JLG 25AM Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
Model(s)
AM Series
20AM
25AM
30AM
36AM
41AM
P/N - 3121211
November 12, 2014

NOTES:

FOREWORD
3121211 – JLG Lift – a
FOREWARD
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 – 3121211
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
DANGER
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE AN ORANGE BACKGROUND.
CAUTION
INDICATES A POTENTIALITY 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.
NOTICE
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 possi-
ble injury or death

FOREWORD
3121211 – 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.
NOTICE
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.
NOTICE
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCI-
DENT 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.
1 JLG Drive
McConnellsburg, PA 17233
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
E-mail: [e-mail]
For :
• Accident Reporting
•ProductSafetyPubli-
cations
•CurrentOwner
Updates
• Questions Regarding
Product Safety
• Standards and Regula-
tions Compliance Infor-
mation
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding
Product Modifications

FOREWORD
d– JLG Lift – 3121211
REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . . . . . . . . July 6, 2005
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 30, 2006
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 4, 2007
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 5, 2008
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . January 5, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 14, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . November 12, 2014

TABLE OF CONTENTS
3121211 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tilt Back Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . .1-10
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
2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 DAILY WALK-AROUND INSPECTION. . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-1
Manual Descent Valve . . . . . . . . . . . . . . . . . . . . . . . 3-3
Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 DECAL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-5
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 BATTERY CHARGING & MAINTENANCE -
(DC MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Maintenance and Safety. . . . . . . . . . . . . . 4-2
Battery Charger Operation . . . . . . . . . . . . . . . . . . . 4-3
Abnormal Cycle Indicator LED. . . . . . . . . . . . . . . . 4-4

TABLE OF CONTENTS
ii – JLG Lift – 3121211
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.4 MACHINE SET-UP AND OPERATION. . . . . . . . . . . . . .4-5
Caster Brake Operation . . . . . . . . . . . . . . . . . . . . . . 4-5
Outrigger Installation. . . . . . . . . . . . . . . . . . . . . . . . 4-6
Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 QUICK-CHANGE PLATFORM MOUNTS. . . . . . . . . . .4-9
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 MACHINE SHUT DOWN AND PARK . . . . . . . . . . . . 4-10
4.7 TRANSPORT, LIFTING AND TIE DOWN. . . . . . . . . . 4-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Transporting by Pushing. . . . . . . . . . . . . . . . . . . . 4-11
Tilt-Back Assembly Set-up (AM36/AM41) -
Machines Prior to S/N - 0900031618 . . . . . . . . 4-11
Tilt-Back Assembly Set-up (AM36/AM41) -
Machines S/N - 0900031618 to Present . . . . . 4-15
Pickup Truck Loading Device (Option). . . . . . . 4-19
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
SECTION - 5 - OPTIONAL EQUIPMENT
5.1 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . 5-1
22" x 25" Quick-Change Platform . . . . . . . . . . . . . 5-1
26" x 26" Quick-Change Platform . . . . . . . . . . . . . 5-1
28" x 26" Quick-Change Platform . . . . . . . . . . . . . 5-1
25" x 26" Step-in Molded Platform
w/Swing-up Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fluorescent Tube Caddy . . . . . . . . . . . . . . . . . . . . . 5-1
Crane Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Straddle Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Ladder for Straddle Extension . . . . . . . . . . . . . . . . 5-1
Extra Power Pack (Battery, Charger & Case) . . . 5-2
Platform Auxiliary Power Lowering Device . . . . 5-2
Laser Positioning Device . . . . . . . . . . . . . . . . . . . . . 5-2
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Machine Cycle Counter Meter . . . . . . . . . . . . . . . . 5-2

TABLE OF CONTENTS
3121211 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.2 AM-SE - STRADDLE EXTENSION –
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straddle Adaptor Wiring Components . . . . . . . 5-3
Straddle Adaptor Wiring Installation . . . . . . . . . 5-3
AM-SE - Straddle Extension –
Set-up And Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Straddle Extension - Components. . . . . . . . . . . . 5-7
Mounting - Straddle Extension to AM . . . . . . . . 5-7
Positioning Straddle Unit and
Lifting AM Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Lowering AM Machine on Straddle Unit . . . . . 5-10
Straddle and AM Machine Disassembly . . . . . 5-11
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine. . . . . . . . . 6-1
Platform Caught Overhead . . . . . . . . . . . . . . . . . . 6-1
Righting of Tipped Machine . . . . . . . . . . . . . . . . . 6-1
6.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 6-2
SECTION - 7 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 7-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . 7-3
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-3
Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Machine Component Weights . . . . . . . . . . . . . 7-5
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 7-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . 7-10
SECTION - 8 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around inspection. . . . . . . . . . . . . . . . . . 2-7
3-1. Ground Control Station.. . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Manual Descent Valve Location.. . . . . . . . . . . . . . . . 3-3
3-3. Manual Descent Valve Location.. . . . . . . . . . . . . . . . 3-4
3-4. Platform Control Station.. . . . . . . . . . . . . . . . . . . . . . . 3-4

TABLE OF CONTENTS
iv – JLG Lift – 3121211
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3-5. Decal Installation. (ANSI/CSA)
(Machines prior to S/N-0900031618) . . . . . . . . . . . .3-5
3-6. Decal Installation (CE)
(Machines prior to S/N-0900031618) . . . . . . . . . . . .3-8
3-7. Decal Installation. (ANSI/CSA)
(Machines S/N-0900031618 to Present). . . . . . . . 3-11
3-8. Decal Installation (CE)
(Machines S/N-0900031618 to Present). . . . . . . . 3-14
4-1. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Battery Box and Charger Assembly.
(D.C. Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-3. Dual Voltage Charger - Front Panel. . . . . . . . . . . . . .4-4
4-4. Setting & Releasing Caster Brake . . . . . . . . . . . . . . . .4-5
4-5. Outrigger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-6. Quick Change Platform Mount. . . . . . . . . . . . . . . . . .4-9
4-7. Tilt-Back Assembly Set-Up.. . . . . . . . . . . . . . . . . . . . 4-12
4-8. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . 4-16
4-9. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . . . . . . . . 4-17
4-10. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . . . . . . . . 4-18
4-11. Loading Machine onto Bed of Pick-Up Truck. . . 4-20
5-1. Hour Meter Location. (Option) . . . . . . . . . . . . . . . . . .5-2
5-2. SE-Adapter - Wiring - Grommet & Spring Clip
Mounting Hole Locations.
(Same For Both Sides) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Straddle Adapter Wiring Harness to AM Wiring
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4. Straddle Extension Component Assembly. . . . . . . 5-8
5-5. Side Lifting Rail - Quick Release Pins.. . . . . . . . . . . 5-11
LIST OF TABLES
1-1 Minimum Approach Distance (M.A.D.) . . . . . . . . . . 1-6
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
3-1 Decal Installation Chart (ANSI and CSA). . . . . . . . . 3-6
3-2 Decal Installation Chart (CE Specification) . . . . . . 3-9
3-3 Decal Installation Chart (ANSI and CSA). . . . . . . . 3-12
3-4 Decal Installation Chart (CE Specification) . . . . . 3-15
4-1 Maximum Platform Capacity. . . . . . . . . . . . . . . . . . . . 4-8
4-2 AM Machine Gross Weights. . . . . . . . . . . . . . . . . . . 4-23
7-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . 7-6
7-2 Lubrication Intervals for Various Components. . . 7-9
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . 8-1