JLG R4045 Operation & Safety Manual
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JLG R4045 Operation & Safety Manual

JLG R4045 Operation & Safety Manual

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Operation & Safety
Keep this manual with the machine at all times.
Copyright ©
ANSI
AS/NZS MOL70 GB
Manual
Original Instructions -
Model
R4045
PVC 2304
31221538
April 10, 2023 - Rev A

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  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. Model R4045 PVC 2304 31221538 April 10, 2023 - Rev A Copyright © ANSI AS/NZS MOL70 GB...
  • 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 re- productive 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

    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.
  • Page 4 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. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 31221538 R4045...
  • Page 5 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.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG Description Date Revision April 10, 2023 Original Issue Other Publications Available Publication Publication Number 31221539 Service & Maintenance Manual 31221540 Illustrated Parts Manual R4045 31221538...
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  • Page 9: Table Of Contents

    Platform Loading ............... 37 Machine Control Locations ..........38 Battery Charging..............38 Ground Control Station............40 PLATFORM CONTROL STATION ..........43 PLATFORM MANUAL DESCENT CONTROL ......48 3.10 GRADE AND SIDESLOPE ............50 3.11 Platform Extension ............. 50 R4045 31221538...
  • Page 10 Platform Worklights............89 5.10 Anti-Vandalism Package............90 5.11 Platform Extension Handles ..........91 5.12 Magnetic Gate Latch............92 5.13 Skysense™................. 92 5.14 Workstation............... 96 SECTION 6 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ................100 General................100 Serial Number Identification ..........100 31221538 R4045...
  • Page 11 Tires and Wheels.............. 111 6.10 Diagnostic Trouble Codes (DTC) ......... 113 6.11 Radio Frequency (RF) Information........123 6.12 Supplemental Information Only Applicable to CE/UKCA Machines ................ 124 6.13 EC Declaration of Conformity..........125 6.14 UKCA Declaration of Conformity ........126 R4045 31221538...
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  • Page 13: Safety Precautions

    Read, understand, and study the Operation & Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognizing and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 14 Do not travel on unsupported surfaces. • This machine can be operated in nominal ambient temperatures of 0° F to 104° F (-20° C to 40° C). Consult JLG to optimize operation outside of this temperature range. 1.2.3 Machine Inspection •...

  • Page 15: Operation

    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.
  • Page 16 Prior to operation, ensure all gates and rails are fastened and secured in their proper position. • JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.
  • Page 17 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. R4045 31221538...
  • Page 18 • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis of the machine a minimum of 2 ft (0.6m) from holes, bumps, drop- offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
  • Page 19 Do not increase the platform size with unauthorized modifications, deck extensions, or attachments. WARNING Do not operate the machine when wind conditions exceed specifications shown in the General Specifications section of this manual or as shown on the capacity placard on the platform billboard. R4045 31221538...
  • Page 20 During operation, keep all body parts inside platform railing. • Keep hands and limbs out of the scissor arm assembly during operation and when elevated without safety prop engaged. • Always post a lookout when driving in areas where vision is obstructed. 31221538 R4045...

  • Page 21: Towing, Lifting, And Hauling

    • When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity. • Refer to the Machine Operation section of this manual for lifting information. R4045 31221538...

  • Page 22: Maintenance

    Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.
  • Page 23 Immediately rinse any contacted area with clean water and seek medical attention. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. R4045 31221538...
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  • Page 26: 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. 31221538 R4045...

  • Page 27: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

  • Page 28: Pre-Start Inspection

    Manual Service & Mainte- nance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.
  • Page 29 Keep gate closed at all times except when entering/exiting the platform and loading/unloading materials. 12. Lanyard Attach Points – JLG Industries, Inc. recommends personnel in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point.

  • Page 30: Walk-Around Inspection

    To avoid possible injury, be sure machine power is off. Do not operate until all malfunctions have been corrected. NOTICE Do not overlook visual inspection of chassis underside. Checking this area may result in discovery of conditions which could cause extensive machine damage. 31221538 R4045...
  • Page 31 11. Platform Control Console – Ensure that the control console is firmly secured in the proper location. Placards secure and legible, control lever and switches return to neutral when activated and released, and emergency stop switch function properly, required manual(s) in storage box. 12. Static Strap – Refer to Inspection Note. R4045 31221538...

