JLG 4045R Service Maintenance Manual
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JLG 4045R Service Maintenance Manual

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Service & Maintenance Manual
Model
4045R
3121761
June 29, 2018 - Rev E
ANSI
AS/NZS GB

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  • Page 1 Service & Maintenance Manual Model 4045R 3121761 June 29, 2018 - Rev E ANSI AS/NZS GB...
  • Page 3 A maintenance program must be fol- • USE ONLY REPLACEMENT PARTS OR COMPONENTS lowed to ensure that the machine is safe to operate. THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, REPLACEMENT PARTS OR COMPONENTS MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
  • Page 4 INTRODUCTION REVISION LOG Original Issue A - June 19, 2017 Revised B - August 11, 2017 Revised C - November 20, 2017 Revised D - February 6, 2018 Revised E - June 29, 2018 - Revised Covers 3121761...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION 1 - SPECIFICATIONS SPECIFICATION ................1-1 Platform Capacities .
  • Page 6 TABLE OF CONTENTS Hydraulic System ..............2-9 Hydraulic Oil.
  • Page 7 SECTION 5 - JLG CONTROL SYSTEM HAND HELD ANALYZER..............5-1 Diagnostic Port .
  • Page 8 TABLE OF CONTENTS CALIBRATION PREPARATION............. . 6-5 CALIBRATION AND VERIFICATION PROCEDURES .
  • Page 9 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Hydraulic Oil Operating Temperature Specifications ........1-7 1-2.
  • Page 10 TABLE OF CONTENTS 4-9. Hydraulic Manifold Assembly - Component Torque........4-10 4-10.
  • Page 11 TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications..............1-1 Platform Capacities .
  • Page 12 TABLE OF CONTENTS This page left blank intentionally viii 3121761...

  • Page 13: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS SPECIFICATION Table 1-1. Operating Specifications DESCRIPTION 4045R PLATFORM ANSI/CSA/CE/AUS/GB Maximum Platform Height (Ground to Platform Floor - Elevated) 39 ft. 3 in. (11.9m) Machine Height (Ground to Top of Rails) 8 ft. 4 in. (2.549m) Machine Height - Rails Folded (Ground to Top of Folded Rails) 6 ft.

  • Page 14: Platform Capacities

    Machine Dimensional Data Tires Table 1-3. Dimensions Table 1-4. Tire Specifications DESCRIPTION 4045R DESCRIPTION 4045R Platform Height - Elevated 16 in. x 5 in. 39 ft. 3 in. (12 m) Size (Ground to Platform Floor) (40.6 cm x12.7 cm)

  • Page 15: Batteries

    Max. Oil Flow: 18 gpm (68 Lpm) - Continuous GER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. THE USE OF • Hydraulic Brake NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG Type: Hydraulic Release ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES Holding Torque: 10,000 in.

  • Page 16: Electrical System

    SECTION 1 - SPECIFICATIONS Electrical System Table 1-6. Battery Charger Specifications DESCRIPTION ALL MACHINES Electrical System Voltage (DC) Battery Charger: Delta-Q PRO - Eagle Perf. Series Green Power - Pylon International Input: AC Input Voltage: 85-270V AC 108-132V AC 100-240V AC Nominal AC Input Voltage: 100VAC / 240VAC RMS 120VAC...

  • Page 17: Limit Switch Activation

    2.50° - indoor 0 - 27 ft. 0 - 8.2 m NOTE: Aside from JLG recommendations, it is not advisable High Drive Speed Cutout to mix oils of different brands or types, as they may not contain the same required additives or be of High drive speed is cut out when the platform is raised comparable viscosities.

  • Page 18: Lubrication Specifications

    EPGL Extreme Pressure Gear Lube (oil) meeting API service classification cSt @ 100° C 4.07 GL-5 or MIL-Spec MIL-L-2105. cSt @ 100° F 15.8 JLG Recommends - Mobil - Mobilfluid 424 cSt @ 212° F 4.07 Mobil EAL ENVIRONSYN H 32 Viscosity Index Mobil SHC HYDRAULIC EAL 32 Density (Kg/l) @ 15°C...
  • Page 19 IN THIS REGION FUNCTION SPEEDS & BATTERY LIFE MAY BE SIGNIFICANTLY REDUCED NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE “HYDRAULIC FLUID OPERATION CHART” MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.

