JLG 100SX Operator's And Safety Manual
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JLG 100SX Operator's And Safety Manual

JLG 100SX Operator's And Safety Manual

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Operators and Safety Manual
ANSI
Model
100SX
110SX
110SXJ
120SXJ
3121809
May 30, 2002

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Summary of Contents for JLG 100SX

  • Page 1 Operators and Safety Manual Model 100SX 110SX 110SXJ 120SXJ 3121809 May 30, 2002 ANSI...
  • Page 3 Any alteration or modification of the machine is strictly forbidden without written approval from JLG Industries, Inc. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED, MAY RESULT IN A MACHINE MAL- FUNCTIONED DAMAGE. WHEN INSTALLED IN A MACHINE, THIS SIGNAL WORD WILL HAVE A GREEN BACKGROUND AS PART OF A DECAL. – JLG Lift – 3121809...
  • Page 5 CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. IMPORTANT JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
  • Page 6 FOREWORD REVISION LOG Original Issue - May 1, 2000 Revised - July 27, 2000 Revised - April 30, 2002 Revised - May 30, 2002 – JLG Lift – 3121809...

  • Page 7: Table Of Contents

    General..............4-2 3121809 – JLG Lift –...
  • Page 8 Use of Ground Controls........... . . 6-1 – JLG Lift –...
  • Page 9 Position of Least Backward Stability - 100SX and 110SX .......4-4...
  • Page 10 TABLE OF CONTENTS (Continued) This page left blank intentionally. – JLG Lift – 3121809...

  • Page 11: Section 1 - Safety Precautions

    -20 C to 40 C (0 F to 104 F). Consult JLG to optimize operation outside of this temperature range. Machine Inspection • An operator must not accept operating responsibilities • Do not operate this machine until the inspections and...

  • Page 12: Operation

    • Do not carry materials directly on platform railing • Check the machine for modifications to original com- ponents. Ensure that any modifications have been unless approved by JLG. approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine opera- •...

  • Page 13: Trip And Fall Hazards

    • Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit JLG Industries, Inc. requires that all persons in the plat- through the gate only with the platform within 1 foot form wear a full body harness with a lanyard attached to (0.3m) of a safe and secure structure.

  • Page 14: Tipping Hazards

    Distribute loads evenly on platform floor. load decals located on the chassis adjacent to each Keep all loads within the confines of the platform, wheel. Do not travel on unsupported surfaces. unless authorized by JLG. – JLG Lift – 3121809...

  • Page 15: Crushing And Collision Hazards

    • 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 • During operation, keep all body parts inside platform for lifting information. railing. 3121809 – JLG Lift –...

  • Page 16: Maintenance

    • Charge batteries only in a well ventilated area. in an unstable position. Ensure adequate support is • Avoid overfilling the battery fluid level. Add distilled provided when raising components of the machine. water to batteries only after the batteries are fully charged. – JLG Lift – 3121809...

  • Page 17: Section 2. Preparation And Inspection

    NOTE: This machine requires periodic safety and mainte- dence of leakage, and security and electrical con- nance inspections by an authorized JLG Dealer. nections for corrosion and tightness. The following checklist provides a systematic inspection 8.

  • Page 18: Turntable

    10. Check hydraulic reservoir and hydraulic lines for age, missing parts and security. damage, leakage and security. NOTE: JLG recommends replacing the hydraulic filter ele- ment after the first 50 hours of operation and then every 300 hours thereafter, unless system indicator require earlier replacement.

  • Page 19: Machine Nomenclature - 100Sx And 110Sx

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Machine Nomenclature - 100SX and 110SX 3121809 – JLG Lift –...

  • Page 20: Machine Nomenclature - 110Sxj And 120Sxj

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-2. Machine Nomenclature - 110SXJ and 120SXJ – JLG Lift – 3121809...

