JLG 400SJ Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
400S
460SJ
3121216
May 25, 2012

FOREWORD
3121216 – 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 – 3121216
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 BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
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 INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-
TECTION 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
3121216 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION 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 PERSONAL PROP-
ERTY 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: Pr[email protected]
For:
• Accident Reporting
•ProductSafety
Publications
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding
Special Product Applica-
tions
• Questions Regarding
Product Modifications

FOREWORD
d– JLG Lift – 3121216
REVISION LOG
Original Issue - June 8, 2005
Revised - October 14, 2005
Revised - February 8, 2006
Revised - May 24, 2006
Revised - July 31, 2007
Revised - October 8, 2008
Revised - November 5, 2009
Revised - October 6, 2011
Revised - May 25, 2012

TABLE OF CONTENTS
3121216 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . 1-7
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-
RATION, 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 . . . . . . . . . . . . . . . . . . . . . . 2-5
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Walk-Around inspection . . . . . . . . . . . . . . . . . . . 2-9
2.3 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1
Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ground Control Indicator Panel . . . . . . . . . . . . . 3-7
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Platform Control Indicator Panel . . . . . . . . . . . . 3-16
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-4
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5
Traveling Forward or Reverse . . . . . . . . . . . . . . . 4-8

TABLE OF CONTENTS
ii – JLG Lift – 3121216
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-9
4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Loading from Ground Level. . . . . . . . . . . . . . . . 4-9
Loading From Positions Above Ground Level . 4-9
Platform Level Adjustment . . . . . . . . . . . . . . . . 4-10
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-11
Raising and Lowering the Main Boom . . . . . . 4-11
Telescoping the Main Boom . . . . . . . . . . . . . . 4-11
4.9 AUXILIARY POWER - NON ADE EQUIPPED
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Activating from the Platform Control Station . . 4-12
Activating from the Ground Control Station . . 4-12
4.10 AUXILIARY POWER - ADE EQUIPPED
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Activating from the Platform Control Station . . 4-13
Activating from the Ground Control Station . . 4-13
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . .4-14
4.12 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-14
4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4.14 PLACARDS AND DECALS . . . . . . . . . . . . . . . . . . .4-19
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1
Operator Unable to Control Machine . . . . . . . . . 5-1
Platform or Boom Caught Overhead . . . . . . . . . 5-2
5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . .5-2
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-12
Serial Number Location . . . . . . . . . . . . . . . . . . 6-13

TABLE OF CONTENTS
3121216 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-25
6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-31
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-32
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-32
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-33
6.5 DRAINING OIL BUILD UP FROM THE
PROPANE REGULATOR (PRIOR TO
S/N 0300109274) . . . . . . . . . . . . . . . . . . . . . . . . .6-34
6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-38
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-38
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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. Ground Control Station - S Models . . . . . . . . . . . . 3-3
3-2. Ground Control Station - SJ Models . . . . . . . . . . . 3-4
3-3. Ground Control Indicator Panel
(Prior to S/N 93233) . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-4. Ground Control Indicator Panel
(S/N 93233 to Present) . . . . . . . . . . . . . . . . . . . . . 3-8
3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-11
3-6. Platform Control Console - w/Drive Orientation . . 3-12
3-7. Platform Control Indicator Panel . . . . . . . . . . . . . 3-17
3-8. Platform Control Indicator Panel - w/Drive
Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
4-1. Position Of Least Backward Stability . . . . . . . . . . . 4-2
4-2. Position Of Least Forward Stability . . . . . . . . . . . . 4-3
4-3. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. Machine Tie Down - 400S Models . . . . . . . . . . . . 4-15
4-5. Machine Tie Down - 460SJ Models . . . . . . . . . . . 4-16
4-6. Lifting and Tie Down . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-7. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-18
4-8. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . 4-20
4-9. Decal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . 4-21

TABLE OF CONTENTS
iv – JLG Lift – 3121216
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4-10. Decal Installation - Sheet 3 of 4. . . . . . . . . . . . . . . 4-22
4-11. Decal Installation - Sheet 4 of 4. . . . . . . . . . . . . . . 4-23
6-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . 6-13
6-2. Engine Operating Temperature Specifications -
Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-3. Engine Operating Temperature Specifications -
Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-4. Engine Operating Temperature Specifications -
Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5. Engine Operating Temperature Specifications -
Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-6. Engine Operating Temperature Specifications -
Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18
6-7. Engine Operating Temperature Specifications -
Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19
6-8. Engine Operating Temperature Specifications -
GM - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-9. Engine Operating Temperature Specifications -
GM - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-10. Engine Operating Temperature Specifications -
Perkins - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . 6-22
6-11. Engine Operating Temperature Specifications -
Perkins - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . 6-23
6-12. Operator Maintenance and Lubrication Diagram . 6-24
6-13. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-37
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10
2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3
4-1 Decals - 400S with 500 lb (227 or 230 kg)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-2 Decals - 400S with 750 lb (340 kg) Capacity . . . . 4-28
4-3 Decals - 460SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
6-1 Operating Specifications - 400S - Prior to S/N
0300142870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Operating Specifications - 400S - S/N 0300142870 to
Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Operating Specifications - 460SJ - Prior to S/N
0300142870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Operating Specifications - 460SJ - S/N 0300142870 to
Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-5 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-6 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-6
6-7 Deutz F3M1011F/F3M2011F/D2011L03 . . . . . . . . 6-6
6-8 Isuzu 4LE1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-9 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-10 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-11 Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