  • Page 20: Hydraulic Pressure Settings

    See Figure 1-2. MODEL MAIN RELIEF LIFT RELIEF STEER RELIEF 3000 ± 70 psi 2500 ± 70 psi 1250 ± 70 psi 4045R (207± 5bar) (172 ± 5 bar) (86 ±5 bar) HYDRAULIC CYLINDER SPECIFICATIONS Table 1-16. Hydraulic Cylinder Specifications DESCRIPTION 4045R...

  • Page 21: Critical Stability Weights

    Platform with Rails/Extension 539 lb. 539 lb. Table 1-17. Critical Stability Weights (Dual Rail) (244 Kg) (244 Kg) COMPONENT 4045R Arm Assembly - 3648 lb. 3648 lb. (Includes Lift Cylinder) (1654 Kg) (1654 Kg) Wheel and Tire Assembly (each) 52.7 lb. (23.9 kg) Chassis w/Wheel/Tire/Steer- 2778 lb.

  • Page 22: Torque Charts

    SECTION 1 - SPECIFICATIONS Torque Charts Figure 1-3. Torque Chart - Sheet 1 of 5 (SAE Fasteners) 1-10 3121761...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 (SAE Fasteners) 3121761 1-11...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 (SAE Fasteners) 1-12 3121761...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 (METRIC Fasteners) 3121761 1-13...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 (METRIC Fasteners) 1-14 3121761...

  • Page 27: General

    Technician as a person who has successfully completed Preparation, Inspection, and Maintenance the JLG Service Training School for the subject JLG prod- It is important to establish and conform to a compre- uct model. Reference the machine Service and Mainte-...
  • Page 28 Preventative At intervals as specified in the Service and Maintenance Manual. Owner, Dealer, or Qualified JLG Mechanic Service and Maintenance Manual Maintenance User NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121761...

  • Page 29: Preventive Maintenance And Inspection Schedule

    2. Visual inspection for damage, cracks, distortion, or TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE excessive wear. JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL. 3. Check for proper adjustment. 4. Check for cracked or broken welds.
  • Page 30 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule INTERVAL PRE-DELIVERY (a) ANNUAL (c) AREA ON MACHINE OR FREQUENT (b) (YEARLY) INSPECTION INSPECTION FUNCTIONS/CONTROLS Platform Controls 5, 6, 7 5, 6, 7 Ground Controls 5, 6 5, 6 Function Control Locks, Guards, or Detents Function Enable System 5, 8...

  • Page 31: Footnotes

    Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Notify JLG of change in Machine Ownership Replace Annually - JLG P/N - 70005423 Replace when system performance is degraded. *** Every two years, drain and remove hydraulic oil reservoir , clean pick-up screen, refill with fresh hydraulic fluid.

  • Page 32: Service Maintenance Components

    SECTION 2 - GENERAL SERVICE MAINTENANCE COMPONENTS Figure 2-1. Machine Component Locations 1. Scissor Arm - Safety Prop 3. Batteries Location 2. Hydraulic Tank/Pump Assembly 3. Lower the platform until the safety props rest Scissor Arm - Safety Prop against the safety prop stops on the arm set (See Figure 2-2.

  • Page 33: Hydraulic Oil Check Procedure

    SECTION 2 - GENERAL To disengage the safety prop: NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For 1. Raise the platform enough to release the safety machines used in multi-shift operations and/or props off the safety prop stops. exposed to hostile environments or conditions, 2.

  • Page 34: 2.4 Service And Guidelines

    SECTION 2 - GENERAL 2.4 SERVICE AND GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, General complete the procedural steps in sequence. Do not par- tially disassemble or assemble one part, then start on The following information is provided to assist you in another.

  • Page 35: Hydraulic Lines And Electrical Wiring

    1. Refer to Section 1 for recommendations for viscos- required, to aid assembly. ity ranges. Lubrication 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscos- Service applicable components with the amount, type, ity index of 152.

  • Page 36: 2.6 Cylinder Drift Test

    SECTION 2 - GENERAL 2.6 CYLINDER DRIFT TEST 2.7 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. 1. Pinned joints should be disassembled and Platform Drift inspected if the following occurs: Measure the drift of the platform to the ground.

  • Page 37: Chassis & Scissor Arms

    SECTION 3 - CHASSIS & SCISSOR ARMS SECTION 3. CHASSIS & SCISSOR ARMS LEFT AND RIGHT SIDE COMPONENT COMPARTMENTS Figure 3-1. Components Mounded on Side Swing - Out Compartment Doors 1. Left Side Component Compartment Door 6. Right Side Component Compartment Door 2.