  • Page 32: Function Check

    (T-handle located at rear of machine next to the battery charger) lowers the platform (refer to Section 3.8). d. Verify the Pothole Protection bars are fully lowered when the platform is raised. SC000125A SC000126A Platform Elevated — Pothole Bars Fully Lowered Platform Fully Lowered - Pothole Bars Raised 31221538 R4045...
  • Page 33 Table 4. High Drive Cutout Height MODEL HIGH DRIVE SPEED CUTBACK DRIVE SPEED REDUCTION HEIGHT R4045 75 in (190.5 cm) 2.0 mph (3.2 kph) to 0.5 mph (0.8 kph) 3. With the platform in the stowed position: a. Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the drive motor brakes hold.
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  • Page 36: Machine Controls, Indicators, And Operation

    Ground controls operate lift up and down functions only. Except for performing inspections and function checks, ground controls are to be used only in an emergency to lower the platform to the ground should the operator in the platform be unable to do so. 31221538 R4045...

  • Page 37: Operating Characteristics And Limitations

    3. All machine systems are functioning properly. 3.3.3 Stability This machine, as originally manufactured by JLG and operated within its rated capacity on a smooth, firm surface, within the limits of the maximum operating slope, provides a stable aerial platform for all platform positions.

  • Page 38: Machine Control Locations

    6. Side Compartment Doors (Both Sides) 3. Platform Manual Descent Control (T-Handle) 7. Side Compartment Door Latch Location (Both Sides) 4. AC Plug (for Platform AC Receptacle Outlet Box) BATTERY CHARGING Note: Park the machine in a well ventilated area before charging. 31221538 R4045...
  • Page 39 MDI battery charger status panel are illuminated. Note: If the charger is left plugged in, the charger will automatically restart a com- plete charge cycle if the battery voltage drops below a minimum voltage, or if 30 days has elapsed. R4045 31221538...

  • Page 40: Ground Control Station

    Ground Control Station. When the switch is turned to the platform position (2), power is supplied to the controls at the Platform Control Station. The switch should be set to the off position (3) when not using machine or parking the machine overnight. 31221538 R4045...
  • Page 41 Note: When ambient temperatures are below freezing, the LSS will have a reduction in available capacity. This will trigger the LSS before achieving the maximum allow- able capacity. R4045 31221538...
  • Page 42 Note: There will be a brief delay between switch activation and movement of the platform. When operating platform from the ground controls, activate the Lift/Lower switch to up position and hold to raise platform, or down position and hold to lower an elevated platform. Release to stop all movement. 31221538 R4045...

  • Page 43: Platform Control Station

    Machine Controls, Indicators, and Operation PLATFORM CONTROL STATION OAD00771 R4045 31221538...
  • Page 44 Steer Switch - The steer switch is a thumb-operated switch located at the top of the joystick controller handle. Depressing the switch to the right will steer the wheels to the right. Depressing the switch to the left will steer the wheels to the left. Joystick Controller - This controls drive and lift. 31221538 R4045...
  • Page 45 Indoor/Outdoor Operation Indicator The Indoor (GREEN) indicator and the Outdoor (YELLOW) indicator displays which mode the machine is currently set to operate in. Indoor/Outdoor Operation Mode Switch This button will toggle between the indoor/outdoor operation modes. R4045 31221538...
  • Page 46 When released, the switch will return to the center-off position and the wheels will remain in the previously selected position. To return the wheels to the center position, the switch must be activated in the opposite direction until the wheels are centered. 31221538 R4045...
  • Page 47 If the code cannot be cleared by the operator, the machine will require service by a qualified JLG mechanic. Tilt Indicator Warning Light and Alarm A red warning light on the control panel illuminates and an audible alarm sounds when the chassis is at or beyond the tilt cutout settings.

