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JLG 100HX Operators & Safety

JLG 100HX Operators & Safety

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OPERATORS & SAFETY
AUSTRALIAN OFFICE
JLG INDUSTRIES, INC.
P.O. Box 5119
11 Bolwarra Road
Port Macquarie, Australia
Telephone: 065 811111
Fax: 065 810122
Models
100HX
100HX+10
110HX
3120889
January 1, 1999
EUROPEAN OFFICE
JLG INDUSTRIES (EUROPE)
Kilmartin Place,
Tannochside Park
Uddingston, Scotland, G71 5PH
Telephone: 01698 811005
Main Fax: 01698 811055
Parts Fax: 01698 811455
CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417
Courtesy of Crane.Market

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  • Page 1 Models 100HX 100HX+10 110HX 3120889 January 1, 1999 AUSTRALIAN OFFICE EUROPEAN OFFICE CORPORATE OFFICE JLG INDUSTRIES, INC. JLG INDUSTRIES (EUROPE) JLG INDUSTRIES, INC. P.O. Box 5119 Kilmartin Place, 1 JLG Drive 11 Bolwarra Road Tannochside Park McConnellsburg, PA. Port Macquarie, Australia...
  • Page 2 Courtesy of Crane.Market...
  • Page 3 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.
  • Page 4 FOREWORD This page left blank intentionally. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 5 13. Personnel shall always stand on the floor of the these requirements constitute an assumption of platform, not on boxes, planks, railing or other responsibility of liability on the part of JLG Indus- devices, for a work position. tries, Inc.
  • Page 6 FOREWORD REVISON LOG January, 1999 Original Issue – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 7: Table Of Contents

    Motion Alarm ..............5-2 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 8 Position of Least Backward Stability - 100HX and 110HX .......3-4...
  • Page 9 Inspection and Repair Log ............7-1 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 10 TABLE OF CONTENTS (Continued) This page left blank intentionally. – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 11: Section 1 - Safety Precautions

    Refer to Section 6 for emergency towing procedures. son, has been completed. If there is a question on appli- cation and or operation, JLG Industries Inc., should be SPECIAL NOTE: consulted.

  • Page 12: Electrocution Hazard

    LINES AND APPARATUS. ALLOW FOR BOOM SWAY , ONSTRATED THAT THEY UNDERSTAND SAFE AND ROCK OR SAG AND ELECTRICAL LINE SWAYING. PROPER OPERATION AND MAINTENANCE OF THE THE MACHINE DOES NOT PROVIDE PROTECTION UNIT. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 13 THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE. • ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION. • APPROVED HEAD GEAR MUST BE WORN BY ALL OPERATING AND GROUND PERSONNEL. 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 14: Driving

    WH EN D RIVIN G IN AREAS WH ERE VISIO N IS OBSTRUCTED. • KEEP NON-OPERATING PERSONNEL AT LEAST 2 M (6 FEET) AWAY FROM MACHINE DURING DRIVING OPERATIONS. • WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING. – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 15: Operation

    THROUGH GATE OPENING. • DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES, AS TIPPING WILL OCCUR. • JLG RECOMMENDS ALL PERSONS IN THE PLAT- FORM TO WEAR LANYARDS WITH AN APPROVED • DO NOT DRIVE MACHINE NEAR PITS, LOADING FALL PROTECTION DEVICE. SECURE LANYARD TO DOCKS OR OTHER DROP-OFFS.
  • Page 16 • THE OPERATOR IS RESPONSIBLE TO AVOID OPER- OR UPRIGHT MECHANISM. ATING MACHINE OVER GROUND PERSONNEL AND TO WARN THEM NOT TO WORK, WALK OR STAND UNDER A RAISED BOOM OR PLATFORM. POSITION BARRICADES ON FLOOR IF NECESSARY . – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 17 THEN MOVE SWITCH TO THE DESIRED POSITION. OPERATE LEVERS WITH SLOW, EVEN PRESSURE. • DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC. • NEVER PUSH OR PULL THE MACHINE OR OTHER OBJECTS BY TELESCOPING THE BOOM.