  • Page 38: Battery Removal/Maintenance

    CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. machine, first disconnect the positive (+) battery THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY cable from the forward most battery connected RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT to the main contactor relay.

  • Page 39: Battery Maintenance And Safety Practices

    SECTION 3 - CHASSIS & SCISSOR ARMS Battery Maintenance and Safety Practices BATTERY CHARGING Non-Sealed - Refillable Lead Acid Batteries Only NOTE: Be sure that machine is parked in a well ventilated area before charging begins. CAUTION CAUTION ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH ONLY PLUG THE CHARGER INTO A PROPER LY INSTALLED AND SKIN OR CLOTHING.

  • Page 40: Delta-Q - Battery Charger

    SECTION 3 - CHASSIS & SCISSOR ARMS Delta-Q - Battery Charger Eagle Performance - Battery Charger All chargers are located at rear of machine inside chassis. 1. AC Voltage Input Plug 2. Charge Indicator LEDs 1. AC Voltage Input Cable 2.

  • Page 41: Battery Charger Maintenance

    3. If the output voltage of the charger seems exces- OTHERWISE DAMAGED IN ANY WAY. sive, return the charger for service. Contact JLG to get the expected battery voltage settings for ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR the charger in question.
  • Page 42 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-2. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution E-0-0-1 Check the battery voltage and cable connections. Check battery size and condition. Battery high voltage E-0-2-1 This error will automatically clear once the condition has been corrected. Check the battery voltage and cable connections.
  • Page 43 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-3. Fault Codes (Green Power) Flash Code Cause Solution 1) Check battery connection is correct. Connection Issue 2) Check charger connection is correct. 3) Check each battery is good. 1) Check AC input cord is connected between charger and AC outlet. Abnormal AC Power Input (Voltage) 2) Make sure AC plug is tightly secured into AC outlet.
  • Page 44 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-4. Fault Codes (Eagle Battery Charger) LED Indications Fault Solution This indication occurs whenever the charger circuitry cannot detect a bat- tery. The charger circuitry will not allow charge current to flow under this 30% RED LED NO BATTERY DETECTED condition.

  • Page 45: Dc/Ac Power Inverter Installation - Option

    SECTION 3 - CHASSIS & SCISSOR ARMS DC/AC POWER INVERTER INSTALLATION - OPTION Set the master power switch (item 5) on the side of the DESCRIPTION ALL MACHINES inverter unit to ON and leave it there. Use the inverter on/ Electrical System Voltage (DC) off switch at the Ground Control panel (see Figure 3-10., item 3) to power the inverter on and off, via the DC power...

  • Page 46: Logic Control Module Installation

    SECTION 3 - CHASSIS & SCISSOR ARMS LOGIC CONTROL MODULE INSTALLATION All machine electrical functions are controlled through the logic control module, the logic control module also moni- tors all the machine’s electrical systems. If a system fault should happen with the logic module or one of the machine’s electrical systems, the logic module will gener- ate a DTC code.

  • Page 47: Main Power Contactor Relay And Pump Control Module

    SECTION 3 - CHASSIS & SCISSOR ARMS MAIN POWER CONTACTOR RELAY AND PUMP NOTICE CONTROL MODULE DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPT- ING TO REMOVE THE MAIN POWER CONTACTOR RELAY OR SERVICING The main power contactor relay and pump control mod- THE ELECTRICAL SYSTEM.

  • Page 48: Pump Control Module

    SECTION 3 - CHASSIS & SCISSOR ARMS PUMP CONTROL MODULE Table 3-6. Pump Power Module Terminal Functions (CO117-J1) The pump control module (item 7 - Figure 3-8.) is J1-1 Power Input (8 - 40 V) - Input located inside the left side component door, mounted to the side of the battery box.
  • Page 49 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-9. Hydraulic Pump Control - Power Connections 1. Batteries 6. To Logic Control Module 2. Main Power Contactor Relay 7. To Battery Charger (+) 3. Pump Control Module 8. To Battery Charger (–) 4.

