JLG T500J Use and care manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
ANSI
®
Trailer Mounted
Boom Lift Models
T350
T500J
P/N - 3121197
May 21, 2014

FOREWORD
3121197 – JLG Lift – a
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.
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.

FOREWORD
b– JLG Lift – 3121197
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
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

FOREWORD
3121197 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
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 PER-
SONAL PROPERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Prod-
uct Modifications

FOREWORD
d– JLG Lift – 3121197
REVISION LOG
Original Issue - December 3, 2004
Revised - March 9, 2005
Revised - July 1, 2005
Revised - September 6, 2005
Revised - November 22, 2005
Revised - January 30, 2006
Revised - May 1, 2007
Revised - December 9, 2009
Revised - May 11, 2010
Revised - April 4, 2012
Revised - August 29, 2012
Revised - May 21, 2014

TABLE OF CONTENTS
3121197 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
1.2 TOWING REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 BEFORE OPERATING THE LIFT. . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . . . 1-8
1.5 LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6 TOWING HAZARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
SECTION - 3 - TOWING
3.1 GENERAL TOWING INFORMATION . . . . . . . . . . . . . . . . . . . . 3-1
3.2 COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 TOW VEHICLE AND HITCH INFORMATION . . . . . . . . . . . . . 3-1
Towing Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 COUPLING AND UNCOUPLING THE TRAILER . . . . . . . . . . 3-1
Before Coupling the Trailer to Tow Vehicle . . . . . . . . . 3-1
Tongue Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Coupler and Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tongue Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Coupling the Trailer to the Hitch . . . . . . . . . . . . . . . . . . . 3-3
Uncoupling the Trailer from the Hitch . . . . . . . . . . . . . . 3-3
Rigging Safety Chains (If equipped) . . . . . . . . . . . . . . . . 3-4
Testing Breakaway Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connect the Electrical Cables . . . . . . . . . . . . . . . . . . . . . . 3-6

TABLE OF CONTENTS
ii – JLG Lift – 3121197
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.5 ENGAGING MANUAL LOCKOUT LEVER . . . . . . . . . . . . . . . . 3-7
3.6 TRAILER MANEUVERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.7 TOWING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.8 PRE-TOW INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
SECTION - 4 - MACHINE CONTROLS AND INDICATORS
4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SECTION - 5 - MACHINE OPERATION
5.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 ENGINE OPERATION (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 5-6
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fuel Valve Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4 OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
From the Ground Console . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
From the Platform Console (Drive & Set Only) . . . . . . 5-8
5.5 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Platform Rotation (If Equipped) . . . . . . . . . . . . . . . . . . . . 5-8
5.6 BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . . 5-9
Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.7 JIB LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.8 USER FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . . . 5-14
5.11 PLATFORM REMOVAL & INSTALLATION. . . . . . . . . . . . . . 5-15
5.12 MATERIAL HOOK INSTALLATION . . . . . . . . . . . . . . . . . . . . 5-16
5.13 MATERIAL HOOK OPERATING PRECAUTIONS . . . . . . . . 5-17
5.14 ACCESSORY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.15 PANEL TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.16 DRIVE & SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
To Set Up The Machine for Drive & Set Operation: . 5-20
To Prepare the Machine For Towing After Drive & Set
Operation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

TABLE OF CONTENTS
3121197 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.17 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.18 TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine . . . . . . . . . . . . . . . 6-1
Platform or Boom Caught Overhead. . . . . . . . . . . . . . . . 6-2
6.4 MANUAL DESCENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lift Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Telescope In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Telescope Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Platform Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fluid Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Electric Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Taillight and Marker Light Bulb Information
(ANSI Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Batteries (Electric Machines) . . . . . . . . . . . . . . . . . . . . . . . 7-5
Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Glossary of Tire and Loading Terminology . . . . . . . . 7-15
Basic Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Tire Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Tire Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Tire Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Lug Nuts (Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Unsealed Wheel Bearings (Hubs) . . . . . . . . . . . . . . . . . 7-22
7.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-22
SECTION - 8 - INSPECTION AND REPAIR LOG

