JLG 120-SXJ Operator Manual
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.
Because the manufacturer has no direct control over machine operation and application, proper safety practices are the responsibility of the owners, users, operators, lessors, and lessees.
All instructions in this manual are based upon the use of the machine under proper operating conditions, with
no deviations from the original design. 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.
3121104 – JLG Lift – a
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. On the machine, the Safety Signal Words will have either a Red, Orange, or Yellow background as part of a
safety sign or decal. The “DANGER”, “WARNING”, and “CAUTION” Safety Signal Words, definitions, and associated colors
are as follows:
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, WILL
SIGNAL WORD IS USED IN THE MOST EXTREME CASES. WHEN
INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL HAVE A
RED BACKGROUND AS PART OF A DECAL.
RESULT IN SERIOUS INJURY OR DEATH. THIS
INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, COULD
WHEN INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL
HAVE AN ORANGE BACKGROUND AS PART OF A DECAL.
INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH IF
NOT AVOIDED, MAY
MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.
WHEN INSTALLED ON THE MACHINE, THIS SIGNAL WORD WILL
HAVE A YELLOW BACKGROUND AS PART OF A DECAL.
The “IMPORTANT” Safety Signal Word may also appear in this manual or on the machine. This Safety Signal Word typically
will not appear with the Safety Alert Symbol, but contains important information that must be followed for safe and proper
operation, The “IMPORTANT” Safety Signal Word definition and associated color is as follows.
RESULT IN SERIOUS INJURY OR DEATH.
RESULT IN MINOR OR MODERATE INJURY. IT
IMPORTANT
INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION AND
WHICH, IF NOT FOLLOWED, MAY RESULT IN A MACHINE MALFUNCTIONED DAMAGE. WHEN INSTALLED IN A MACHINE, THIS
SIGNAL WORD WILL HAVE A GREEN BACKGROUND AS PART OF A
DECAL.
b – JLG Lift – 3121104
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. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
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.
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
Toll Free: 877-JLG-SAFE
877-554-7233
E-mail: ProductSafety@JLG.com
3121104 – JLG Lift – c
FOREWORD
Original Issue - April 1, 2000
Revised - April 30, 2002
Revised - May 30, 2002
Revised - June 10, 2003
REVISION LOG
d – JLG Lift – 3121104
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 Towing, Lifting, and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SECTION 2 - PREPARATION AND INSPECTION
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Delivery and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Extend-A-Reach (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Load Management System Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operator Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Remote Control Box (120SXJ Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
SECTION 4 - MACHINE OPERATION
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
3121104 – JLG Lift – i
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT - SECTION, PARAGRAPH PAGE NO.
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5 Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Traveling Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.7 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.8 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Loading From Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Loading From Positions Above Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9 Axles, Extending and Retracting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Machines without Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Machines with Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 Axles, Extending and Retracting w/Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.11 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Raising and Lowering the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.12 Shut Down and Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.13 Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.14 Steer/tow Selector (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4.15 Towing (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Prior to towing the machine, complete the following:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
After towing the machine, complete the following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.16 Swing-Away Jib (120SXJ Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
To Erect the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
To Stow the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
SECTION 5 - OPTIONAL EQUIPMENT
5.1 Dual Fuel System (Gas Engine Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Changing From Gasoline to LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Changing From LP Gas to Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Electric Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.4 Strobe Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.5 Cylinder Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.6 Boom Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.7 110 Volt/60Hz Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.8 220 Volt Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.9 Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.10 110 Volt Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION 6 - EMERGENCY PROCEDURES
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.3 Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ii – JLG Lift – 3121104
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT - SECTION, PARAGRAPH PAGE NO.