  • Page 50: Ground Control Station - Folding Cover

    SECTION 3 - CHASSIS & SCISSOR ARMS GROUND CONTROL STATION - FOLDING COVER Components Location Figure 3-10. Ground Control Station - Folding Cover 1. Ground/Platform/OFF Key Selector Switch 5. Hourmeter 2. Platform Lift/Lower Switch 6. Overload Indicator 7. MDI - Indicator (If Equipped) 3.
  • Page 51 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-11. Ground Control Station Removal 1. Ground Control Housing 6. Emergency Stop Switch 2. Attach Bolt, Nut and Washers 7. Hourmeter 3. Rear Panel Protective Cover (Fold-Under) 8. Overload Indicator (If LSS Equipped) 4.

  • Page 52: Ground Control Station - Fixed Cover

    SECTION 3 - CHASSIS & SCISSOR ARMS GROUND CONTROL STATION - FIXED COVER Components Location Figure 3-13. Ground Control Station - Fixed Cover 1. Ground/Platform/OFF Key Selector Switch 5. Hourmeter 2. Platform Lift/Lower Switch 6. Overload Indicator 7. MDI - Indicator (If Equipped) 3.
  • Page 53 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-14. Ground Control Station Removal 1. Ground Control Housing 6. Emergency Stop Switch 2. Attach Bolts, Washers and Tinnerman Nuts 7. Hourmeter 3. Ground Control Back Bracket 8. Overload Indicator (If LSS Equipped) 4.

  • Page 54: 3.10 Platform Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 PLATFORM CONTROL STATION NOTICE POWER MACHINE DOWN AT THE GROUND CONTROL STATION BEFORE DISCONNECTING THE PLATFORM CONTROL STATION. Overview of Control Station Components 1. Emergency Stop Switch 10. Horn Button 1. Emergency Stop Switch 10.

  • Page 55: Installation/Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Installation/Removal washers (item 1) and the two (2) bolts and wash- ers (item 2) on the bottom of the assembly. 1. Disconnect the platform control station harness at the round connector on front the control sta- tion.
  • Page 56 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-18. Platform Control Station Components - Internal 1. Drive, Lift and Steer Joystick 6. Horn Button Switch Control 7. Overload Indicator 2. Indicator Panel Module (If Equipped) 3. Speed Select Switch 8. Alarm 4.

  • Page 57: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS Joystick Controller Figure 3-19. Joystick Table 3-7. Joystick Specifications Table 3-8. Connector Chart Input Voltage +5 (±0.1) VDC CONNECTOR PINOUT Current Consumption 10 mA @ 12 VDC Term Color Function HANDLE COM Output: Handle Centered 2.5 (±0.1) VDC VIOLET TRIGGER N.O.

  • Page 58: 3.11 Tilt Sensor Installation

    4. Wire Harness Connector 7. Power machine up and check tilt sensor calibra- 2. Mounting Plate 5. Mounting Plate Hardware tion with handheld analyzer. See Section 5, JLG 3. Tilt Sensor Mounting Control System for tilt sensor calibration proce- Hardware dure.

  • Page 59: 3.12 Elevation Sensor

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.12 ELEVATION SENSOR On LSS-equipped machines, this sensor works in tandem with the lift cylinder pressure switch to accurately deter- This machine is equipped with a scissor arm elevation sen- mine platform load for any given platform height. sor switch.

  • Page 60: Elevation Sensor Installation

    SECTION 3 - CHASSIS & SCISSOR ARMS Elevation Sensor Installation 4. With the Angle sensor and bracket oriented as shown (1) in (Figure 3-22.), gently slide keeper See Figure 3-22. pin into sensor pin from other end. Secure keeper pin with mounting hardware. 1.

  • Page 61: 3.13 Pot-Hole Protection System Components

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.13 POT-HOLE PROTECTION SYSTEM COMPONENTS 1. Bearing 2. Bearing Bracket 3. Limit Switch 4. Pad 5. Upper Actuator 6. Mounting Plate 7. Spring 8. Lower Actuator 9. Pinion Plate 10. Anti-Static Strap 11. Link 12.

  • Page 62: 3.14 Steer And Spindle Assembly Components

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.14 STEER AND SPINDLE ASSEMBLY COMPONENTS Figure 3-24. Steer and Spindle Assembly Installation 1. Mount steer cylinder with ports facing the rear of the machine. 3. Spindle weldment interchangeable with either side.lo 2. Apply Loctite #242 to bolt threads before tightening. 3-26 3121761...

  • Page 63: Drive Motor Covers Installation - Option

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Covers Installation - Option Figure 3-25. Drive Motor Cover Installation - Option NOTE: Cover installation same for both sides. 1. Drive Motor Cover 2. Cover carriage bolts, nuts, and washers 3121761 3-27...