  • Page 18: Towing And Hauling

    BEING USED REACHES END OF TRAVEL. THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE. • DO NOT OPERATE ANY MACHINE ON WHICH DAN- GER, WARNING, CAUTION OR INSTRUCTION PLAC- ARDS OR DECALS ARE MISSING OR ILLEGIBLE. – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 19: Section 2. Preparation And Inspection

    NOTE: This machine requires periodic safety and mainte- chafing drive hubs, hydraulic motors, brakes and nance inspections by an authorized JLG Dealer. A hydraulic lines for damage and leaks. decal located on the turntable provides a place to record (stamp)Annual Inspection dates.
  • Page 20 3. Check hydraulic lines and electrical cable for dam- damage, leakage and security. age, missing parts 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 21 SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Machine Nomenclature 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 22: Daily Walk-Around Inspection

    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. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 23 SECTION 2 - PREPARATION AND INSPECTION Figure 2-2. Daily Walk-Around Inspection Diagram 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 24 8. Drive Motor and Brake, Right Rear - No visible dam- 26. Engine Oil Supply - Full mark on dipstick; filler cap age, no evidence of leakage. secure. Figure 2-3. Daily Walk-Around Inspection Points - Sheet 1 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 25 31. Frame - No visible damage, no loose or missing 37. Platform Pivot and Slave Cylinder Attach Pins - hardware (top and underside). Properly secured; evidence of proper lubrication where applicable. Figure 2-4. Daily Walk-Around Inspection Points - Sheet 2 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 26: Daily Functional Check

    MACHINE WHEN EXTENDING AND RETRACTING AXLES. d. Position LIFT control to DOWN and hold until drive wheels rise from the ground; it may be nec- essary to feather the lift control to maintain drive wheel elevation. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 27 SECTION 2 - PREPARATION AND INSPECTION Figure 2-5. Lubrication Point Location 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 28 300 hrs. thereafter 1 Grease Fitting MPG - Pressure Gun Telescope Cylinder Sheave Extend Chain Sheave 1 Grease Fitting MPG - Pressure Gun Retract Chain Sheave 1 Grease Fitting MPG - Pressure Gun 2-10 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 29 Release the toggle switch. SON. d. Retract the boom until tele out will function. The system is now reset. 100HX + 10. e. Position the toggle switch to the M position and NOTE: The blue light should illuminate when the ignition is hold.
  • Page 30 If it does not, shut down 7. Raise, lower, and swing boom to LEFT and RIGHT a machine and contact a certified JLG service minimum of 45 degrees (Cycle function several technician.

  • Page 31: Torque Requirements

    1. The battery is maintenance free except for occa- extended after being retracted 3 meters without sional battery terminal cleaning, as noted in the fol- resetting, system must be repaired by JLG autho- lowing. rized service personnel before machine can be 2.
  • Page 32 Figure 2-6. Torque Chart Courtesy of Crane.Market...

  • Page 33: Section 3. User Responsibilities And Machine Control

    JLG Distribu- Operator Training tor before proceeding.

  • Page 34: Operating Characteristics And Limitations

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Stability OPERATING CHARACTERISTICS AND This machine as originally manufactured by JLG Indus- LIMITATIONS tries Inc., when operated within its rated capacity on a smooth, firm and level supporting surface, and in accor-...
  • Page 35 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-1. Position of Least Forward Stability 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 36 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-2. Position of Least Backward Stability - 100HX and 110HX – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 37 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-3. Position of Least Backward Stability - 100HX+ 10 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 38: Controls And Indicators

    TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 39 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-4. Ground Control Station - Dual Capacity Only - 100HX and 110HX - Prior to January 1992 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 40 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-5. Ground Control Station - Single Capacity Only - 100HX+ 10 - Prior to January 1992 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 41 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-6. Ground Control Station - 100HX and 110HX - January 1992 to Present 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 42 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-7. Ground Control Station - 100HX+ 10 - January 1992 to Present 3-10 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 43 3120889 – JLG Lift – 3-11 Courtesy of Crane.Market...
  • Page 44 Load Management System. The switch it is level before extending the boom or raising the is used to reset the system during the checking pro- cedure. boom above horizontal. 3-12 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 45 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-8. Platform Station - 100HX and 110HX - Prior to Sept. 1991 3120889 – JLG Lift – 3-13 Courtesy of Crane.Market...
  • Page 46 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-9. Platform Station - 100HX+ 10 - Prior to Sept. 1991 3-14 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 47 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-10. Platform Station - 100HX and 110HX - Sept. 1991 to Present 3120889 – JLG Lift – 3-15 Courtesy of Crane.Market...
  • Page 48 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-11. Platform Station - 100HX+ 10 - Sept. 1991 to Present 3-16 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 49 DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED, HIGH The EXTEND-A-REACH LIFT control switch allows WHEEL MOTOR SPEED, OR HIGH PUMP VOLUME OPERATE operator to raise or lower the extend-a-reach, as WHEN BOOM IS ABOVE HORIZONTAL. required. 3120889 – JLG Lift – 3-17 Courtesy of Crane.Market...
  • Page 50 The broken extend chain indicator lights in the event control switch or lever, and footswitch. of a broken extend chain in the boom. g. Position the POWER/EMERGENCY STOP switch to the OFF position. 3-18 – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 51: Placards And Decals

