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Oshkosh JLG 25AM Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
Model
25AM, 30AM, 38AM
PVC 2108
31219101
July 2, 2021 - Rev A
Copyright ©
ANSI
AS/NZS

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Summary of Contents for Oshkosh JLG 25AM

  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. Model 25AM, 30AM, 38AM PVC 2108 31219101 July 2, 2021 - Rev A Copyright © ANSI AS/NZS...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.

  • Page 3: Foreword

    FOREWORD The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed various compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard compliance information. 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.
  • Page 4 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. DANGER Indicates an imminently hazardous situation.
  • Page 5 Foreword WARNING This product must comply with all safety related bulletins. Contact JLG Industries, Inc. or the local authorized JLG representative for information regarding safety related bulletins which may have been issued for this product. NOTICE JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine.
  • Page 6 Foreword 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.

  • Page 7: Revision Log

    REVISION LOG DATE REVISION DESCRIPTION July 2, 2021 Original Issue 25AM, 30AM, 38AM 31219101...
  • Page 8 This Page is intentionally left blank...

  • Page 9: Table Of Contents

    SECTION CONTENTS Page Section Subject FOREWORD ..................3 REVISION LOG .................. 7 SECTION 1 SAFETY PRECAUTIONS..............11 General................11 Transporting..............11 Pre-Operation..............14 Operation ................. 17 Maintenance Safety Precautions........... 19 SECTION 2 USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION ..................21 Personnel Training .............
  • Page 10 Section Contents Transport, Lifting and Tie Down ........... 43 SECTION 5 OPTIONAL EQUIPMENT..............51 Optional Equipment ............51 SECTION 6 EMERGENCY PROCEDURES ............53 General Information ............53 Emergency Operation ............53 Incident Notification ............54 SECTION 7 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ................

  • Page 11: Safety Precautions

    SECTION 1 Safety Precautions GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, 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.
  • Page 12 Safety Precautions 1.2.2 Tipping Hazards WARNING Failure to comply with the following tipping hazard instructions could cause the unit to tip over or be hard to control when being moved, which could result in serious injury or death. • On a level surface, always travel with the platform end leading the way. •...
  • Page 13 Safety Precautions • Before placing machine on floors, trucks and other surfaces, check allowable capacity of surfaces. • Two persons are required on slopes up to 5°. A forklift must be used when moving units on slopes greater than 5°. •...

  • Page 14: Pre-Operation

    Safety Precautions 1.2.3 Tilt Back Procedure (AM38 Machines Only - see Section — Transport, Lifting and Tie Down for further instructions) • The platform must be completely empty of tools and debris. • Ensure platform is fully lowered. Remove and stow outriggers. •...
  • Page 15 Safety Precautions • Only properly trained personnel who have received unit specific familiarization shall operate a MEWP. The user shall determine if personnel are qualified to operate the MEWP prior to operation. • Before operation check work area for machine traffic such as forklifts, cranes, and other construction equipment.
  • Page 16 Safety Precautions • Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved by JLG. 1.3.2 Electrocution Hazard Table 1. Minimum Approach Distance (M.A.D.) VOLTAGE RANGE (PHASE TO PHASE) MINIMUM APPROACH DISTANCE - Feet (m) 0-50KV 10 (3)

  • Page 17: Operation

    Safety Precautions OPERATION • Do not operate any machine on which instruction placards or decals are missing or illegible. • Never exceed the maximum platform capacity. • Operate AC units with an extension cord rated at a minimum of 15 amps. •...
  • Page 18 Safety Precautions • Check work area for clearance overhead, on sides, and bottom of platform when lifting and lowering platform. • Never use the mast assembly to enter or leave the platform. • Do not increase the platform size with unauthorized deck extensions or attachments, increasing the area exposed to wind will decrease stability.

  • Page 19: Maintenance Safety Precautions

    Safety Precautions • Avoid any build up of debris on the platform floor. keep mud, oil, grease and other slippery substances from footwear and platform floor. • Do not operate machine from platform without the gate in place and properly closed.
  • Page 20 This Page is intentionally left blank...

  • Page 21: User Responsibilities, Machine Preparation, And Inspection

    SECTION 2 User Responsibilities, Machine Preparation, and Inspection PERSONNEL TRAINING The Mobile Elevating Work Platform (MEWP) is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel. Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.
  • Page 22 User Responsibilities, Machine Preparation, and Inspection 2.1.3 Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. 2.1.4 Machine Familiarization Note: Responsibilities for familiarization may vary by region.

