JLG 100HX, Operators & Safety

Page 1: ...ralia Telephone 065 811111 Fax 065 810122 EUROPEAN OFFICE JLG INDUSTRIES EUROPE Kilmartin Place Tannochside Park Uddingston Scotland G71 5PH Telephone 01698 811005 Main Fax 01698 811055 Parts Fax 0169...

Page 2: ...Courtesy of Crane Market...

Page 3: ...AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITI...

Page 4: ...FOREWORD b JLG Lift 3120889 This page left blank intentionally Courtesy of Crane Market...

Page 5: ...their function 4 The controls shall be tested each day prior to use to determine that they are in safe operating condition 5 All personnel in the platform shall at all times wear approved fall protec...

Page 6: ...FOREWORD d JLG Lift 3120889 REVISON LOG January 1999 Original Issue Courtesy of Crane Market...

Page 7: ...onnel Training 3 1 3 3 Operating Characteristics and Limitations 3 2 3 4 Controls and Indicators 3 6 3 5 Placards and Decals 3 19 SECTION 4 MACHINE OPERATION 4 1 Description 4 1 4 2 General 4 1 4 3 En...

Page 8: ...10HX 3 4 3 3 Position of Least Backward Stability 100HX 10 3 5 3 4 Ground Control Station Dual Capacity Only 100HX and 110HX Prior to January 1992 3 7 3 5 Ground Control Station Single Capacity Only 1...

Page 9: ...TENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distances M S A D to energized exposed or insulated power lines and parts 1 2 1 1 Lubrication Chart 2 10 7 1 Inspection and Repair...

Page 10: ...iv JLG Lift 3120889 TABLE OF CONTENTS Continued This page left blank intentionally Courtesy of Crane Market...

Page 11: ...on and or operation JLG Industries Inc should be consulted MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF THE MANUFACTURER 1 2 DRIVING TOWING Befo...

Page 12: ...VOLTS OR LESS 1 4 PRE OPERATIONAL READ YOUR MANUAL UNDERSTAND WHAT YOU VE READ THEN BEGIN OPERATIONS ALLOW ONLY AUTHORIZED AND QUALIFIED PER SONNEL TO OPERATE MACHINE WHO HAVE DEM ONSTRATED THAT THEY...

Page 13: ...NTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION NEVER DISABLE OR MODIFY THE FOOTSWITC...

Page 14: ...AYS POSITION BOOM OVER REAR DRIVE AXLE IN LINE WITH DIRECTION OF TRAVEL REMEMBER IF BOOM IS OVER FRONT STEER AXLE DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPO SITE FROM NORMAL OPERATION DO NOT U...

Page 15: ...YOU VE READ THEN BEGIN OPERATIONS PRIOR TO ENTERING AND EXITING PLATFORM AT GROUND LEVEL FULLY LOWER THE BOOM EXTEND BOOM UNTIL END OF FLY BOOM CON TACTS GROUND WITH BOOM LIFT IN THIS CONFIG URATION...

Page 16: ...AREA OF THE MACHINE NEVER POSITION LADDERS STEPS OR SIMILAR ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH FOR ANY PURPOSE WHEN RIDING IN OR WORKING FROM PLATFORM BOTH FEET MUST BE FIRMLY POSITIONED ON THE...

Page 17: ...IRED POSITION OPERATE LEVERS WITH SLOW EVEN PRESSURE DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC NEVER PUSH OR PULL THE MACHINE OR OTHER OBJECTS BY TELESCOPING THE...

Page 18: ...TRACTED FOR ANY LENGTH OF TIME ALWAYS BUMP CONTROL IN OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION BEING USED REACHES END OF TRAVEL THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE DO NOT OPERATE...

Page 19: ...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 improp...

Page 20: ...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...

Page 21: ...SECTION 2 PREPARATION AND INSPECTION 3120889 JLG Lift 2 3 Figure 2 1 Machine Nomenclature Courtesy of Crane Market...

Page 22: ...or 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...

Page 23: ...SECTION 2 PREPARATION AND INSPECTION 3120889 JLG Lift 2 5 Figure 2 2 Daily Walk Around Inspection Diagram Courtesy of Crane Market...

Page 24: ...ge 7 Power Track No loose damaged or missing parts no visible damage 8 Drive Motor and Brake Right Rear No visible dam age no evidence of leakage 9 Drive Hub Right Rear No visible damage no evi dence...

Page 25: ...n 31 Frame No visible damage no loose or missing hardware top and underside 32 Drive Hub Left Rear No visible damage no evi dence of leakage 33 Wheel Tire Assembly Left Rear Properly secured no loose...