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.4 Emergency Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Use of Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Platform or Boom Caught Overhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Righting a Tipped Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Post Incident Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
SECTION 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Machine Nomenclature - 100SX and 110SX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2-2. Machine Nomenclature - 110SXJ and 120SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-4. Daily Walk-Around Inspection Points - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-5. Daily Walk-Around Inspection Points - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-6. Lubrication Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-7. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
3-1. Ground Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-5. Caution, Danger, Warning Decal Location - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-6. Caution, Danger, Warning Decal Location - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-7. Control Panel Symbols - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-8. Control Panel Symbols - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-9. Control Panel Symbols - Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-2. Position of Least Backward Stability - 100SX and 110SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3. Position of Least Backward Stability - 110SXJ & 120SXJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-5. Lifting the Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-6. Lifting Chart - 100SX and 110SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-7. Lifting Chart - 110SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-8. Lifting Chart - 120SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4-9. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-10. Swing-Away Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
4-1 Operating Specifications - 100SX, 110SX & 110SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2 Operating Specifications - 120SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
3121104 – JLG Lift – iii
TABLE OF CONTENTS (Continued)
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iv – JLG Lift – 3121104
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. A maintenance program, using the information
provided in this manual and the Service and Maintenance
Manual, must also be established by a qualified person
and must be followed to ensure that the machine is safe to
operate.
The owner/user/operator/lessor/lessee of the machine
should not accept operating responsibility 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.
The owner/user/operator/lessor/lessee must be familiar
with Sections 6, 7, 8, 9, 10 of ANSI A92.5-1992. These
sections contain the responsibilities of the owner, user,
operator, lessor, and lessee concerning safety, training,
inspection, maintenance, application, and operation.
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, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operators and Safety Manual must be read and
understood in its entirety before operating the
machine. For clarification, questions, or additional
information regarding any portions of this manual, contact JLG Industries, Inc.
• An operator must not accept operating responsibilities
until adequate training has been given by competent
and authorized persons.
• Allow only those authorized and qualified personnel to
operate the machine who have demonstrated that they
understand the safe and proper operation and maintenance of the unit.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the
machine and in this manual.
• Ensure that the machine is to be used in a manner
which is within the scope of its intended application as
determined by JLG.
• All operating personnel must be familiar with the emergency 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
your utilization and application of the machine.
Workplace Inspection
• Precautions to avoid all hazards in the work area must
be taken by the user before operation of the machine.
• Do not operate or raise the platform from a position on
trucks, trailers, railway cars, floating vessels, scaffolds
or other equipment unless the application is approved
in writing by JLG.
• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other
potential overhead obstructions.
• Check floor surfaces for holes, bumps, drop-offs,
obstructions, debris, concealed holes, and other
potential hazards.
• Check the work area for hazardous locations. Do not
operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Ensure that the ground conditions are adequate to
support the maximum tire load indicated on the tire
load decals located on the chassis adjacent to each
wheel.
• Do not operate the machine when wind conditions
exceed 30 mph (12.5 m/s).
• This machine can be operated in nominal ambient tem-
peratures of 0
JLG to optimize operation outside of this temperature
range.
o
F to 104o F (-20o C to 40o C). Consult
3121104 – JLG Lift – 1-1
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. Modification of these devices is a
safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.
• Check the machine for modifications to original components. Ensure that any modifications have been
approved by JLG.
• Avoid accumulation of debris on platform floor. Keep
mud, oil, grease, and other slippery substances from
footwear and platform deck.
1.3 OPERATION
General
• Do not use the machine for any purpose other than
positioning personnel, their tools, and equipment.
• Before operation, the user must be familiar with the
machine capabilities and operating characteristics of
all functions as specified in Section 4 - Machine Operation.
• Never operate a malfunctioning machine. If a malfunctions occurs, shut down the machine. Remove the unit
from service and notify the proper authorities.
• Do not remove, modify, or disable the footswitch or any
other safety devices.
• 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 at end of travel
(fully extended or fully retracted) before shutdown or
for long periods of time. Always “bump” control in
opposite direction slightly when function reaches end
of travel. This applies both to machines in operation or
in the stowed position.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform, 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 operations.
• Always ensure that power tools are properly stowed
and never left hanging by their cord from the platform
work area.
• When driving, always position boom over rear axle in
line with the direction of travel. Remember, if boom is
over the front axle, the direction of steer and drive will
be opposite from normal operation.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Assist only by
pulling at the chassis tie-down lugs.
• Do not place boom or platform against any structure to
steady the platform or to support the structure.
• Stow boom and shut off all power before leaving
machine.
