JLG 19BD Operator Manual
Operation and Safety Manual
Keep this manual with the machine at all times.
Model(s)
15BD
19BD
Vertical Lift
ANSI
P/N - 3121153
May 3, 2011
NOTES:
SECTION - FOREWORD
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.
3121153 – JLG Lift – a
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
DANGER
CAUTION
NOTICE
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
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
DECAL WILL HAVE AN ORANGE BACKGROUND.
RESULT IN SERIOUS INJURY OR DEATH. THIS
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.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
b – JLG Lift – 3121153
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
NOTICE
NOTICE
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.
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
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
PROPERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
3121153 – JLG Lift – c
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
SECTION - REVISION LOG
REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . February 5, 2009
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . .May 3, 2011
d – JLG Lift – 3121153
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B
Contact:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D
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. . . . . . . . . . . . . . . . . . . . . . . . 1-5
Crushing And Collision Hazards. . . . . . . . . . . . . . . . 1-6
1.4 LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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
2.3 WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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 Location . . . . . . . . . . . . . . . . 3-2
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . 3-3
18 Ft. Height Limiter - (19BD ONLY - OPTION) . . . . 3-4
Platform Gate Interlock - (OPTION). . . . . . . . . . . . . . 3-4
Platform Gate Lock - (OPTION) -
S/N-0130016195 to Present . . . . . . . . . . . . . . . . . . . 3-4
Platform Foot Control Switches - (OPTION) . . . . . . . 3-5
3121153 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 SET-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . 4-2
Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 PLATFORM CONFIGURATIONS . . . . . . . . . . . . . . . . . 4-3
4.5 MACHINE SHUT DOWN. . . . . . . . . . . . . . . . . . . . . . . . 4-4
SECTION - 5 - OPTIONAL EQUIPMENT
5.1 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 5-1
28" x 26" Front Entry Gullwing Platform . . . . . . . . . . 5-1
Tool/Bottle Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Foot Control Switch . . . . . . . . . . . . . . . . . . 5-1
Tube Carrier (PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
18 Ft. Height Limiter - (19BD ONLY - OPTION) . . . . 5-1
Platform Gate Interlock - (OPTION). . . . . . . . . . . . . . 5-1
Platform Gate Lock - (OPTION) -
S/N-0130016195 to Present . . . . . . . . . . . . . . . . . . . 5-2
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
6.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . 6-1
SECTION - 7 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 7-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-2
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . .7-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
SECTION - 8 - INSPECTION AND REPAIR LOG
ii – JLG Lift – 3121153
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around inspection . . . . . . . . . . . . . . . . 2-6
3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Manual Descent Valve Location. . . . . . . . . . . . . . . 3-2
3-3. Platform Control Station. . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Platform Control Footswitch. . . . . . . . . . . . . . . . . . 3-5
3-5. 15BD/19BD - Decal Installation . . . . . . . . . . . . . . . 3-6
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5
2-1 Inspection and Maintenance Table. . . . . . . . . . . . . 2-3
3-1 15BD - Decal Installation . . . . . . . . . . . . . . . . . . . . . 3-7
7-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 7-3
7-1 15BD Lubrication Points . . . . . . . . . . . . . . . . . . . . . 7-4
7-2 Lubrication Intervals for Various Components . . . . 7-5
8-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 8-1
LIST OF TABLES
3121153 – JLG Lift – iii
TABLE OF CONTENTS
This page intentionally left blank.
iv – JLG Lift – 3121153
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
1.1 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.
The owner/user/operator/lessor/lessee of the machine should not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has been
completed under the supervision of an experienced 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
DAMAGE, 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 performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
• 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.
3121153 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• 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
operation of the machine.
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 unless the machine is
properly secured to a suitable floor surface.
• This machine can be operated in temperatures of 0° F to
104° F (-20° C to 40° C). Consult JLG for operation outside this range.
• Do not operate the machine in hazardous environments
unless approved for the purpose by JLG.
Machine Inspection
• Before machine operation, perform inspections and functional 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.
• Ensure all 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 PRIOR WRITTEN PERMISSION FROM THE
MANUFACTURER
• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.
• Avoid any build up of debris on platform floor. Keep mud,
oil, grease, and other slippery substances from footwear
and platform floor.
1-2 – JLG Lift – 3121153
SECTION 1 - SAFETY PRECAUTIONS
1.3 OPERATION
General
• Always ensure the machine is properly attached to a solid,
firm and level floor surface.
• Do not use the machine for any purpose other than positioning personnel, their tools and equipment.
• Never operate a machine that is not working properly. If a
malfunction occurs, shut down the machine.
• 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.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
• Fully lower mast assembly and shut off all power before
leaving machine.
• When performing welding operations at elevation, precautions must be taken to protect all machine components
from contact with weld splatter or molten metal.
• Never exceed the maximum platform capacity. Distribute
loads evenly in the platform.
• Never attempt to use the machine as a crane.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If mast assembly or platform is caught while elevated, the
operator must be removed before attempting to free the
machine. Use cranes, forklift trucks, or other appropriate
equipment to stabilize machine prior to removing personnel.
Trip and Fall Hazards
• JLG Industries, Inc. recommends that the operator in the
platform use an approved fall restraint device with a lanyard attached to the authorized lanyard anchorage point.
For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.
3121153 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all railing and
gates are 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 mast assembly to enter or leave the platform.
• Use extreme caution when entering or leaving platform.
Ensure that the mast assembly is fully lowered. Face the
machine when entering or leaving the platform. Always
maintain “three point contact” with the machine, using two
hands and one foot or two feet and one hand at all times
during entry and exit.
1-4 – JLG Lift – 3121153
SECTION 1 - SAFETY PRECAUTIONS
Electrocution Hazards
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
• 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
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.
• 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 working dimensions of the insulating barrier. This determination shall be
MINIMUM APPROACH DISTANCE
in Feet (Meters)
3121153 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
DANGER
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 (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
Crushing And Collision Hazards
• Personal protection equipment must be worn by all operating and ground personnel.
• Check work area clearances above, on sides, and bottom
while lifting or lowering the platform.
• During platform operation, keep all body parts inside platform railing.
• Keep non-operating personnel at least 6 ft. (1.8m) away
while operating machine.
1-6 – JLG Lift – 3121153
SECTION 1 - SAFETY PRECAUTIONS
• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and person in the platform.
• Ensure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
platform. Position barricades on floor as necessary.
1.4 LIFTING MACHINE
• When lifting machine with a forklift, position forks only at
designated areas of the machine. Lift with a forklift of adequate capacity.
• Ensure machine is secure on the forks before transporting. Keep machine as low to the ground as possible.
• Refer to the Machine Operation section of this manual for
lifting information.
3121153 – JLG Lift – 1-7
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