  • Page 21: Platform

    In addition to the Daily Walk-Around Inspection, be sure to include the following as part of the daily inspection: 1. Overall cleanliness. Check all standing surfaces for oil, fuel and hydrau- lic oil spillage and foreign objects. Ensure overall cleanliness. 3121809 – JLG Lift –...

  • Page 22: Daily Walk-Around Inspection Diagram

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-3. Daily Walk-Around Inspection Diagram – JLG Lift – 3121809...

  • Page 23: General

    7. Power Track - No loose, damaged or missing parts, evidence of leakage. no visible damage. 24. Engine Oil Supply - Full mark on dipstick; filler cap secure. Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1 3121809 – JLG Lift –...
  • Page 24 29. Frame - No visible damage, no loose or missing 35. Platform Pivot and Slave Cylinder Attach Pins - hardware (top and underside). Properly secured; evidence of proper lubrication where applicable. Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2 – JLG Lift – 3121809...

  • Page 25: Daily Functional Check

    7 sec- c. Position LIFT control to DOWN and hold until onds. drive wheels rise from the ground; it may be nec- essary to feather the lift control to maintain drive wheel elevation. 3121809 – JLG Lift –...
  • Page 26 EXTENDED AFTER BEING RETRACTED 3 METERS WITHOUT Remove foot from footswitch, motion should RESETTING, THE SYSTEM MUST BE REPAIRED BY JLG AUTHO- stop. If it does not, shut down machine and con- RIZED SERVICE PERSONNEL BEFORE MACHINE CAN BE USED.

  • Page 27: Load Management System Daily Check

    9. If boom does not stop at white tape or boom can be extended after being retracted 3 meters without resetting, system must be repaired by JLG autho- rized service personnel before machine can be used. 2.6 TORQUE REQUIREMENTS The Torque Chart (See Figure 2-7.) consists of standard...

  • Page 28: Lubrication Point Location

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-6. Lubrication Point Location 2-12 – JLG Lift – 3121809...
  • Page 29 MPG - Pressure Gun Jib Pivot Pin 2 Grease Fittings MPG - Pressure Gun NOTES: Key to Lubricants: Engine Oil EPGL Extreme Pressure Gear Lube Hydraulic Fluid (Mobil #424 or equivalent) MPG t Multi-Purpose Grease 3121809 – JLG Lift – 2-13...
  • Page 30 SECTION 2 - PREPARATION AND INSPECTION 2-14 – JLG Lift – 3121809...

  • Page 31: Section 3. User Responsibilities And Machine Control

    Operator Training tion from his/her supervisor or an authorized JLG Distribu- Operator training must include instruction in the following tor before proceeding.

  • Page 32: Controls And Indicators

    Operate appropriate control switch or lever for desired function and hold. e. Position ENGINE START/AUXILIARY POWER switch to DOWN and hold. f. Release AUXILIARY POWER switch, allowed by the selected control switch or lever. – JLG Lift – 3121809...

  • Page 33: Ground Control Console

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-1. Ground Control Console 3121809 – JLG Lift –...

  • Page 34: Ground Control Indicator Panel

    Load Management Test Switch for matic self leveling system by positioning the control checking the Load Management System. The switch switch to UP or DOWN. is used to reset the system during the checking pro- cedure. – JLG Lift – 3121809...

  • Page 35: Remote Control Box (120Sxj Only)

    When illuminated indicates that the axles are fully decrease drive speed as desired. extended. 5. Rear Steer Switch This switch allows the operator to steer the rear wheels as desired. The Speed Control switch does not affect the steer function. 3121809 – JLG Lift –...

  • Page 36: Remote Control Box

    7. Jack/Steer/Axle Select Switch This switch allows the operator to select between This switch allows the operator to select the Jack, operation of the front or rear jack. Steer, or Axle function. Figure 3-3. Remote Control Box – JLG Lift – 3121809...

  • Page 37: Platform Station

    The auxiliary pump will operator boom lift, telescope and swing. It should be noted that the functions will operate at a slower than normal rate because of lower hydraulic flow. 3121809 – JLG Lift –...