1-2 – JLG Lift – 3121104
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.
• Prior to operation, ensure all gates are fastened and
secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and
securely attach the lanyard. Attach only one (1) lanyard per lanyard anchorage point.
• 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 utilizing two lanyards.
One lanyard must be attached to the platform with the
second lanyard attached to the structure. The lanyard
connected to the platform must not be disconnected
until such time the transfer to the structure is safe and
complete.
• Keep oil, mud, and slippery substances cleaned from
footwear and the platform floor.
Electrocution Hazards
• This machine is not insulated and does not provide
protection from contact with an electrically charged
conductor.
• Keep both feet firmly positioned on the platform floor at
all times. Never position ladders, boxes, steps, planks,
or similar items on unit to provide additional reach for
any purpose.
• Never use the boom assembly to gain access to or
leave the platform.
• Use extreme caution when entering or leaving platform. Ensure that the boom is fully lowered. Face the
machine when entering or leaving the platform. Always
maintain “three point contact” with the machine, using
two hands and one foot or two feet and one hand at all
times during entry and exit.
• Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in
accordance with the Minimum Safe Approach Distance
(MSAD) as specified in Table 1-1. Allow for machine
movement and electrical line swaying.
3121104 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)
Voltage Range
(Phase to Phase)
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)
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain a clearance of at least 10 ft (3m) between any
part of the machine and its occupants, their tools, and
their equipment from any electrical line or apparatus
carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or
less.
MINIMUM SAFE APPROACH
DISTANCE
in Feet (Meters)
• The user should be familiar with the driving surface
before driving. Do not exceed the allowable sideslope
and grade while driving.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND
WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• Ensure that the ground conditions are adequate to
support the maximum tire load indicated on the tire
load decals located on the machine. Do not travel on
unsupported surfaces.
• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface. Ensure
machine is positioned on a firm, level and uniformly
supported surface before elevating platform or driving
with the platform in the elevated position.
• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
• Never exceed the maximum work load as specified on
the platform. Distribute loads evenly on platform floor.
Keep all loads within the confines of the platform,
unless authorized by JLG.
1-4 – JLG Lift – 3121104
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.
• Do not operate the machine when wind conditions
exceed 28 mph (12.5 m/s).
• Do not cover the platform sides or carry large surfacearea items in the platform when operating outdoors.
The addition of such items increases the exposed wind
area of the machine.
• Do not increase the platform size with unauthorized
deck extensions or attachments.
• If boom assembly or platform is caught so that one or
more wheels are off the ground, all persons must be
removed before attempting to free the machine. Use
cranes, forklift trucks, or other appropriate equipment
to stabilize machine and remove personnel.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating
and ground personnel.
• Keep hands and limbs away from boom assembly during operation.
• Watch for obstructions around machine and overhead
when driving. Check clearances above, on sides, and
bottom of platform when lifting or lowering platform.
• During operation, keep all body parts inside platform
railing.
• Use the boom functions, not the drive function, 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 6 ft. (1.8m)
away from machine during all driving operations.
• Under all travel conditions, the operator must limit
travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel,
and other factors causing hazards of 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 quarters or when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls
and persons in the platform.
• Ensure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes. Barricade floor area if necessary.
• Avoid operating over ground personnel. Warn personnel not to work, stand, or walk under a raised boom or
platform. Position barricades on floor as necessary.
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.
• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. 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.
3121104 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
1.5 MAINTENANCE
General
This section contains general safety precautions which
must be observed during maintenance of this machine.
Additional precautions to be observed during machine
maintenance are inserted at the appropriate points in this
manual and in the Service and Maintenance Manual. It is
of utmost importance that maintenance personnel pay
strict attention to these precautions to avoid possible
injury to personnel or damage to the machine or property.
A maintenance program must be established by a qualified person and must be followed to ensure that the
machine is safe.
Maintenance Hazards
• Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion
prior to performing any adjustments or repairs.
• Never work under an elevated platform until it has been
fully lowered to the full down position, if possible, or
otherwise supported and restrained from movement
with appropriate safety props, blocking, or overhead
supports.
• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.