TABLE OF CONTENTS
3121216 – JLG Lift – v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-14 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-15 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-10
6-16 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . 6-10
6-17 Mobil EAL Envirosyn H Specs . . . . . . . . . . . . . . . 6-11
6-18 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-11
6-19 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . 6-12
6-20 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-25
6-21 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-34
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

TABLE OF CONTENTS
vi – JLG Lift – 3121216
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This page left blank intentionally.

SECTION 1 - SAFETY PRECAUTIONS
3121216 – JLG Lift – 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for 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
program, using the information provided in this manual and
the Service and Maintenance Manual, must also be estab-
lished by a qualified person and followed to ensure the
machine is safe to operate.
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 completed under the supervision of an experi-
enced and qualified operator.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-
AGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read and understand this manual before operating the
machine.
• Do not operate this machine until complete training is per-
formed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.

SECTION 1 - SAFETY PRECAUTIONS
1-2 – JLG Lift – 3121216
• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, 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 emer-
gency 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
operation of the machine.
Workplace Inspection
• The operator is to take safety measures to avoid all haz-
ards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trail-
ers, railway cars, floating vessels, scaffolds or other equip-
ment 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 func-
tional checks. Refer to Section 2 of this manual for
detailed instructions.
• 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 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 WRITTEN PERMISSION FROM THE MANU-
FACTURER
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from foot-
wear and platform floor.

SECTION 1 - SAFETY PRECAUTIONS
3121216 – JLG Lift – 1-3
1.3 OPERATION
General
• Do not use the machine for any purpose other than posi-
tioning personnel, their tools, and equipment.
• Never operate a machine that is not working properly. If a
malfunctions 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. Oper-
ate controls with slow and even pressure.
• Hydraulic cylinders should never be left fully extended or
fully retracted before shutdown or 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. Contact
JLG for approved material handling accessories.
• When two or more persons are in the platform, the opera-
tor 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.
• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.
• When driving, always position boom over rear axle in line
with the direction of travel. Remember, if boom is over the
front axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.
• 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 lan-
yard anchorage point. Attach only one (1) lanyard per lan-
yard anchorage point.

SECTION 1 - SAFETY PRECAUTIONS
1-4 – JLG Lift – 3121216
• 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. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the boom assembly to enter or leave the plat-
form.
• Use extreme caution when entering or leaving platform.
Be sure that the boom is fully lowered. It may be neces-
sary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.
Electrocution Hazards
• This machine is not insulated and does not provide pro-
tection from contact or proximity to electrical current.

SECTION 1 - SAFETY PRECAUTIONS
3121216 – JLG Lift – 1-5
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-
1.
• Allow for machine movement and electrical line swaying.
• 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0 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.

SECTION 1 - SAFETY PRECAUTIONS
1-6 – JLG Lift – 3121216
• The minimum approach distance may be reduced if insulat-
ing 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 working dimensions of the insulating
barrier. This determination shall be made by a qualified per-
son in accordance with the employer, local, or governmental
requirements for work practices near energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• The user should be familiar with the surface before driv-
ing. Do not exceed the allowable sideslope and grade
while driving.

SECTION 1 - SAFETY PRECAUTIONS
3121216 – JLG Lift – 1-7
• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.
• Before driving on floors, bridges, trucks, and other sur-
faces, check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
• Do not raise the platform or drive from an elevated posi-
tion unless the machine is on firm, level and smooth sur-
faces.
• Keep the chassis of the machine at least 2 ft. (0.6m) from
holes, bumps, drop-offs, obstructions, debris, concealed
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. Do not tie-
off machine to any adjacent structure.
• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For
Reference Only).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If boom assembly or platform is in a position that one or
more wheels 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.
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
bottom of platform when lifting or lowering platform, and
driving.
• During operation, keep all body parts inside platform rail-
ing.

SECTION 1 - SAFETY PRECAUTIONS
1-8 – JLG Lift – 3121216
• 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 and swing operations.
• Limit travel speed according to conditions of ground sur-
face, congestion, visibility, slope, location of personnel,
and other factors which may cause collision or injury to
personnel.
• Be aware of stopping distances in all drive speeds. When
driving in high speed, switch to low speed before stop-
ping. 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 per-
sons in the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s pres-
ence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if neces-
sary.
1.4 TOWING, LIFTING, AND HAULING
• Never allow personnel in platform while towing, lifting, or
hauling.
• This machine should not be towed, except in the event of
emergency, malfunction, power failure, or loading/unload-
ing. 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 the unit with equipment of adequate capac-
ity.
• Refer to the Machine Operation section of this manual for
lifting information.