JLG 120-SXJ Operator Manual

4.5 (2)

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.

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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 RESULT IN SERIOUS INJURY OR DEATH. THIS

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.

INDICATES A POTENTIALITY HAZARDOUS SITUATION WHICH, IF

NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.

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 RESULT IN MINOR OR MODERATE INJURY. IT

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.

IMPORTANT

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.

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3121104

FOREWORD

ALL SAFETY-RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT. JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY-

RELATED 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

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FOREWORD

REVISION LOG

Original Issue

- April 1, 2000

Revised

- April 30, 2002

Revised

- May 30, 2002

Revised

- June 10, 2003

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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

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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

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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

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TABLE OF CONTENTS (Continued)

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1GENERAL

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, PROP-

ERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2PRE-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 temperatures of 0o F to 104o F (-20o C to 40o C). Consult JLG to optimize operation outside of this temperature range.

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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 PERMIS-

SION 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.

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.

1.3OPERATION

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.

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.

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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.

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.

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.

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.

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SECTION 1 - SAFETY PRECAUTIONS

Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)

Voltage Range

MINIMUM SAFE APPROACH

DISTANCE

(Phase to Phase)

in Feet (Meters)

 

 

 

0 to 300V

AVOID CONTACT

 

 

Over 300V to 50 KV

10 (3)

 

 

Over 50KV to 200 KV

15 (5)

 

 

Over 200 KV to 350 KV

20 (6)

 

 

Over 350 KV to 500 KV

25 (8)

 

 

Over 500 KV to 750 KV

35 (11)

 

 

Over 750 KV to 1000 KV

45 (14)

 

 

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.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB-

ITED 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.

The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving.

Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. 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.

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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.

1.4TOWING, 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.

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1-5

SECTION 1 - SAFETY PRECAUTIONS

1.5MAINTENANCE

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 PERMIS-

SION 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.

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3121104

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1GENERAL

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.

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.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-

TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2PREPARATION 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.

2.3DELIVERY AND FREQUENT INSPECTION

NOTE: This machine requires periodic safety and maintenance 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.

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.

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.

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SECTION 2 - PREPARATION AND INSPECTION

Turntable

3. Check lift cylinder and cross pins and hydraulic lines

 

for damage, wear, leakage and security.

 

1.Check turntable and turntable lock for damage, loose or missing parts, and security. Check swing drive hub, hydraulic motor, and brake for damage, loose or missing parts, hydraulic lines and component housings for evidence of leakage; pinion for proper mesh with swing gear.

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.

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 element 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

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)

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.

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.

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Figure 2-1. Machine Nomenclature - 100SX and 110SX

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Figure 2-2. Machine Nomenclature - 110SXJ and 120SXJ

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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.

Torque Requirements

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.

2.4DAILY 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.)

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.

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 A92.5- 1992 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 operation 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.

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Figure 2-3. Daily Walk-Around Inspection Diagram

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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” DUR-

ING WALK-AROUND INSPECTION.

NOTE: Do not overlook visual inspection of chassis underside. 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-A- Reach)

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

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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).

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.

Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2

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