TABLE OF CONTENTS
iv – JLG Lift – 3121197
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . 2-8
2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . 2-9
2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . 2-10
3-1. Pre-Tow Inspection - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . 3-10
3-2. Pre-Tow Inspection - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . 3-11
4-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2. Platform Control Console - Standard Machine . . . . . . . . 4-7
4-3. Platform Control Console w/Drive & Set Option. . . . . . . 4-8
5-1. Position of Least Forward Stability (T350) . . . . . . . . . . . . . 5-2
5-2. Position of Least Backward Stability (T350) . . . . . . . . . . . 5-3
5-3. Position of Least Forward Stability (T500J) . . . . . . . . . . . . 5-4
5-4. Position of Least Backward Stability (T500J). . . . . . . . . . . 5-5
5-5. Generator Plug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-6. Panel Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-7. Grade and Sideslope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-8. Lifting and Tie Down Chart Prior to S/N 0030000864 . 5-28
5-9. Lifting and Tie Down Chart S/N 0030000864 to
Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-10. Decal Location - ANSI (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 5-30
5-11. Decal Location - ANSI (Sheet 2 of 2) . . . . . . . . . . . . . . . . . 5-31
5-12. Decal Location - CE & Australia (Sheet 1 of 2). . . . . . . . . 5-34
5-13. Decal Location - CE & Australia (Sheet 2 of 2). . . . . . . . . 5-35
5-14. Decal Location - Country Specs (Sheet 1 of 2) . . . . . . . . 5-38
5-15. Decal Location - Country Specs (Sheet 2 of 2) . . . . . . . . 5-39
7-1. Operator Maintenance & Lubrication Diagram . . . . . . . . 7-8
7-2. Information on Tires - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . 7-18
7-3. Information on Tires - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . 7-19

TABLE OF CONTENTS
3121197 – JLG Lift – v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . .1-10
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
5-1 User Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-10 Battery Charger Fault Codes (Delta-Q) . . . . . . . . . . . . . . .5-14
5-2 Decal Legend (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
5-3 Decal Legend - CE & Australia. . . . . . . . . . . . . . . . . . . . . . . .5-36
5-4 Decal Legend - Country Specs . . . . . . . . . . . . . . . . . . . . . . .5-40
7-1 Operating & Towing Specifications . . . . . . . . . . . . . . . . . . . 7-1
7-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4 Electric Power Unit Specifications. . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Taillight and Marker Light Bulb Information. . . . . . . . . . . 7-4
7-6 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-8 Engine Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10 Component Weights - T350 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 Component Weights - T500J . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-14 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-15 Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7-16 Wheel Torque Chart - ANSI . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
7-17 Wheel Torque Chart - T350 CE . . . . . . . . . . . . . . . . . . . . . . .7-21
7-18 Wheel Torque Chart - T500J CE . . . . . . . . . . . . . . . . . . . . . .7-21
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

TABLE OF CONTENTS
vi – JLG Lift – 3121197
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SECTION 1 - SAFETY
3121197 – JLG Lift – 1-1
SECTION 1. SAFETY
1.1 GENERAL
This section outlines the necessary precautions for towing and
also proper and safe machine operation and maintenance. For
proper machine use, it is mandatory that a daily routine is estab-
lished based on the content of this manual. A maintenance pro-
gram, using the information provided in this manual and the
Service and Maintenance Manual, must also be established by a
qualified person and followed to ensure the machine is safe to
operate.
An owner’s manual that provides general trailer information can-
not cover all of the specific details necessary for the proper com-
bination of every trailer, tow vehicle and hitch. Therefore, you
must read, understand and follow the instructions given by the
tow vehicle and trailer hitch manufacturers, as well as the instruc-
tions in this manual.
The owner/user/operator/lessor/lessee of the machine should
not operate the machine until this manual has been read, training
is accomplished, and operation of the machine has been com-
pleted under the supervision of an experienced and qualified
operator.
If there are any questions with regard to safety, training, inspec-
tion, 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.
Operator Training and Knowledge
• Read and understand this manual before towing or operating
the machine.
• Do not tow or operate this machine until complete training is
performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.