  • Page 38: Platform Control Console

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-4. Platform Control Console – JLG Lift – 3121809...
  • Page 39 In addition to drive, the controller is used to control steering left or right, extension and retraction of the jacks, or extension and retraction of the axles. The function being operated is dependent upon the position of the Jack/Steer/Axle Select switch. 3121809 – JLG Lift –...
  • Page 40 When illuminated (Yellow), the fuel tank is 1/8 full or less. When the light first turns on, there are approxi- The LIGHTS switch allows the operator to turn the mately four usable gallons of fuel remaining. installed light options on or off. 3-10 – JLG Lift – 3121809...

  • Page 41: Placards And Decals

    See Figure 3-5., Caution, Danger, Warning Decal Loca- tion - Sheet 1 of 2 and Figure 3-6., Caution, Danger, Warning Decal Location - Sheet 2 of 2 3121809 – JLG Lift – 3-11...
  • Page 42 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-5. Caution, Danger, Warning Decal Location - Sheet 1 of 2 3-12 – JLG Lift – 3121809...
  • Page 43 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-6. Caution, Danger, Warning Decal Location - Sheet 2 of 2 3121809 – JLG Lift – 3-13...
  • Page 44 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1701518 P/N 1703806 A 3-14 – JLG Lift – 3121809...
  • Page 45 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1703807 A 3121809 – JLG Lift – 3-15...
  • Page 46 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL P/N 1704606 A P/N 1704755 A 3-16 – JLG Lift – 3121809...
  • Page 47 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-7. Control Panel Symbols - Sheet 1 3121809 – JLG Lift – 3-17...
  • Page 48 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-8. Control Panel Symbols - Sheet 2 3-18 – JLG Lift – 3121809...
  • Page 49 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-9. Control Panel Symbols - Sheet 3 3121809 – JLG Lift – 3-19...
  • Page 50 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL This page left blank intentionally. 3-20 – JLG Lift – 3121809...

  • Page 51: Section 4. Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION The JLG Lift is not intended to be used to lift material other 4.1 DESCRIPTION than supplies which personnel in the platform require to do their job. Supplies or tools which extend outside the This machine is a self-propelled aerial work platform on platform are prohibited.

  • Page 52: Operating Characteristics And Limitations

    SECTION 4 - MACHINE OPERATION Table 4-1. Operating Specifications - 100SX, 110SX & 4.2 OPERATING CHARACTERISTICS AND 110SXJ LIMITATIONS Maximum Work Load (Capacity) General Unrestricted: 230 kg (500 lb) Maximum Travel Grade (Gradeablility A thorough knowledge of the operating characteristics...

  • Page 53: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION Figure 4-1. Position of Least Forward Stability 3121809 – JLG Lift –...

  • Page 54: Position Of Least Backward Stability - 100Sx And 110Sx

    SECTION 4 - MACHINE OPERATION Figure 4-2. Position of Least Backward Stability - 100SX and 110SX – JLG Lift – 3121809...

  • Page 55: Position Of Least Backward Stability - 110Sxj & 120Sxj

    SECTION 4 - MACHINE OPERATION Figure 4-3. Position of Least Backward Stability - 110SXJ & 120SXJ 3121809 – JLG Lift –...

  • Page 56: General

    STOP switch to ON, then push the ENGINE START switch to the forward position until engine starts. NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE. – JLG Lift – 3121809...

  • Page 57: Traveling Forward Or Reverse

    9. For traveling up grades, position switches as fol- 4. Turn off SELECT switch and remove key. lows: a. Position DRIVE SPEED/TORQUE SELECT switch to HIGH. NOTE: For smoother operation when driving with fully extended boom, place DRIVE control to SLOW before stopping. 3121809 – JLG Lift –...