    See Figure 3-12., Caution, Danger, Warning Decal Loca- tion - Sheet 1 of 2 and Figure 3-13., Caution, Dan- ger, Warning Decal Location - Sheet 2 of 2 3120889 – JLG Lift – 3-19 Courtesy of Crane.Market...
  • Page 52 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3-20 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 53 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 – JLG Lift – 3-21 Courtesy of Crane.Market...
  • Page 54 7. DO NOT OPERATE MALFUNCTIONING MACHINE. OPERATORS HANDBOOK TO ENSURE INSULATED. 8. CHECK ENGINE AND DRIVE SPEED CUT-OUT SWITCHES. SAFE OPERATION OF THE MACHINE. 9. MAXIMUM OPERATING SLOPE: 3° 1690696 P/N 1690696 C 3-22 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 55 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-14. Common Symbols - Sheet 1 3120889 – JLG Lift – 3-23 Courtesy of Crane.Market...
  • Page 56 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-15. Common Symbols - Sheet 2 3-24 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 57 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-16. Common Symbols - Sheet 3 3120889 – JLG Lift – 3-25 Courtesy of Crane.Market...
  • Page 58 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-17. Common Symbols - Sheet 4 3-26 – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 59: Section 4. Machine Operation

    The JLG Lift is not intended to be used to lift material other than supplies which personnel in the platform require to do their job. Supplies or tools which extend outside the platform are prohibited.

  • Page 60: Engine Operation

    START switch to the forward position until engine starts. NOTE: The footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE THE MACHINE. – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 61: Steering

    Position WHEEL MOTOR SPEED switch to HIGH. c. Position PUMP VOLUME switch to HIGH. 5. Prior to stopping the machine, position switches as follows: a. Position HIGH ENGINE switch to LOW. 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 62: Parking And Stowing

    PLATFORM LEVEL control switch to 5. With the aid of an assistant, position EXTENDABLE DOWN and hold until platform is level. AXLE/STEER switch located on platform control Figure 4-2. Lifting the Axle – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 63 Position the LIFT control to DOWN and hold until the steer wheels rise from the ground; it may be necessary to feather the LIFT control to maintain wheel elevation. 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 64 If retracting the drive axles, remove the axle lock opposite end of the machine. pins. If retracting the steer axles, remove the tie rod lock pins, steer cylinder pin and axle lock pins. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 65 SECTION 4 - MACHINE OPERATION 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 66 SECTION 4 - MACHINE OPERATION – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 67: 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. 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 68: 4.11 Tie Down And Lifting

    When steering the unit (self-propelled operation) the valve knob is pushed IN. When towing the unit the valve knob is pulled OUT to the float position. 4-10 – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 69 SECTION 4 - MACHINE OPERATION 3120889 – JLG Lift – 4-11 Courtesy of Crane.Market...
  • Page 70 2. Reconnect drive hubs by inverting disconnect cap. (See Figure 4-5.) 3. Disconnect towbar from steering hitch and from tow- ing vehicle. The machine is now in the driving mode. Figure 4-6. Drive Disconnect Hug 4-12 – JLG Lift – 3120889 Courtesy of Crane.Market...

  • Page 71: Section 5. Optional Equipment

    1. With engine operating on LP under a no-load condi- use where sharp objects are frequently encountered on tion, position DUAL FUEL switch at Ground Control Station to GASOLINE position. operating surface of jobsite. 3120889 – JLG Lift – Courtesy of Crane.Market...

  • Page 72: Rotating Beacon

    This pack- When not in use the excess wire and p lug are to b e age includes the boom wipers, cylinder bellows, heavy stowed beside the battery. – JLG Lift – 3120889 Courtesy of Crane.Market...
  • Page 73 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 3120889 – JLG Lift – Courtesy of Crane.Market...
  • 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 IF THE PLATFORM OPERATOR IS PINNED, TRAPPED injury or property damage is evident, the factory should...
  • Page 75 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments 3120889 – JLG Lift – Courtesy of Crane.Market...
  • Page 76 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments – JLG Lift – 3120889 Courtesy of Crane.Market...
  • 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 78 Courtesy of Crane.Market...
  • Page 79 Courtesy of Crane.Market...
  • 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.

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