• Always disconnect batteries when servicing electrical
components or when performing welding on the
machine.
• Shut down the engine (if equipped) while fuel tanks are
being filled.
• Ensure replacement parts or components are identical
or equivalent to original parts or components.
• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest
in an unstable position. Ensure adequate support is
provided when raising components of the machine.
• 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.
• Use only clean approved non-flammable cleaning solvents.
• Never alter, remove, or substitute any items such as
counterweights, tires, batteries, platforms or other
items that may reduce or affect the overall weight or
stability of the machine. Reference the Service and
Maintenance Manual for the weights of critical stability
items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER
Battery Hazards
• Always disconnect batteries when servicing electrical
components or when performing welding on the
machine.
• Do not allow smoking, open flame, or sparks near battery during charging or servicing.
• Do not contact tools or other metal objects across the
battery terminals.
• Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not
come in contact with skin or clothing.
BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH
SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY
CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL
ATTENTION.
• Charge batteries only in a well ventilated area.
• Avoid overfilling the battery fluid level. Add distilled
water to batteries only after the batteries are fully
charged.
1-6 – JLG Lift – 3121104
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. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtaining maximum service life and safe operation.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.
2.2 PREPARATION FOR USE
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 Delivery and Frequent Inspection (Section 2.3,
Delivery and Frequent Inspection). During initial start-up
and run, the unit should be thoroughly checked for
hydraulic leaks. A check of all components should be
made to ensure their security.
All preparation necessary to place the machine in operation readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate properly) coupled with a series of visual inspections. The mandatory requirements are given in the Daily Walk Around
Inspection (Section 2.4, Daily Walk-Around Inspection).
It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.
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.
This inspection checklist is also applicable and must be
followed for all machines that have been in storage or for
all machines that will be exposed to harsh or changing climates.
These checks are also performed after maintenance has
been performed on the machine.
Chassis
1. Check front tire and wheel assemblies for loose or
worn spindles, components and hardware for security, tires for wear and damage.
2. Check steering assembly for loose or bent tie rod,
cylinder and hydraulic lines for leaks and security,
and hardware for proper installation.
3. Check rear tire and wheel assemblies for security,
tires for wear and damage.
4. Check drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.
5. Check oil level in drive hub by removing pipe plug
on side and feeling for oil level. (Contact Service
Personnel for assistance if needed).
NOTE: Drive hubs should be one-half full of lubricant.
6. Check 4WS steering assembly (if equipped) for
loose or bent tie rod, cylinder and hydraulic lines for
leaks and security, and hardware for proper installation.
2.3 DELIVERY AND FREQUENT INSPECTION
NOTE: This machine requires periodic safety and mainte-
nance inspections by an authorized JLG Dealer. A
decal located on the turntable provides a place to
record (stamp) Annual Inspection dates. Check
decal and notify dealer if inspection is overdue.
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.
7. Check counterbalance, flow divider valves, hydraulic
swivel assembly and lines for visible damage, evidence of leakage, and security and electrical connections for corrosion and tightness.
8. Check extending axle assemblies for evidence of
leakage and security; pressure lines for abnormal
chafing drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.
9. Check extending axles for visible damage and loose
or missing parts.
3121104 – JLG Lift – 2-1
SECTION 2 - PREPARATION AND INSPECTION
Turnt abl e
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.
2. Check swing bearing for damage, wear, lubrication
and loose or missing bearing bolts.
3. Check solenoid valves and hydraulic lines for damage, leakage, security and electrical connections for
tightness and evidence of corrosion.
4. Check ground controls for damage, loose or missing parts, security, electrical connections for evidence of corrosion and tightness and wiring for
insulation damage. Assure that all switches function
properly.
5. Check batteries for damage, loose or missing vent
caps, electrical connections for tightness, and evidence of corrosion, holddown brackets for tightness, and electrolyte for proper water level. Add only
clean distilled water to battery.
6. Check engine and accessories for damage, loose or
missing parts, leakage and security. Check throttle
solenoid and linkage for damage, electrical connections for tightness, and evidence of corrosion and
wiring for insulation damage.
