strip which also attaches to the base section. 5.7 The spark arrestor is mounted directly aft of the standard muffler and serves to contain any sparks the engine might emit that a standard muffler normally would not.
SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES 6.1 GENERAL This section provides information on the procedures to be followed and on the systems and controls to be used in the event an emergency situation is encountered during machine operation. Prior to operation of the machine and periodically thereafter, the entire operating manual, including this section, should be reviewed by all personnel whose responsibilities include any work or contact with the machine. 6.
SECTION 6 - EMERGENCY PROCEDURES functions. Training should include operation of the machine, review and understanding of this section and hands-on operation of the controls in simulated emergencies. Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED O R U N A B L E T O O P E R AT E O R C O N T R O L T H E MACHINE: Righting a Tipped Machine No attempt should be made to right the machine using platform or ground controls.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
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 is necessary.
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.