  • Page 64: Tire Wear And Damage

    JLG as an approved replacement. Please refer to 4. Install cotter pin (2), if hole in slots do not align the JLG Parts Manual for the part number of the approved with cotter pin hole on the tapered shaft, con- tires for a particular machine model.

  • Page 65: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.15 ARMS AND PLATFORM POSITIONING AND 3.17 SCISSOR ARMS REMOVAL SUPPORT 1. Remove platform (refer to Section 3.16, Platform Removal). 2. Disconnect all wiring and cables attached to scissor arm assembly. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR 3.
  • Page 66 SECTION 3 - CHASSIS & SCISSOR ARMS NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING. LIFTING STRAP ARMS SAFETY PROP Figure 3-27. Arms and Platform Positioning with Overhead Support 3-30 3121761...
  • Page 67 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-28. Platform Assembly - Installation/Removal 1. Platform 4. Platform to Arm Attach Pin 2. Slide Block (Install with thick section above 5. Centering Link to Arm Attach Pin hole) 6. Cotter Pin 3.
  • Page 68 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-29. Scissor Arm Assembly 3-32 3121761...
  • Page 69 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-30. Scissor Arm Assembly - Pin Configuration 3121761 3-33...
  • Page 70 SECTION 3 - CHASSIS & SCISSOR ARMS SECURE TO PLUG & RECEPTACLE VERTICAL RAIL INSTALLS, FOR AC ONCE IT EXITS CABLE ATTACHMENT THE GROMMET WITH THE TIE STRAP SECURE PLATFORM CABLE CONNEC- TOR (X60) TO PLATFORM/AC CABLE CONNECTOR (X59) POSITION 1070 mm SECURE FROM END OF THE HOSES/HARNESS...
  • Page 71 SECTION 3 - CHASSIS & SCISSOR ARMS SECURE TO VERTICAL RAIL PLUG & RECEPTACLE ONCE IT EXITS INSTALLS, FOR AC THE GROMMET CABLE ATTACHMENT WITH THE TIE STRAP SECURE PLATFORM CABLE CONNEC- TOR (X60) TO PLATFORM/AC CABLE CONNECTOR (X59) SECURE POSITION 1070 mm HOSES/HARNESS FROM END OF THE...
  • Page 72 SECTION 3 - CHASSIS & SCISSOR ARMS SECURE TO VERTICAL RAIL PLUG & RECEPTACLE ONCE IT EXITS INSTALLS, FOR AC THE GROMMET CABLE ATTACHMENT WITH THE TIE STRAP SECURE PLATFORM CABLE CONNEC- TOR (X60) TO PLATFORM/AC CABLE CONNECTOR (X59) SECURE HOSES/HARNESS ALONG POSITION 1070 mm...
  • Page 73 SECTION 3 - CHASSIS & SCISSOR ARMS SECURE TO VERTICAL RAIL PLUG & RECEPTACLE ONCE IT EXITS INSTALLS, FOR AC THE GROMMET CABLE ATTACHMENT WITH THE TIE STRAP SECURE PLATFORM CABLE CONNEC- TOR (X60) TO PLATFORM/AC CABLE CONNECTOR (X59) SECURE HOSES/HARNESS ALONG POSITION 1070 mm...
  • Page 74 SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-38 3121761...

  • Page 75: Hydraulics

    SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS CYLINDERS - THEORY OF OPERATION Relief Valves Cylinders are of the double acting type. The Lift and Steer Main relief valves are installed at various points within the systems incorporate double acting cylinders. A double hydraulic system to protect associated systems and com- acting cylinder is one that requires oil flow to operate the ponents against excessive pressure.

  • Page 76: Pump/Motor

    (Lift Up from Ground Mode). Troubleshooting The following difficulties can be examined using the JLG Analyzer, a voltmeter, and simple hand tools. Unless other- wise noted, the Control System shall be energized in Ground Mode during testing.
  • Page 77 After examination, re-connect the Pump Pump Motor will not operate. Under DIAGNOS- Motor Positive Terminal and main power at the TICS - PUMP, the JLG Analyzer will show PUMP batteries. PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.

