Jlg 120HX ANSI Operator Manual User Manual

Operators and Safety ManualANSIModel120HX3120685April 20, 2000

SECTION 1 - SAFETY PRECAUTIONS1-2 – JLG Lift – 31206851.3 ELECTROCUTION HAZARD• MAINTAIN SAFE CLEARANCE FROM ELECTRICALLINES AND APPARATUS. ALLOW FOR

SECTION 1 - SAFETY PRECAUTIONS3120685 – JLG Lift – 1-3• AN OPERATOR MUST NOT ACCEPT OPERATINGRESPONSIBILITIES UNTIL ADEQUATE TRAINING HASBEEN GIVEN BY

SECTION 1 - SAFETY PRECAUTIONS1-4 – JLG Lift – 3120685.• READ AND OBEY ALL DANGERS, WARNINGS, CAU-TIONS AND OPERATING INSTRUCTIONS ONMACHINE AND IN TH

SECTION 1 - SAFETY PRECAUTIONS3120685 – JLG Lift – 1-5• CHECK TRAVEL PATH FOR PERSONS, HOLES,BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS,AND COVERINGS WHIC

SECTION 1 - SAFETY PRECAUTIONS1-6 – JLG Lift – 3120685• TRANSFERS BETWEEN A STRUCTURE AND THEAERIAL PLATFORM EXPOSE OPERATORS TO FALLHAZARDS. THIS PRA

SECTION 1 - SAFETY PRECAUTIONS3120685 – JLG Lift – 1-7.• ENSURE MACHINE IS POSITIONED ON A FIRM,LEVEL AND UNIFORM SUPPORTING SURFACEBEFORE RAISING OR

SECTION 1 - SAFETY PRECAUTIONS1-8 – JLG Lift – 3120685• NEVER ATTEMPT TO FREE A MACHINE STUCK INSOFT GROUND OR ASSIST A MACHINE UP A STEEPHILL OR RAMP

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-1SECTION 2. PREPARATION AND INSPECTION2.1 GENERALThis section provides the necessary inf

SECTION 2 - PREPARATION AND INSPECTION2-2 – JLG Lift – 3120685Turntable1. Check turntable and turntable lock for damage,loose or missing parts, and se

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-3DRIVE/STEERWHEELSPLATFORMPLATFORMCONTROLBOXFLY BOOMOUTER MID BOOMFOOTSWITCHEXTEND-A-REAC

– JLG Lift –

SECTION 2 - PREPARATION AND INSPECTION2-4 – JLG Lift – 3120685Platform1. Check platform and control console for damage,loose or missing parts, and sec

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-55. Start each day with a full fuel tank.TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL

SECTION 2 - PREPARATION AND INSPECTION2-6 – JLG Lift – 312068512678945311121314151620212223242526272829303132333435363717, 18, 1910Figure 2-2. Daily

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-7GENERALBegin the “Walk-Around Inspection” at Item 1, as notedon the diagram. Continue to

SECTION 2 - PREPARATION AND INSPECTION2-8 – JLG Lift – 312068526. Engine Oil Supply - Full mark on dipstick; filler capsecure.27. Muffler and Exhaust

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-92.5 DAILY FUNCTIONAL CHECKTHE LOAD MANAGEMENT SYSTEM AND THE AXLES (PROPEREXTENSION AND

SECTION 2 - PREPARATION AND INSPECTION2-10 – JLG Lift – 3120685NoteThe lubrication intervals in thischart are equivalent to the following:150 hours =

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-11Figure 2-3. Lubrication Chart (Sheet 2 of 2)1234567891011121314151617181920212223242526

SECTION 2 - PREPARATION AND INSPECTION2-12 – JLG Lift – 31206856. Check platform rotator for smooth operation andassure platform will rotate 90 degree

SECTION 2 - PREPARATION AND INSPECTION3120685 – JLG Lift – 2-132.7 BATTERY MAINTENANCETO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE ORALLOW SPARKS O

FOREWORD3120685 – JLG Lift – a FOREWORDDANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATIONWHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY ORDEATH

SECTION 2 - PREPARATION AND INSPECTION2-14 – JLG Lift – 3120685Figure 2-4. Torque Chart

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-1SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL3.1 GENERALSINCE THE

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-2 – JLG Lift – 31206853.3 OPERATING CHARACTERISTICS AND LIMITATIONSGeneralA thorough knowledge

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-3Figure 3-1. Position of Least Forward Stability

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-4 – JLG Lift – 312068576°Boom fully retracted and elevated toapproximately 76°, with extend-a-r

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-53.4 CONTROLS AND INDICATORSPrecision Control GovernorThis control allows

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-6 – JLG Lift – 3120685Figure 3-3. Ground Control Station - Prior to May 1994

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-7Figure 3-4. Ground Control Station - May 1994 to Present

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-8 – JLG Lift – 31206856. Lift Control (Extend-A-Reach).A three-position EXTEND-A-REACH lift con

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-9Axle Extension/Axle Jacks Control.NOTE: The boom must be fully retracted

FOREWORDb – JLG Lift – 3120685This page left blank intentionally.