  • Page 48: Platform Manual Descent Control

    The manual descent control T-handle is located on the left rear of the machine, just below the platform ladder. Look for the instruction decal located beside the release handle. The lowering procedure is as follows: 31221538 R4045...
  • Page 49 Keep hands and arms out of the path of the scissor arms and platform while lowering. 2. Grasp the T-handle and slowly pull out to lower the scissor arms/platform. When the platform is lowered to desired level, allow the T-handle to return to its closed position. SC000122A R4045 31221538...

  • Page 50: Grade And Sideslope

    2. While holding the lever, grasp the top handrails (2) and push forward until the locking mechanism pin locks into the forward platform extension lock (4 or 5). To retract the deck: 1. Press foot down on locking mechanism lever (1) until it clears the forward platform extension lock (4 or 5). 31221538 R4045...

  • Page 51: Platform Rails Fold-Down Procedure (If Equipped)

    1. Remove platform top rail pins (four total - two front, two rear) and fold the FRONT and REAR GATE platform rails down onto the platform deck. 2. Fold down both platform extension side rails next. 3. Fold down main platform left side rail. R4045 31221538...
  • Page 52 If driving machine with the platform control station from ground, do not hang the control box on any part of the machine while driving. Hold the control box and keep at least 3 ft (1 M) distance from machine. SC000128A Figure 6. Step 1 31221538 R4045...
  • Page 53 Machine Controls, Indicators, and Operation SC000129A Figure 7. Step 2 Figure 8. Step 3 Figure 9. Step 4 R4045 31221538...
  • Page 54 If driving machine with the platform control station from ground, do not hang the control box on any part of the machine while driving. Hold the control box and keep at least 3 ft (1 M) distance from machine 31221538 R4045...
  • Page 55 Machine Controls, Indicators, and Operation Figure 10. Step 1 Figure 11. Step 2 Figure 12. Step 3 R4045 31221538...

  • Page 56: Parking And Stowing Machine

    5. If necessary, cover the platform control box, instruction placards, caution and warning decals so that they will be protected from hostile environment. 6. Chock at least two wheels when parking the machine for an extended period of time. 31221538 R4045...
  • Page 57 Machine Controls, Indicators, and Operation To prevent unauthorized removal, the platform control station can be secured to its mount by replacing the lock pin located on its mounting tab with a keyed or combination lock. R4045 31221538...

  • Page 58: Machine Lifting And Tie Down

    Adjust the width of the forklift truck, lifting tines to properly fit the machine forklift pockets. Slide the forklift tines into the forklift pockets and carefully lift machine. 31221538 R4045...
  • Page 59 (stowed position) and secure the machine to the truck or trailer deck. There are two tie-down/lift lugs at the rear of the machine, and two tie-downs and one lifting lug at the front of the machine. R4045 31221538...

  • Page 60: Towing

    Machine Controls, Indicators, and Operation OAD00730 3.15 TOWING It is not recommended to tow this machine except in the event of an emergency such as a machine malfunction or total machine power failure. 31221538 R4045...
  • Page 61 Note: If machine is disabled to a point where the hydraulic system cannot be oper- ated, the steer circuit will also not be operational. Then the machine will only track in the direction the front wheels are currently positioned. R4045 31221538...

  • Page 62: Beacons

    ClearSky Smart Fleet section for more information. 3.16.2 Amber Beacon This amber-colored beacon flashes at a constant rate to alert those nearby that the machine is in an active work state. The device may also use different flash patterns to identify specific machine alerts. 31221538 R4045...

  • Page 63: Clearsky Smart Fleet

    Refer to the Access Control and Beacons sections of this manual for more information. Visit the ClearSky section of the JLG website for more resources and information about accessing web portal or mobile app data. 3.18 ACCESS CONTROL - CLEARSKY SMART FLEET™ (IF...
  • Page 64 Machine Controls, Indicators, and Operation Note: Restricted functionality may occur if the CS550 (ClearSky® LED Motion / Amber Beacon) is damaged or removed. A protective cage is available through JLG. Machines equipped with ClearSky Smart Fleet Access Control are also equipped with the CS550.

  • Page 65: Safety Decal Locations

    Machine Controls, Indicators, and Operation 3.19 SAFETY DECAL LOCATIONS R4045 31221538...
  • Page 66 Machine Controls, Indicators, and Operation 31221538 R4045...
  • Page 67 Machine Controls, Indicators, and Operation R4045 31221538...
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  • Page 70: Emergency Procedures

    INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, JLG must be contacted by telephone and provided with all necessary details. • USA: 877-JLG-SAFE (554-7233) •...