  • Page 78: Hydraulic Tank Installation

    SECTION 4 - HYDRAULICS HYDRAULIC TANK INSTALLATION 1. Machine Right Side Swing-Out Compartment Door 2. Hydraulic Oil Tank 3. Hydraulic Oil Filter 4. Tank Return Hose/Port 5. Filter/Return Housing Screws and Washers (Torque to 5 ft. lb.) 6. Tank Placement Emboss Features On Bottom of Tank 7.

  • Page 79: Hydraulic Oil Check Procedure

    SECTION 4 - HYDRAULICS Hydraulic Oil Check Procedure NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For See Figure 4-2., and Figure 4-3. machines used in multi-shift operations and/or exposed to hostile environments or conditions, • Lube Point(s) - Hydraulic Reservoir lubrication frequencies must be increased accord- •...

  • Page 80: Hydraulic Pump And Electric Motor Assembly

    SECTION 4 - HYDRAULICS HYDRAULIC PUMP AND ELECTRIC MOTOR 4. Label and disconnect the positive (+) and nega- tive (–) power cables on the electric motor. ASSEMBLY 5. Unbolt the four bolts (4), and washers (3) from the pump/motor assembly and raise the pump The hydraulic pump and motor are located on the right end up above the oil level in the hydraulic tank.

  • Page 81: Pump/Motor Disassembly

    SECTION 4 - HYDRAULICS Pump/Motor Disassembly 2. Replace the pump to motor gasket and slide the pump assembly into the motor assembly align- 1. Remove the four bolts and washers securing the ing the pump shaft with the motor receptacle. pump to the pump motor.

  • Page 82: Hydraulic Manifold Valve Installation

    SECTION 4 - HYDRAULICS HYDRAULIC MANIFOLD VALVE INSTALLATION Figure 4-6. Hydraulic Manifold Assembly - Installation (Located mid-chassis inside right side compartment door) 1. Chassis Mounting Plate 3. Manifold Valve Assembly 2. Valve Mounting Screws/Washers - (Apply Loctite NOTE: The mounting screws (item 2) when only loosened, allow the #242 and Torque to 10 ft.
  • Page 83 SECTION 4 - HYDRAULICS FRONT VIEW Figure 4-8. Hydraulic Manifold Assembly - Component Location 1. Lift Cylinder Control Valve Block 7. Brake Circuit Port 13. Drive Pressure Relief Adjust (Port B) 2. Drive Motor Control Valve Block 8. Drive Motor Release (Needle) Valve 14.

  • Page 84: Hydraulic Manifold Assembly - Component Torque

    SECTION 4 - HYDRAULICS RIGHT FRONT VIEW Figure 4-9. Hydraulic Manifold Assembly - Component Torque 1. Socket Head Screws - 16 ft. lb. (21 Nm) 7. Port B Fitting - Steer - 23 ft. lb. (31 Nm) 13. Bypass Valve - 33 ft. lb. (45 Nm) 2.

  • Page 85: Hydraulic Hose Routing

    SECTION 4 - HYDRAULICS Figure 4-10. Hydraulic Hose Routing 1. Manifold Valve Block 4. Drive Motors (Interchangeable) 7. Lift Cylinder - Lower 2. Oil Tank/Filter/Drain Plug 5. Steer Cylinder (Also reference Figure 3-31. to Figure 3-34.) 3. Pump/Motor 6. Brakes 8.

  • Page 86: Drive Motor Installation

    3. Motor Mounting Screws (Apply Loctite #242 on assembly) 2. Steer/Spindle Mount 4. Motor Mounting Nuts/Washers NOTE: The drive motors for the 4045R may make an audi- ble noise when driving and turning the machine. This condition is normal due to the hydraulic oil flow characteristics of the series drive circuit.

  • Page 87: Hydraulic Brake Installation

    SECTION 4 - HYDRAULICS HYDRAULIC BRAKE INSTALLATION Figure 4-12. Rear Hydraulic Brake - Installation 1. Hydraulic Brake Assembly (Mount with Ports on Top) 3. Mounting Nuts and Washers (Inside of Frame) 2. Mounting Screws and Washers (Apply Loctite #242 on assembly 4.

  • Page 88: Pressure Setting Procedure

    MP port gauge reads 2500 ± 70 psi (172 ± 5 bar). NOTE: Refer to Section 5 for more information on using the NOTE: To return the Lift Up personality to its original set- JLG handheld analyzer and switching between tings, navigate to the PERSONALITIES: LIFT and access levels.