3. Check lift cylinder and cross pins and hydraulic lines
for damage, wear, leakage and security.
4. Check boom pivot pins for damage, wear, and security.
5. Check hydraulic line and electrical cable track
assembly for visible damage, loose or missing parts,
and security.
6. Check boom for damage, missing parts and security.
7. Check boom wear pads for damage, wear and security.
8. Check boom telescope cylinder and cross pins and
hydraulic lines for damage, wear, leakage and security.
9. Check platform leveling cylinder and cross pins and
hydraulic lines for damage, wear, leakage and security.
10. Check boom/platform pivot pin for damage, wear
and security.
11. Check horizontal and capacity limit switches
mounted on turntable for security of mounting, damage to switch arms and rollers; and for debris.
12. Check boom tape for correct length, tearing, or
defacing at any point.
Extend-A-Reach (If Equipped)
7. Check fuel lines for damage, leakage and security.
8. Check all access doors for damage, proper operation of latches, props and security.
9. Check fuel tank for damage, leakage and filler cap
for security.
10. Check hydraulic reservoir and hydraulic lines for
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.
11. Check all cylinder pin and shaft retaining hardware
for security and wear.
12. Check all electrical cables for defects, damage,
loose or corroded connections.
Boom
1. Check all cylinder pin and shaft retaining hardware
for security and wear.
2. Check hydraulic lines, electrical cable and track
assemblies for damage, missing parts and security.
1. Check the slave cylinder, weld link and cross pins,
and lines for visible damage, wear, lubrication, evidence of leakage, and security.
2. Check extend-a-reach for visible damage, loose or
missing parts, and security.
3. Check hydraulic lines and electrical cable for damage, missing parts and security.
2-2 – JLG Lift – 3121104
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-1. Machine Nomenclature - 100SX and 110SX
3121104 – JLG Lift – 2-3
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-2. Machine Nomenclature - 110SXJ and 120SXJ
2-4 – JLG Lift – 3121104
SECTION 2 - PREPARATION AND INSPECTION
Platform
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. Check control switches, levers and electrical connections for tightness and evidence of corrosion,
and wiring for defects and chafing damage. Assure
that all switches function properly.
4. Check access gate hinges and latch for proper
operation, damage and security.
5. Check platform rotator mechanism for proper operation, damage, security. Check hydraulic lines for
leakage, damage and security.
NOTE: Check all DANGER, WARNING, CAUTION and
INSTRUCTION placards for legibility and security on
the entire machine.
Tor q ue R e q u i r e m e n t s
The Torque Chart (See Figure 2-7.) consists of standard
torque values based on bolt diameter and grade, also
specifying dry and wet torque values in accordance with
recommended shop practices. This chart is provided as
an aid to the operator in the event he/she notices a condition that requires prompt attention during the walk-around
inspection or during operation, until the proper service
personnel can be notified. The Service and Maintenance
manual provides specific torque values and periodic
maintenance procedures with a listing of individual components. Utilizing this Torque Chart in conjunction with the
preventive maintenance section in the Service and Maintenance manual will enhance safety, reliability, and performance of the machine.
2.4 DAILY WALK-AROUND INSPECTION
It is the operator’s responsibility to inspect the machine
before the start of each workday. It is recommended that
each operator inspect the machine before operation, even
if the machine has already been put into service under
another operator. This Daily Walk-Around Inspection is the
preferred method of inspection. (See Figure 2-3.)
2. Placards.
Keep all information and operating placards clean
and unobstructed. Cover when spray painting or
shot blasting to protect legibility.
3. Operator’s and Safety Manual.
Ensure a copy of this manual and the ANSI A92.51992 Responsibilities, are enclosed in the manual
storage box.
4. 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.
5. Start each day with a full fuel tank.
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.
NOTE: Check boom horizontal limit switch for proper opera-
tion and security, both visually and manually. Switch
must shut down high engine and high drive speed
when boom is raised above horizontal:
6. Check platform footswitch for proper operation.
Switch must be released to start engine and
depressed to operate machine.
7. Check that drive brakes hold when machine is
driven up a grade and stopped.