SECTION 1 - SAFETY
1-2 – JLG Lift – 3121197
• Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, and operating instructions on the machine and in this
manual.
• Use the machine in a manner which is within the scope of its
intended application set 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 towing and oper-
ation of the machine.
1.2 TOWING REGULATIONS
There are local and national regulations (height, width, brakes
etc.) that must be followed by the owner and operator. It is the
responsibility of the trailer mounted boom lift owner and opera-
tor to determine which regulations apply and to comply with
these requirements.
1.3 BEFORE OPERATING THE LIFT
Workplace Inspection
• The operator is to take safety measures to avoid all hazards in
the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers,
railway cars, floating vessels, scaffolds or other equipment
unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the machine.
Machine Inspection
• Before machine operation, perform inspections and functional
checks. Refer to Section 2 of this manual for detailed instruc-
tions.

SECTION 1 - SAFETY
3121197 – JLG Lift – 1-3
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the Service
and Maintenance Manual.
• Be sure the enable trigger 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 WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which 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 any buildup of debris on the platform floor. Keep mud,
oil, grease, and other slippery substances from footwear and
platform floor.
1.4 OPERATION
General
• Do not use the machine for any purpose other than position-
ing personnel, their tools, and equipment unless using the
optional JLG Material Hook attachment.
• Never operate a machine that is not working properly. If a mal-
functions occurs, shut down the machine.
• 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 con-
trols with slow and even pressure.
• Hydraulic cylinders should never be left fully extended for
long periods of time.
• 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.

SECTION 1 - SAFETY
1-4 – JLG Lift – 3121197
• Always ensure that power tools are properly stowed and never
left hanging by their cord from the platform work area.
• Supplies or tools which extend outside the platform are pro-
hibited unless approved by JLG.
• 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.
Trip and Fall Hazards
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard anchor-
age point.
• Before operating the machine, make sure all gates are closed
and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Do not climb on platform rails. Never use ladders, boxes,
steps, planks, or similar items on platform to provide addi-
tional reach.
• Never use the boom assembly or the trailer structure to enter
or leave the platform.
• Use extreme caution when entering or leaving platform. Be
sure that the boom is telescoped out and fully lowered. Face
the machine, maintain “three point contact” with the machine,
using two hands and one foot or two feet and one hand dur-
ing entry and exit.

SECTION 1 - SAFETY
3121197 – JLG Lift – 1-5
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
• Maintain safe distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the Mini-
mum Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.

SECTION 1 - SAFETY
1-6 – JLG Lift – 3121197
• 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.
• The minimum approach distance may be reduced if insulating
barriers are installed to prevent contact, and the barriers are rated
for the voltage of the line being guarded. These barriers shall not
be part of (or attached to) the machine. The minimum approach
distance shall be reduced to a distance within the designed work-
ing dimensions of the insulating barrier. This determination shall
be made by a qualified person in accordance with the employer,
local, or governmental requirements for work practices near
energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MSAD).
ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-
ERWISE.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0to50KV 10(3)
Over50KVto200KV 15(5)
Over200KVto350KV 20(6)
Over350KVto500KV 25(8)
Over500KVto750KV 35(11)
Over750KVto1000KV 45(14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.

SECTION 1 - SAFETY
3121197 – JLG Lift – 1-7
Tipping Hazards
• The user should be familiar with the surface before operating.
Do not exceed the allowable sideslope and grade while oper-
ating.
• Do not elevate platform while on a soft surface.
• Before operating on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
• Do not raise the platform unless the machine is on firm sur-
faces and outriggers are properly set.
• Keep the chassis and outriggers of the machine at least 2 ft.
(0.6m) from holes, bumps, drop-offs, obstructions, debris, con-
cealed holes, and other potential hazards on the floor/surface.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane with platform
attached. Do not tie-off machine to any adjacent structure.
• Do not operate the machine when wind conditions exceed 28
mph (12.5 m/s).
• Do not increase the surface area of the platform or the load.
Increase of the area exposed to the wind will decrease stability
and could result in a tip-over.
• Do not increase the platform size with unauthorized platform
extensions or attachments.
• If boom assembly or platform is in a position that one or more
outriggers are off the ground, all persons must be removed
before attempting to stabilize the machine. Use cranes, forklift
trucks, or other appropriate equipment to stabilize machine.

SECTION 1 - SAFETY
1-8 – JLG Lift – 3121197
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and bot-
tom of platform when lifting or lowering platform, and driving.
• During operation, keep all body parts inside platform railing.
• 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 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 caus-
ing hazards of collision or injury to personnel.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Dis-
connect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if necessary.