  • Page 89: 4.10 Cylinder Checking Procedure

    SECTION 4 - HYDRAULICS 4.10 CYLINDER CHECKING PROCEDURE 4.11 LIFT CYLINDER REMOVAL/INSTALLATION NOTE: Cylinder check must be performed anytime a system NOTE: If there is a pump failure, a crane or a forktruck can component is replaced or when improper system be used to raise the platform.

  • Page 90: 4.12 Lower Lift Cylinder

    SECTION 4 - HYDRAULICS 4.12 LOWER LIFT CYLINDER 4.13 UPPER LIFT CYLINDER NOTE: Refer Figure 4-14., Lift Cylinder - Lower. NOTE: Refer Figure 4-15., Lift Cylinder - Upper. Disassembly Disassembly 1. Fully close then remove cylinder from machine. 1. Fully close then remove cylinder from machine. 2.
  • Page 91 SECTION 4 - HYDRAULICS Torque to 11 ft. lbs. Torque to 18-20 ft. lbs. (15 Nm) (24.5-27 Nm) Torque to 7.4 ft. lbs. (10 Nm) Torque to 18-20 ft. lbs. (24.5-27 Nm) Torque to 28.7-37.6 ft. lbs. (39-51 Nm) Torque to 24.7 ft. lbs. (33.5 Nm) 1001212482 G Figure 4-14.
  • Page 92 SECTION 4 - HYDRAULICS Torque to 11 ft. lbs. (15 Nm) Torque to 18.4-22.1 ft. lbs. (25-30 Nm) Torque to 24.7 ft. lbs. (33.5 Nm) 1001212483 I Figure 4-15. Lift Cylinder - Upper 1. Barrel 6. Piston Seal 10. O-ring 14.
  • Page 93 SECTION 4 - HYDRAULICS 1001163178 D Figure 4-16. Steer Cylinder 1. Barrel 5. Rod Seal 8. O-ring 2. Rod 6. Backup Ring 9. O-ring 3. Head (Torque to 434 ft. lb. (588 Nm)) 7. Dry Bearing 10. Piston Seal 4. Wiper Seal 3121761 4-19...

  • Page 94: 4.14 Cylinder Repair

    SECTION 4 - HYDRAULICS 4.14 CYLINDER REPAIR again. Repeat if necessary, until head is com- pletely removed. NOTE: The following are general procedures that apply to 7. Attach a suitable pulling device to the cylinder the cylinders on this machine. Procedures that apply rod port block end or cylinder rod end, as appli- to a specific cylinder will be so noted.

  • Page 95: Cleaning And Inspection

    NOTE: Prior to cylinder assembly, ensure that the proper 11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as cylinder seal kit is used. See your JLG Parts Manual for these machine models. necessary.
  • Page 96 10. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor cap- screws) through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 97 SECTION 4 - HYDRAULICS 12. After the screws have been torqued, tap the 20. After the cylinder has been reassembled, the rod tapered bushing with a hammer (16 to 24 oz.) should be pushed all the way in (fully retracted) and brass shaft (approximately 3/4"...
  • Page 98 SECTION 4 - HYDRAULICS NOTES: 4-24 3121761...

  • Page 99: Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub Level, To return home or access previ- and item menus ous menu Left &...
  • Page 100 SECTION 5 - JLG CONTROL SYSTEM 1. Diagnostic Port Plug 3. Controller Logic Module 2. Hydraulic Valve Manifold Figure 5-2. Diagnostic Port Location (Inside right side compartment door) 3121761...

  • Page 101: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer EVERYTHING OK, With the machine power on and the analyzer connected In ground mode, properly, the analyzer will display the following: HELP: (002) GROUND MODE OK If ENTER is pressed again, the display moves to the follow-...

  • Page 102: Changing The Access Level Of The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer When the analyzer is first connected, you will be in access MENU: level 2 which enables you to only view most configuration ACCESS LEVEL 1 settings which cannot be changed until you enter a pass- word to advance to a lower level.

  • Page 103: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Once you have gained access to level 1, and a personality...

  • Page 104: Joystick Calibration

    SECTION 5 - JLG CONTROL SYSTEM JOYSTICK CALIBRATION a. Machine mounting and/or grade: Try to measure the top of the tilt sensor for The joystick calibration should be completed levelness. If unable to get a good reading, if the joystick is replaced. To perform the joystick calibra- unbolt the tilt sensor and check the sensor’s...