  • Page 23: Preparation, Inspection, And Maintenance

    User Responsibilities, Machine Preparation, and Inspection PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. Frequency of inspections and maintenance must be increased as necessary when machine is used in a harsh or hostile environment, if machine is used with increased frequency, or if machine is used in a severe manner.

  • Page 24: Pre-Start Inspection

    User Responsibilities, Machine Preparation, and Inspection PRE-START INSPECTION The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2.

  • Page 25: Daily Walk-Around Inspection

    User Responsibilities, Machine Preparation, and Inspection DAILY WALK-AROUND INSPECTION 2.5.1 General Begin Walk-Around Inspection at item 1 (See Figure — Daily Walk-Around inspection, page 26). Continue around machine checking each item in this check list. CAUTION To avoid possible injury, be sure machine power is OFF during walk-around inspection.
  • Page 26 User Responsibilities, Machine Preparation, and Inspection 11. Manual Release Control Valve - See note above. 12. Ground Controls - Key switch operable, placards secure and legible; emergency stop switch, properly set for operation. 13. Mast Assembly - Inspect mast chains or cables as per note above. 14.

  • Page 27: Machine Controls And Indicators

    SECTION 3 Machine Controls and Indicators GENERAL NOTICE The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. This section provides the necessary information needed to understand control functions.
  • Page 28 Machine Controls and Indicators 4. HYDRAULIC RESERVOIR / CIRCUIT BREAKER / FUSE (located inside the ground control station housing) The hydraulic oil level can be checked through an access hole in the side of the cover. Note: Check hydraulic oil only when platform is completely lowered and after cycling platform up/down a few times.
  • Page 29 Machine Controls and Indicators 1. PLATFORM EMERGENCY STOP Switch Power is turned on by pulling the switch out, and is turned off by depressing switch. A two-position, red, mushroom shaped emergency stop switch, when positioned to ON with the key selector switch positioned to platform, furnishes operating power to the platform control station.

  • Page 30: Decal Installations

    Machine Controls and Indicators Figure 4. Platform Control Station. 1. Emergency Stop (RED) 3. Function Enable (GREEN) 2. Platform UP (WHITE) 4. Platform DOWN (WHITE) DECAL INSTALLATIONS 2 19 OAR00421 Figure 5. Decal Installation. (ANSI/CSA) 31219101 25AM, 30AM, 38AM...
  • Page 31 Machine Controls and Indicators 25AM, 30AM, 38AM 31219101...
  • Page 32 Machine Controls and Indicators 31219101 25AM, 30AM, 38AM...
  • Page 33 Machine Controls and Indicators CE SPEC. AUSTRALIAN SPEC. OAR00441 Figure 6. Decal Installation (CE/UKCA and AUS) Table 4. Decal Installation Chart (CE/UKCA and AUS Specification) (See Figure — Decal Installation (CE/UKCA and AUS).) CE/UKCA CE/UKCA CE/UKCA CE/UKCA CE/UKCA CE/UKCA (AUS) Item (ENG) (DUT)
  • Page 34 Machine Controls and Indicators Table 4. Decal Installation Chart (CE/UKCA and AUS Specification) (See Figure — Decal Installation (CE/UKCA and AUS).) (continued) Model Designation- 25AM- 1001271756 / 30AM- 1001271757 / 38AM- 1001271758 1001115864 1001126700 Serial Number Plate - Not Available Not Used 1703789 1705796...

  • Page 35: Machine Operation

    SECTION 4 Machine Operation DESCRIPTION This machine is a manually propelled machine, with a work platform mounted to an elevating aluminum mast mechanism. The personnel lift’s intended purpose is to provide personnel (with their tools and supplies) access to areas above ground level. The primary operator control station is in the platform.
  • Page 36 Machine Operation 4.3.1 Battery Maintenance and Safety BATTERY ACID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES.
  • Page 37 Machine Operation 4. The charger runs through a self-diagnostic check. The LED’s on the face of the charger flash in the following sequence; First all five (5) LED’s flash three (3) times. Next each LED lights in sequence. Finally all five (5) LED’s flash three (3) times again. 5.