  • Page 71: Platform Manual Descent Control

    The manual descent control T-handle is located on the left rear of the machine, just below the platform ladder. Look for the instruction decal located beside the release handle. The lowering procedure is as follows: R4045 31221538...

  • Page 72: Clearsky Smart Fleet™ - Locked Out State

    The machine may be placed into a Locked Out state remotely through ClearSky Smart Fleet. If the CS550 (ClearSky® LED Motion / Amber Beacon) is removed from a machine or disconnected from the control system through damage, the machine may also be placed into a Locked Out state. 31221538 R4045...
  • Page 73 Emergency Procedures NOTICE Contact the ClearSky Smart Fleet™ account owner if the machine is in a Locked Out state. R4045 31221538...
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  • Page 76: Accessories

    ACCESSORY INCOMPATIBLE WITH (Note 1) (Note 2) — — DC/AC Power Inverter — Inverter, Electrician’s Tree, Pipe Platform Work Lights, Rail Padding, Racks, Panel Carrier, Anti-Vandal Extension Handles, Dual Rails Workstation Package, Machinist’s Vise, Footswitch, Magnetic Gate Latch 31221538 R4045...
  • Page 77 Extension Handles, Footswitch, Dual Rails, Magnetic Gate Latch — — Electrician’s Tree, Pipe Racks, Panel Carrier, Platform Work Platform Lights, Anti-Vandal Package, Rail Extension Padding, Machinist’s Vise, Handles Inverter, Footswitch, Dual Rails, Magnetic Gate Latch — — Footswitch R4045 31221538...
  • Page 78 Carrier, Machinist’s Vise, Platform SkySense Worklights, Platform Rail Padding, Platform Extension Handles, Magnetic Gate Latch Note 1: Any accessory not listed under "COMPATIBLE WITH" is assumed to be incompatible. Note 2: Can be used on same unit but not simultaneously. 31221538 R4045...

  • Page 79: Dc/Ac Power Inverter

    The inverter module is mounted on the inside of the battery compartment door. 1. Inverter Module 5.2.1 Specifications DESCRIPTION SPECIFICATION Electrical System Voltage (DC) Power Inverter: Power Bright DC Input: DC Input Voltage: 20 to 30 VDC Operating Temperature: -4° F (-20° C) to 113° F (+45° C) AC Output: R4045 31221538...

  • Page 80: Electrician's Tree

    The Electrician’s Tree provides a stable rack on which to hang spools of wire. Its design is ideal for pulling wire and reducing friction associated with ground-based wire spools. Note: This accessory is rated for INDOOR USE only. INDOOR USE is use in areas shielded from wind so that there is no wind. 31221538 R4045...
  • Page 81 Check for loose nuts and bolts. If necessary, torque according to the Torque Chart specifications in Section 1 of the Service Manual. • Replace any missing or illegible decals. • Ensure release pins are intact and function properly. R4045 31221538...

  • Page 82: Footswitch

    Note: This accessory is only available in MOL70 and Korean markets. 5.4.1 Operation To operate a function, engage the footswitch and joystick trigger in any sequence before operating a function. 31221538 R4045...

  • Page 83: Panel Carrier

    Safety Precautions WARNING Multiple material-handling accessories can be installed but only one may be loaded at a time unless approved by JLG Industries, Inc. WARNING This accessory affects the overall platform capacity. Refer to the capacity decal and adjust accordingly.

  • Page 84: Pipe Racks

    Pipe Racks store pipe or conduit inside the platform in order to prevent rail damage and optimize platform utility. The accessory consists of two racks attached to the lower platform handrail with adjustable straps that secure the load in place. 31221538 R4045...
  • Page 85 Safety Precautions WARNING This accessory affects overall platform capacity. Refer to capacity decals and adjust accordingly. Weight in racks plus weight in platform must not exceed rated capacity. NOTICE Retract platform extension before attaching pipe racks and loading material. R4045 31221538...