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-10 – JLG Lift – 3120685EMERG. STOPPUSH DOWNSTEERLEFTFWDREVDRIVE DRIVEPLATFORM SHALL NOT BEOCCUP

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-11Platform Station.NOTE: For engine starting, the footswitch must be in th

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-12 – JLG Lift – 3120685Figure 3-7. Platform Station - Prior to May 1994

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-13Figure 3-8. Platform Station - May 1994 to Present

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-14 – JLG Lift – 312068512. Platform Level.The PLATFORM LEVEL control switch allows theoperator

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-153.5 PLACARDS AND DECALSRead and understand all placards and decals. Do n

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-16 – JLG Lift – 3120685Figure 3-9. Caution Decal Location - Sheet 1

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-17Figure 3-10. Caution Decal Location - Sheet 2

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-18 – JLG Lift – 3120685

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-19

FOREWORD3120685 – JLG Lift – cAll procedures herein are based on the use of themachine under proper operating conditions, with nodeviations from ori

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-20 – JLG Lift – 3120685FUNCTIONAUXILIARYPOWERFUELL.P. - GASPLATFORMCONTROLGROUNDCONTROLHIGH ENG

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3120685 – JLG Lift – 3-21FUNCTIONMAXIMUM SPEEDMINIMUM TORQUEMINIMUM SPEEDMAXIMUM TORQUEOFFSWINGPL

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL3-22 – JLG Lift – 3120685This page left blank intentionally.

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-1SECTION 4. MACHINE OPERATION4.1 DESCRIPTIONThis machine is a self-propelled aerial work platform

SECTION 4 - MACHINE OPERATION4-2 – JLG Lift – 31206854.3 ENGINE OPERATIONNOTE: Initial starting should always be performed from theGround Control stat

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-34.5 AXLESNOTE: To extend or retract jacks or to extend or retract theaxles, the boom must be belo

SECTION 4 - MACHINE OPERATION4-4 – JLG Lift – 3120685Figure 4-1. Spindle Stop Pin Usage

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-54.6 PARKING AND STOWINGPark and stow machine as follows:1. Park machine in travel position; boom

SECTION 4 - MACHINE OPERATION4-6 – JLG Lift – 31206854.8 BOOMA RED TILT ALARM WARNING LIGHT, LOCATED ON THE CON-TROL CONSOLE, LIGHTS WHEN THE CHASSIS

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-74. Remove all load and allow engine to operate 3-5minutes at LOW setting to permit reduction ofen

FOREWORDd – JLG Lift – 3120685REVISON LOGJune 1992 - Original IssueSeptember, 1997 - RevisedNovember, 1997 - RevisedMarch 1, 1999 - RevisedApril 11,

SECTION 4 - MACHINE OPERATION4-8 – JLG Lift – 3120685When transporting the machine over rough terrain or longdistances, the boom needs to be chocked a

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-9Figure 4-4. Machine Tie Down - Sheet 2

SECTION 4 - MACHINE OPERATION4-10 – JLG Lift – 3120685Figure 4-5. Machine Tie Down - Sheet 3

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-11Figure 4-6. Machine Tie Down - Sheet 4

SECTION 4 - MACHINE OPERATION4-12 – JLG Lift – 3120685SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAV-ELING LONG DISTANCES OR HAULING MACHINE ON TRUC

SECTION 4 - MACHINE OPERATION3120685 – JLG Lift – 4-13Figure 4-8. Swing-Away Jib

SECTION 4 - MACHINE OPERATION4-14 – JLG Lift – 3120685

SECTION 5 - OPTIONAL EQUIPMENT3120685 – JLG Lift – 5-1SECTION 5. OPTIONAL EQUIPMENT5.1 COLD START KIT (DIESEL ENGINE)A cold weather start system for

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SECTION 6 - EMERGENCY PROCEDURES3120685 – JLG Lift – 6-1SECTION 6. EMERGENCY PROCEDURES6.1 GENERALThis section provides information on the procedures

3120685 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION - FOREWORDSECTION 1 - SAFETY PRE

SECTION 6 - EMERGENCY PROCEDURES6-2 – JLG Lift – 3120685Ground Control StationThe Ground Control Station is located on the right frontside of the turn

SECTION 6 - EMERGENCY PROCEDURES3120685 – JLG Lift – 6-3Righting a Tipped MachineNo attempt should be made to right the machine usingplatform or groun

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SECTION 7 - INSPECTION AND REPAIR LOG3120685 – JLG Lift – 7-1SECTION 7. INSPECTION AND REPAIR LOGTable 7-1.Inspection and Repair LogDate Comments

SECTION 7 - INSPECTION AND REPAIR LOG7-2 – JLG Lift – 3120685Table 7-1.Inspection and Repair LogDate Comments

To: JLG, Gradall, Lull and Sky Trak product owner:If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would l

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

ii – JLG Lift – 3120685TABLE OF CONTENTS(Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.6.3 Emergency Controls and

SECTION 1 - SAFETY PRECAUTIONS3120685 – JLG Lift – 1-1SECTION 1. SAFETY PRECAUTIONS1.1 GENERALThis section prescribes the proper and safe practices f