  • Page 38: Machine Set-Up And Operation

    Machine Operation Figure 9. Dual Voltage Charger - Front Panel. 1. % of Charge in Progress LED’s (Green) 4. Circuit AC Circuit Breakers 2. Charger On LED (Green) 5. AC Voltage Selection Switch 3. Abnormal Cycle LED (Yellow) MACHINE SET-UP AND OPERATION To set-up machine for operation the operator must: 1.
  • Page 39 Machine Operation 2. To disengage caster brake, apply pressure or lift up on caster brake lever. Figure 10. Setting & Releasing Caster Brake 4.4.2 Outrigger Installation (See Figure — Outrigger Installation., page NOTICE As a safety precaution, due to different lengths, outrigger beams are designed to fit a specific model and are not interchangeable.
  • Page 40 Machine Operation Figure 11. Outrigger Installation. 1. Bubble Level Indicator 4. Outrigger Beam Assembly 2. Outrigger Lock/Release Pin 5. Leveling Jack 3. Interlock LED’s 4.4.3 Platform Loading Platform maximum rated load capacity is shown on a placard located on the platform control panel.

  • Page 41: Quick-Change Platform Mounts

    Machine Operation 2. To raise platform, press FUNCTION ENABLE button and platform UP button simultaneously. Upon reaching desired elevation level, release UP and FUNCTION ENABLE buttons. WARNING Check area beneath platform is free of personnel and obstructions prior to lowering platform.

  • Page 42: Machine Shut Down And Park

    Machine Operation Figure 12. Quick Change Platform Mount. 1. Platform Upper Mount 3. Platform Lower Mount 2. Upper Mount Attach Pins 4. Lower Mount Attach Pins 4.5.2 Platform Installation 1. Using two people or suitable lifting equipment, lift platform and set platform upper support rail into the upper platform mount on the mast.

  • Page 43: Transport, Lifting And Tie Down

    Machine Operation TRANSPORT, LIFTING AND TIE DOWN 4.7.1 General To move machine from work area to work area the operator may: • Push machine on its base wheels. • Push machine in Tilt-Back mode. (38AM only) • Move machine using a forklift. •...
  • Page 44 Machine Operation 3. Lower the tilt-back assembly as far as it will go onto it’s rubber bumpers. 4. (Step 2) Pull the gas spring cylinder out of it’s retaining clip on the back of the mast assembly. Lower and extend or retract the cylinder to guide the groove pins on the end of the cylinder into the slots on the tiltback crossbar assembly bracket.
  • Page 45 Machine Operation 7. Push machine around using the loop grips just behind the front swivel wheel assemblies under the base frame. Figure 13. Tilt-Back Assembly Set-Up Figure 14. Tilt-Back Assembly Set-Up 25AM, 30AM, 38AM 31219101...
  • Page 46 Machine Operation Figure 15. Tilt-Back Assembly Set-Up 4.7.4 Pickup Truck Loading Device (Option) (See Figure — Loading Machine onto Bed of Pick-Up Truck, page 47.) Note: The stowed mast height of the 38AM exceeds the length of most pick-up truck beds.
  • Page 47 Machine Operation Figure 16. Loading Machine onto Bed of Pick-Up Truck. Figure 17. Loading Machine onto Bed of Pick-Up Truck. 25AM, 30AM, 38AM 31219101...
  • Page 48 Machine Operation Figure 18. Loading Machine onto Bed of Pick-Up Truck. 4.7.5 Lifting To lift the machine, use suitable lifting equipment capable of handling the weight of the machine. Note: Fork lifts, cranes, chains, slings, etc. must be capable of handling the following weights: Table 6.
  • Page 49 Machine Operation 4.7.6 Machine Tie Down Secure the machine to the transport vehicle using the tie down lug weldments provided on the rear and sides of the machine. 1. Transport only with platform in the stowed position. 2. Remove all loose items from machine. 25AM, 30AM, 38AM 31219101...
  • Page 50 This Page is intentionally left blank...

  • Page 51: Optional Equipment

    SECTION 5 Optional Equipment OPTIONAL EQUIPMENT The following optional equipment is available for AM model machines: 5.1.1 22" x 22" Quick-Change Platform (Not Available in CE/ UKCA Markets) The 22" (56cm) long by 22" (56cm) wide platform features a gull wing gate opening. 5.1.2 26"...
  • Page 52 Optional Equipment Figure 19. Hour Meter Location. 1. Hour Meter 31219101 25AM, 30AM, 38AM...