  • Page 86: Machinist's Vise

    5. When not in use, remove locking pins, rotate racks 90 degrees to the stowed position, then secure locking pins. MACHINIST’S VISE The Vise allows the operator to secure material for assembling, disassembling, drilling, etc., while working from the platform. 31221538 R4045...
  • Page 87 • Do not drive machine with material in the Vise. 5.7.2 Preparation and Inspection • Ensure the Vise is secured to the platform. • Check for any missing or damaged components. Replace if necessary. R4045 31221538...

  • Page 88: Platform Rail Padding

    5.8.1 Platform Rail Padding with Proximity Switches This accessory is also available with proximity switches, which adds an attached padded frame to the bottom of the platform and eight proximity switches mounted to every corner of the platform. 31221538 R4045...

  • Page 89: Platform Worklights

    1. Release selected function, then reverse the direction. 2. Re-engage the selected function. Note: The machine will move in creep mode until proximity switch is no longer triggered. PLATFORM WORKLIGHTS The Platform Worklights accessory consists of two 12V lights mounted to the platform railings. R4045 31221538...

  • Page 90: Anti-Vandalism Package

    Ground Control Stations that prevent unauthorized use of the machine. Locks are not provided with this kit. This accessory is available for both control stations. Figure 14. Platform Control Station 1. Lock Position (Covers Closed) 2. Covers Open 31221538 R4045...

  • Page 91: Platform Extension Handles

    The Platform Extension Handles are mounted to the top rails of the extension platform at the roller tabs. When rotated up 90°, the handles provide the operator an optional grip to push the extension platform out from its stowed position. R4045 31221538...

  • Page 92: Magnetic Gate Latch

    The operator must not rely on SkySense as a substitute for following the instructions and warnings on machine placards and in this manual. 31221538 R4045...
  • Page 93 6. Remove hand or object from the sensor zone, then release the joystick and enable switch. Lower the platform to stowed. 7. Lift the platform with no hand or object above the sensor. The platform should lift without interruption. 8. Lower the platform to stowed. R4045 31221538...
  • Page 94 A bi color LED indicator on the platform control box signals SkySense activity. • No LED: Normal operation. • LED Flashing Yellow: Machine is in SkySense warning zone and will reduce to elevated drive height speed. Flash frequency correlates to proximity of the object. 31221538 R4045...
  • Page 95 Note: Override button is only required to be engaged if the operator desires to move the platform closer to an object that is in or entering the stop zone. 5.13.8 SkySense Coverage Areas Level One Note: Sensor Cones shown are approximations for reference only. R4045 31221538...

  • Page 96: Workstation

    The Workstation offers an adjustable work surface and additional space for storage of tools and objects. Note: This accessory is rated for INDOOR USE only. INDOOR USE is use in areas shielded from wind so that there is no wind. 31221538 R4045...
  • Page 97 Ensure the Workstation is secured to the platform. • Check for missing or damaged components. Replace if necessary. • Check for loose nuts and bolts. Torque to JLG Torque Chart Specifications if necessary. • Replace any missing or illegible decals.
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  • Page 100: General Specifications And Operator Maintenance

    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 & Maintenance Manual. SERIAL NUMBER IDENTIFICATION Note: Ladder removed for illustrative purposes. 31221538 R4045...

  • Page 101: Machine Specifications

    General Specifications and Operator Maintenance MACHINE SPECIFICATIONS DESCRIPTION R4045 PLATFORM Maximum Platform Height (Ground to Platform Floor - 39.3 ft (11.9 m) Elevated) Machine Height (Ground to Top of Rails) 8 ft 4 in (2.549 m) Machine Height - Rails Folded (Ground to Top of 6 ft 3 in (1.903 m)
  • Page 102 General Specifications and Operator Maintenance DESCRIPTION R4045 PLATFORM Approximate Gross Machine Weight 7,000 lb (3175 kg) ANSI/CE/UKCA/CSA/GB: 7,525 lb (3413 kg) AUS: 7,470 lb (3388 kg) MOL70: Wheelbase 80 in (2.032 m) Machine Overall Width 45 in (1.143 m) Maximum Tire Load (per wheel)
  • Page 103 MEWP in an environment that can be exposed to wind. 6.3.3 Machine Dimensions DESCRIPTION R4045 Platform Height - Elevated(Ground to Platform Floor) 39.3 ft (12 m) Platform Height - Stowed(Ground to Platform Floor) 55 in (140 cm) Rail Height(Platform Floor to Top of Rail) 44 in (113.2 cm) -Folding Rail...