Page 26: ...rom the ground it may be nec essary to feather the lift control to maintain drive wheel elevation e With the aid of an assistant position EXTEND ABLE AXLE STEER switch located on platform control cons...

Page 27: ...SECTION 2 PREPARATION AND INSPECTION 3120889 JLG Lift 2 9 Figure 2 5 Lubrication Point Location Courtesy of Crane Market...

Page 28: ...ingEach MPG PressureGun 150 14 Drive Hubs FillPlug EPGL SAE90 150 1200 Checkevery150hrs Changeevery1200hrs 15 Swing Bearing Gear N A MPG Brush 150 16 Swing Bearing 1GreaseFitting MPG PressureGun 150 1...

Page 29: ...ed marking band on the inner mid section is exposed from the base section The red light should illuminate at this point c Continue extending the boom until the white marking band on the inner mid sect...

Page 30: ...illuminate shut down machine and contact a qualified service technician before continuing operation 14 Footswitch FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY...

Page 31: ...per service per sonnel can be notified The Service and Maintenance manual provides specific torque values and periodic maintenance procedures with a listing of individual com ponents Utilizing this To...

Page 32: ...4623 0 3604 0 2700 0 1969 0 1331 0 0925 0 0508 0 0808 0 0445 0 0356 0 0232 0 0153 0 0374 0 0258 0 0168 2 7254 2 1742 1 6840 1 2929 0 9474 0 6502 0 5156 0 4061 0 3015 0 2230 0 1473 3 1750 2 8575 2 5400...

Page 33: ...rgency controls and safety systems 2 Knowledge and understanding of this manual and of the control markings instructions and warnings on the machine itself 3 Knowledge and understanding of all safety...

Page 34: ...ove horizontal and or the extension of the boom beyond the retracted position with or without any load in the platform is based on the following criteria 1 Machine is positioned on a smooth firm and l...

Page 35: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 3 Figure 3 1 Position of Least Forward Stability Courtesy of Crane Market...

Page 36: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 4 JLG Lift 3120889 Figure 3 2 Position of Least Backward Stability 100HX and 110HX Courtesy of Crane Market...

Page 37: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 5 Figure 3 3 Position of Least Backward Stability 100HX 10 Courtesy of Crane Market...

Page 38: ...HES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED 3 Ignition Switch The machine is equipped with an on off ignition switch and a separate start push button switch on th...

Page 39: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 7 Figure 3 4 Ground Control Station Dual Capacity Only 100HX and 110HX Prior to January 1992 Courtesy of Crane Market...

Page 40: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 8 JLG Lift 3120889 Figure 3 5 Ground Control Station Single Capacity Only 100HX 10 Prior to January 1992 Courtesy of Crane Market...

Page 41: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 9 Figure 3 6 Ground Control Station 100HX and 110HX January 1992 to Present Courtesy of Crane Market...

Page 42: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 10 JLG Lift 3120889 Figure 3 7 Ground Control Station 100HX 10 January 1992 to Present Courtesy of Crane Market...

Page 43: ...ons will operate at a slower than normal rate due to the lower amount of hydraulic flow provided 10 Glow Plug Switch Diesel Engine Only The push button switch relays power to the glow plugs used to wa...

Page 44: ...s used in con juction with the Load Management Test Switch for checking the Load Management System The switch is used to reset the system during the checking pro cedure Platform Station NOTE For engin...

Page 45: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 13 Figure 3 8 Platform Station 100HX and 110HX Prior to Sept 1991 Courtesy of Crane Market...

Page 46: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 14 JLG Lift 3120889 Figure 3 9 Platform Station 100HX 10 Prior to Sept 1991 Courtesy of Crane Market...

Page 47: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 15 Figure 3 10 Platform Station 100HX and 110HX Sept 1991 to Present Courtesy of Crane Market...

Page 48: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 16 JLG Lift 3120889 Figure 3 11 Platform Station 100HX 10 Sept 1991 to Present Courtesy of Crane Market...

Page 49: ...ues to operate at a lower speed DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED HIGH WHEEL MOTOR SPEED OR HIGH PUMP VOLUME OPERATE WHEN BOOM IS ABOVE HORIZONTAL 10 High Engine The two position HIGH ENGINE...

Page 50: ...Set Indicator If equipped The green AXLES SET indicator lights to inform the operator that the axles are set and locked pinned in position 21 Lights Switch If equipped The LIGHTS switch allows the op...

Page 51: ...llegible Decals are made of Lexan Pressure Sensitive Adhesive with a protective film on the front Remove the damaged decal and thoroughly clean the surface before installing a new decal Simply peel of...