  • Page 53: Emergency Procedures

    SECTION 6 Emergency Procedures GENERAL INFORMATION This section explains the steps to be taken in case of an emergency situation while operating the machine. EMERGENCY OPERATION 6.2.1 Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE, USE THE FOLLOWING INSTRUCTIONS AS A GUIDELINE.

  • Page 54: Incident Notification

    Emergency Procedures 6.2.3 Righting of Tipped Machine Before righting a tipped machine, check machine for any damage which may prevent it from setting properly on its base wheels once in a vertical position, (i. e. base wheels damaged, base frame distorted, etc.). Use a crane, forklift or other suitable lifting equipment and carefully lift the machine to an upright position.

  • Page 55: General Specifications And Operator Maintenance

    SECTION 7 General Specifications and Operator Maintenance INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine. The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.
  • Page 56 General Specifications and Operator Maintenance 30AM 30AM (EXCEPT (CE/UKCA SPECIFICATION 25AM 38AM CE/UKCA) ONLY) (per outrigger) (231 kg) (231 kg) (231 kg) (231 kg) 68 x 62 79 x 79 75 x 72 in. 86 x 84 in. Outrigger Footprint: (Length x Width) in.
  • Page 57 General Specifications and Operator Maintenance 7.2.4 Platform Data SPECIFICATION 25AM 30AM 38AM Occupants: (Persons allowed in Platform) 1 Person 1 Person 1 Person ANSI/CSA: Platform Capacity : 350 lb. 300 lb. 300 lb. (U.S.A, Brazil, Japan, China, Latin America) (160 kg) (136 kg) (136 kg) CE/UKCA/AUS:...

  • Page 58: Operator Maintenance

    General Specifications and Operator Maintenance OPERATOR MAINTENANCE 7.3.1 Lubrication Hydraulic Oil (HO) HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE SAE VISCOSITYGRADE +0°F to +180° F (-18° C to -83° C) +0°F to +210°F (-18°C to +99°C) 10W-20, 10W-30 +50° F to +210° F (+10° C to +99° C) 20W-20 Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service.
  • Page 59 General Specifications and Operator Maintenance CAUTION Battery acid is highly corrosive. Avoid contact with skin and clothing at all times. Battery acid releases an explosive gas while charging, allow no open flames, sparks or lighted tobacco products in the area while charging batteries. Charge batteries only in a well ventilated area.
  • Page 60 General Specifications and Operator Maintenance Table 8. Lubrication Intervals for Various Components INTERVAL HOURS NO/TYPE COMPO LUBE/ ITEM LUBE COMMENTS 1 YEAR YEARS NENT METHOD MONTHS MONTHS POINTS 600 Hrs. 1200 150 Hrs. 300 Hrs. HO/Check Check Fill To Hydraulic level every Line on Oil Level...

  • Page 61: Supplemental Information Only Applicable To Ce/Ukca Machines

    General Specifications and Operator Maintenance Table 8. Lubrication Intervals for Various Components (continued) INTERVAL HOURS NO/TYPE COMPO LUBE/ ITEM LUBE COMMENTS 1 YEAR YEARS NENT METHOD MONTHS MONTHS POINTS 1200 600 Hrs. 150 Hrs. 300 Hrs. Notes: 1. Be certain to lubricate like items on each side of the machine. 2.
  • Page 62 General Specifications and Operator Maintenance Contact / Position: Senior Manager — Product Safety & Reliability Date / Place: Hoofddorp, Netherlands Machine Type: Mobile Elevating Work Platform 25AM, 30AM, 38AM Model Type: Notified Body: Kuiper Certificering b.v. 2842 EC-Number: Address: Van Slingelandtstraat 75, 7331 NM Apeldoorn, The Netherlands KCEC4431 Certificate Number:...
  • Page 63 General Specifications and Operator Maintenance 7.4.2 UKCA Declaration of Conformity Manufacturer: JLG Industries, Inc. Address: 1 JLG Drive 1McConnellsburg, PA 17233 USA Technical File: JLG Industries UK Ltd Braunstone Frith Industrial Estate Unit 3 Sunningdale Road Leicester, LE3 1UX United Kingdom Contact / Position: Director of Engineering —...
  • Page 64 General Specifications and Operator Maintenance JLG Industries Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 2016 •...
  • Page 65 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 66 Inspection, Maintenance and Repair Log...
  • Page 68 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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