NOTE: On new machines, those recently overhauled, or
after changing hydraulic oil, operate all systems a
minimum of two complete cycles and recheck oil
level in reservoir.
8. Assure that all items requiring lubrication are serviced. Refer to Table 2-1, Lubrication Chart, for specific requirements.
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 hydraulic oil spillage and foreign objects. Ensure overall
cleanliness.
3121104 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-3. Daily Walk-Around Inspection Diagram
2-6 – JLG Lift – 3121104
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.
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. Platform Assembly - No loose or missing parts, no
visible damage. Footswitch in good working order,
not modified, disabled or blocked. Check area of fly
boom nose section above and under platform slave
level cylinder for accumulation of foreign material.
Remove any foreign material present.
2. Platform Control Console - Switches and levers
return to neutral and are properly secured, no loose
or missing parts, no visible damage, decals/placards secure and legible, control marking legible.
3. Slave Leveling Cylinder, Extend-A-Reach - Properly
secured, no visible damage, no evidence of leakage. (If equipped with Extend-A-Reach)
4. Extend-A-Reach Pivot - No loose, damaged, or
missing parts, evidence of proper lubrication. (If
equipped with Extend-A-Reach)
5. Extend-A-Reach Lift Cylinder - Properly secured, no
visible damage, or signs of leakage, evidence of
proper lubrication. (If equipped with Extend-AReach)
6. Hose and Cable Guards/Clamps - Properly
secured, no visible damage.
7. Power Track - No loose, damaged or missing parts,
no visible damage.
8. Drive Motor and Brake, Right Rear - No visible damage, no evidence of leakage.
9. Drive Hub, Right Rear - No visible damage, no evidence of leakage.
10. Wheel/Tire Assembly, Right Rear - Properly
secured, no loose or missing lug nuts, no visible
damage.
11. Swing Drive Motor and Brake - No visible damage,
no evidence of leakage.
12. Fuel Supply - Fuel filler cap secure. Tank - no visible
damage; no evidence of leaks.
13. Cowling and Latches - All cowling and latches in
working condition, properly secured, no loose or
missing part.
14. Control Valve Compartment - No loose or missing
parts; evidence of leakage; unsupported wires or
hoses; damaged or broken wires.
15. Hydraulic Oil Filter Housing - Housing secure; no
visible damage or signs of leakage.
16. Hydraulic Oil Supply - Recommended oil level in
sight gauge. (Check level with cold oil, systems
shut down, machine in stowed position) Cap in
place and secure.
17. Hydraulic Oil Breather - Element in place, not
clogged, no signs of overflow.
18. Wheel/Tire Assembly, Right Front - Properly
secured, no loose or missing lug nuts, no visible
damage.
19. Turntable Springs - Properly secured, no loose or
missing nuts or bolts.
20. Ground Controls - Switches operable, no visible
damage, decals secure and legible.
21. Tie Rod and Steering Linkage - No loose or missing
parts, no visible damage. Tie rod end studs locked.
22. Wheel/Tire Assembly, Left Front - Properly secured,
no loose or missing lug nuts, no visible damage.
23. Muffler and Exhaust System - Properly secured, no
evidence of leakage.
24. Engine Oil Supply - Full mark on dipstick; filler cap
secure.
Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1
3121104 – JLG Lift – 2-7
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. Battery - Proper electrolyte levels; cables tight, no
visible damage or corrosion.
29. Frame - No visible damage, no loose or missing
hardware (top and underside).
Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2
30. Drive Hub, Left Rear - No visible damage, no evidence of leakage.
31. Wheel/Tire Assembly, Left Rear - Properly secured,
no loose or missing lug nuts, no visible damage.
32. Drive Motor and Brake, Left Rear - No visible damage, no evidence of leakage.
33. Boom Sections - No visible damage; wear pads
secure. All cylinders - rod end shafts and barrel-end
shafts properly secured.
34. Rotator and Motor - Properly secured, no visible
damage, no evidence of leakage.
35. Platform Pivot and Slave Cylinder Attach Pins Properly secured; evidence of proper lubrication
where applicable.
2-8 – JLG Lift – 3121104
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