Page 52: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 20 JLG Lift 3120889 Figure 3 12 Caution Danger Warning Decal Location Sheet 1 of 2 Courtesy of Crane Market...

Page 53: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 21 Figure 3 13 Caution Danger Warning Decal Location Sheet 2 of 2 Courtesy of Crane Market...

Page 54: ...DBOOK TO ENSURE SAFE OPERATION OF THE MACHINE CAUTION 1690696 1690697 B MAX 12 5 m s MAX FORCE 400N 2 PERSONS 70KG SWL 230KG THIS MACHINE MUST ONLY BE OPERATED BY TRAINED PERSONNEL REFERENCES SHOULD B...

Page 55: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 23 Figure 3 14 Common Symbols Sheet 1 Courtesy of Crane Market...

Page 56: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 24 JLG Lift 3120889 Figure 3 15 Common Symbols Sheet 2 Courtesy of Crane Market...

Page 57: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120889 JLG Lift 3 25 Figure 3 16 Common Symbols Sheet 3 Courtesy of Crane Market...

Page 58: ...SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 26 JLG Lift 3120889 Figure 3 17 Common Symbols Sheet 4 Courtesy of Crane Market...

Page 59: ...t of service until all discrepancies are corrected The JLG Lift is not intended to be used to lift material other than supplies which personnel in the platform require to do their job Supplies or tool...

Page 60: ...p position before starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE THE MACHINE Shutdown Procedure IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHU...

Page 61: ...ate the following switches a Position HIGH ENGINE switch to HIGH b Position WHEEL MOTOR SPEED switch to HIGH c Position PUMP VOLUME switch to HIGH 5 Prior to stopping the machine position switches as...

Page 62: ...EVEL control switch to DOWN and hold until platform is level Platform Rotation 1 Depress footswitch to rotate platform to the left PLATFORM ROTATE control is positioned to the LEFT and held until desi...

Page 63: ...g the steer control for removal of lock pins d Position the LIFT control to DOWN and hold until the steer wheels rise from the ground it may be necessary to feather the LIFT control to maintain wheel...

Page 64: ...b If retracting the drive axles remove the axle lock pins If retracting the steer axles remove the tie rod lock pins steer cylinder pin and axle lock pins NOTE It may be necessary to elevate the wheel...

Page 65: ...SECTION 4 MACHINE OPERATION 3120889 JLG Lift 4 7 Figure 4 3 Lifting Chart 100HX and 110HX Courtesy of Crane Market...

Page 66: ...SECTION 4 MACHINE OPERATION 4 8 JLG Lift 3120889 Figure 4 4 Lifting Chart 100HX 10 Courtesy of Crane Market...

Page 67: ...FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE Swinging the Boom ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTING ANY SWING OPERATION 1 Depress footswitch to swing boom position SWI...

Page 68: ...MAGE THE MACHINE A push pull type selector valve located adjacent to the steer cylinder assembly and linkage regulates oil flow in the steer circuit for steering and towing applications When steering...

Page 69: ...SECTION 4 MACHINE OPERATION 3120889 JLG Lift 4 11 Figure 4 5 Machine Tie Down Courtesy of Crane Market...

Page 70: ...steer tow selector valve for steering push valve knob IN to the actuated position 2 Reconnect drive hubs by inverting disconnect cap See Figure 4 5 3 Disconnect towbar from steering hitch and from tow...

Page 71: ...s engine begins to stumble place the switch to LP position allowing LP gas to flow to the fuel regulator Changing From LP Gas to Gasoline 1 With engine operating on LP under a no load condi tion posit...

Page 72: ...oom wipers cylinder bellows heavy duty air cleaner console cover and air breather described in the Hostile Environment package in this section In addition to these items a hydraulic oil cooler fitted...

Page 73: ...side of the turntable The controls on this panel provide the means for overriding the platform controls and for controlling the platform level boom and swing functions from the ground Place the SELECT...

Page 74: ...ved to a secure location Only then should an attempt be made to free the platform using any necessary equipment and per sonnel Do not operate controls to cause one or more wheels to leave the ground R...

Page 75: ...SECTION 7 INSPECTION AND REPAIR LOG 3120889 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments Courtesy of Crane Market...

Page 76: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3120889 Table 7 1 Inspection and Repair Log Date Comments Courtesy of Crane Market...

Page 77: ...o the current ownership of JLG Products Please return completed form to the JLG Product Safety Reliability Department via facsimile 717 485 6573 or mail to address as specified on the back of this for...

Page 78: ...Courtesy of Crane Market...

Page 79: ...Courtesy of Crane Market...

Page 80: ...Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industrie...