  • Page 58: Platform

    4. Push and hold the Jack/Steer/Axle Select switch in 2. Depress footswitch to rotate platform to the right, the Axle position. PLATFORM ROTATE control is positioned to the RIGHT and held until desired position is reached. Figure 4-5. Lifting the Axle – JLG Lift – 3121809...

  • Page 59: Axles, Extending And Retracting (Machines With Jacks)

    ING THE AXLES. THEY ARE NOT TO BE USED AS A MAINTE- NANCE. 1. From the platform controls, activate the machine hydraulic system and position the boom over the drive wheel end of the machine. 3121809 – JLG Lift –...

  • Page 60: Axles, Extending And Retracting W/Remote Control Box

    2. Position the Steer Select switch to the Front Steer position. The boom must be retracted within the lim- its of the 10 foot cutout switch and below horizontal. 3. Position the Front/Rear Jack switch to the desired jack. 4-10 – JLG Lift – 3121809...
  • Page 61 Axle position until axles are fully extended and the Axles Set light is on. 8. If the light does not illuminate when the axles are fully extended, contact a qualified service technician before continuing operation. 3121809 – JLG Lift – 4-11...
  • Page 62 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. 4-12 – JLG Lift – 3121809...
  • Page 63 SECTION 4 - MACHINE OPERATION 3121809 – JLG Lift – 4-13...
  • Page 64 SECTION 4 - MACHINE OPERATION 4-14 – JLG Lift – 3121809...
  • Page 65 SECTION 4 - MACHINE OPERATION 3121809 – JLG Lift – 4-15...

  • Page 66: Boom

    1. Depress footswitch to swing boom, position SWING control switch or controller to RIGHT or LEFT for direction desired. NOTE: When boom functions are being operated there is an interlock that prevents the use of DRIVE and STEER functions. 4-16 – JLG Lift – 3121809...

  • Page 67: Tie Down And Lifting

    MAXIMUM TOWING SPEED 8 K.M.H. (5 M.P.H.). and that the turntable lock pin is engaged. See Figure 4- 6., Lifting Chart - 100SX and 110SX, Figure 4-7., Lifting Prior to towing the machine, complete the Chart - 110SXJ, and Figure 4-8., Lifting Chart - 120SXJ.

  • Page 68: After Towing The Machine, Complete The Following

    Figure 4-9. Drive Disconnect Hub 3. Install the lockpin through the aligned holes in the jib plates. The machine must now be operated from the ground controls or the remote control box. 4-18 – JLG Lift – 3121809...

  • Page 69: Swing-Away Jib

    SECTION 4 - MACHINE OPERATION Figure 4-10. Swing-Away Jib 3121809 – JLG Lift – 4-19...
  • Page 70 SECTION 4 - MACHINE OPERATION This page left blank intentionally. 4-20 – JLG Lift – 3121809...

  • Page 71: Section 5. Optional Equipment

    The lead from the ground control and also at the platform. The lead from the ground control to the platform is routed along the boom power track thus eliminating the use of extension cords hanging freely from the platform. 3121809 – JLG Lift –...
  • Page 72 SECTION 5 - OPTIONAL EQUIPMENT This page left blank intentionally. – JLG Lift – 3121809...

  • Page 73: Section 6. Emergency Procedures

    The Ground Control Station is located on the right front side of the turntable. The controls on this panel provide Ground personnel must be thoroughly familiar with the the means for overriding the platform controls, and for machine operating characteristics and the ground control 3121809 – JLG Lift –...

  • Page 74: Operator Unable To Control Machine

    It is imperative that JLG Industries, Inc. be notified imme- diately of any incident involving a JLG product. Even if no 2. Other qualified personnel on the platform may use injury or property damage is evident, the factory should the platform controls with regular or auxiliary power.

  • Page 75: Section 7. Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments 3121809 – JLG Lift –...
  • Page 76 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments – JLG Lift – 3121809...
  • Page 77 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.
  • Page 80 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.

This manual is also suitable for:

110sx110sxj120sxj

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