  • Page 104: Battery Maintenance And Charging

    General Specifications and Operator Maintenance 6.3.4 Tires DESCRIPTION R4045 Size 16 in x 5 in(40.6 cm x12.7 cm) Wheel Nut Torque(1-1/8 inch - Slotted Nut with Cotter 150 ft.lb. (203 Nm) Pin) BATTERY MAINTENANCE AND CHARGING 6.4.1 Battery Maintenance and Safety Practices Note: These instructions are for unsealed (wet) batteries only.
  • Page 105 Note: Rear crossmember and ladder shown removed for illustration purposes only. • Battery Charging - (YELLOW LED - AGM - Flashes Quickly /FLOODED - Remains ON/ AGM-FLOODED - Flashes Slowly) • Charge Complete - (GREEN LED ON) • Fault Indicator - (RED LED ON) R4045 31221538...

  • Page 106: Battery Quick-Disconnect

    To disconnect power, locate the RED quick-disconnect connector on top of the batteries inside the battery compartment and pull halves apart. LUBRICATION 6.6.1 Lubrication Capacities COMPONENT R4045 Hydraulic Reservoir(at Full mark) 6.6 gal (25 L) Hydraulic System(Including Reservoir) 7.9 gal (30 L) 31221538 R4045...

  • Page 107: Safety Prop

    OK 40 pounds minimum.) EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105. JLG Recommends - Mobil - Mobilfluid 424Mobil EAL ENVIRONSYN H 32Mobil SHC HYDRAULIC EAL 32EAL and SHC are compatible with each other. 6.6.3...
  • Page 108 1. Raise the platform enough to release the safety props off the safety prop stops. 2. Rotate the prop assemblies until they align with the scissor arm and the release pin locks into the detent disk behind the arm. Figure 17. Prop Engaged 31221538 R4045...

  • Page 109: Hydraulic Oil Check Procedure

    MAX (maximum) marking (2). The MIN marking (3) is the bottom edge of the cutout on the door. The oil level must be kept within these markings for the hydraulic system to operate properly. R4045 31221538...
  • Page 110 Note: Care should be taken not to introduce any impurities (dirt, water, etc.) while cap is removed. Note: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be in- creased accordingly. 31221538 R4045...

  • Page 111: Tires And Wheels

    The tires and rims installed on machines are to be inspected daily as part of the daily walk-around inspection. JLG requires that the daily walk-around inspection be performed at each operator change during a shift and at each shift change.
  • Page 112 JLG recommends that any replacement tire be the same size and brand as originally installed on the machine or offered by JLG as an approved replacement. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model.

  • Page 113: Diagnostic Trouble Codes (Dtc)

    The more detailed three to five digit code numbers in the DTC column of the following tables are only indicated on a JLG handheld diagnostic analyzer connected to the machine, or on the Ground Control Station - MDI indicator, if equipped.
  • Page 114 General Specifications and Operator Maintenance 31221538 R4045...
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  • Page 121 General Specifications and Operator Maintenance R4045 31221538...
  • Page 122 General Specifications and Operator Maintenance 31221538 R4045...

  • Page 123: Radio Frequency (Rf) Information

    Consequently, a person within 20 cm (8 inches) of a CS550 that is connected to machine battery power could expose that person to RF energy in excess of what has been established by the ISED RF exposure guidelines. R4045 31221538...

  • Page 124: Supplemental Information Only Applicable To Ce/Ukca Machines

    The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s 31221538 R4045...

  • Page 125: Ec Declaration Of Conformity

    EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) Note: This declaration conforms with the requirements of annex II-A of the council di- rective 2006/42/EC.

  • Page 126: Ukca Declaration Of Conformity

    EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 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 20165 •...
  • Page 127 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 128 Inspection, Maintenance and Repair Log...
  • Page 130 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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