  • Page 105: Elevation Sensor Calibration

    Sensing System) must also be calibrated in order for the laptop computer, connecting cable, and software update pressure curves to align properly (refer to Section 6.4 for cd. Contact JLG Industries to acquire the software. more information on calibrating LSS). Before updating the software, use the Hand-held Analyzer to view the machine’s settings (MACHINE SETUP and PER-...
  • Page 106 SECTION 5 - JLG CONTROL SYSTEM 3121761...
  • Page 107 SECTION 5 - JLG CONTROL SYSTEM 3121761...
  • Page 108 SECTION 5 - JLG CONTROL SYSTEM 5-10 3121761...
  • Page 109 SECTION 5 - JLG CONTROL SYSTEM 3121761 5-11...

  • Page 110: Machine Configuration Programming Information

    SECTION 5 - JLG CONTROL SYSTEM MACHINE CONFIGURATION PROGRAMMING INFORMATION NOTE: 1. When configuring a R scissors machine, the Machine Configuration must be completed before any Personality settings can be changed, see Table 5-2. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default.

  • Page 111: Machine Model Adjustment (Personality Settings)

    SECTION 5 - JLG CONTROL SYSTEM MACHINE MODEL ADJUSTMENT (PERSONALITY SETTINGS) Table 5-2. Machine Model Adjustment (Personality Settings) Adjustment Adjustment Range 4045R DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 2.0 (Sec) MINIMUM 1 - 25% MAXIMUM 26 -100% ElEV.
  • Page 112 SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-14 3121761...

  • Page 113: Lss (Load Sensing System) Service

    The LSS can be periodically verified without test weights to extend calibration intervals. The procedure within the For vehicles with a double lift cylinder (4045R), a single CALIBRATIONS ' VERIFY LOAD menu allows the control channel pressure transducer with voltage output (0.5V system to confirm net lift cylinder forces against calibra- to 4.5V) is mounted on the lower lift cylinder to measure...

  • Page 114: Lss Component Locations

    SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE limit according to their weight and the LOAD ' ACC'Y set- must be to the values recommended by JLG. Follow the ting must be set to account for their total weight. documentation furnished with factory-provided acces-...

  • Page 115: Analyzer Information

    YES when platform load is excessive PRES1 RAW: Displays the lift cylinder head pressure 1 raw reading; mA or Volts shown as volts for 4045R and mA for all remaining 0.00 mA/V models PRES1: Displays the lift cylinder head pressure 1 scaled read- 0.0-9999.9 PSI...
  • Page 116 SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE Table 6-2. Diagnostic Menu Descriptions (Continued) PARAMETER PARAMETER VALUE DIAGNOSTICS MENU (Displayed on Analyzer (Displayed on Analyzer DESCRIPTION (Displayed on Analyzer 1 Line) Line) Line) PRES2: Displays the lift cylinder head pressure 2 scaled read- 0.0-9999.9 PSI XXXX PSI ing in PSI...

  • Page 117: Calibration Preparation

    CAL LOAD: For the 4045R, engage lift up so the control system can gather static calibration information until LIFT TO MAX ELEV the platform reaches maximum height; control system will automatically pause lift up to take...

  • Page 118: Calibration And Verification Procedures

    • Vehicle temperature is at least +32°F/0°C. • Batteries are fully charged (25.0 V or greater). 4045R 847 lb (385 Kg) • Machine is on a level surface. 3. Lift up to maximum elevation using the ground con- Empty Platform (Load 0%) Calibration trols when the LIFT TO MAX ELEV prompt appears.

  • Page 119: Partial Height Calibration

    10% of lift height, the Ground Overload Indicator should flash, and the alarm should sound. 8. Use the JLG Analyzer to set MACHINE SETUP ' LOAD to CUTOUT PLTM. This will prevent LSS interlocks to work from Ground Mode.

  • Page 120: Lss Connector Pin Assignments

    MACHINE SETUP ' LOAD to the original setting. 12. If unsuccessful, the LSS should be re-calibrated. Press Connections for 4045R Lower & Upper Lift Cylinder Head ESC to return to the top level menu and then re- Pressure Transducer adjust MACHINE SETUP ' LOAD to the original setting.

  • Page 121: Lss Troubleshooting

    LSS Visual and Audible Overload Warnings fail • LSS is not enabled in the control system. Connect the JLG Analyzer and enter the Access Level 1 password (33271). Navigate to MACHINE SETUP à LOAD and adjust the configuration to CUTOUT ALL to prevent platform and ground to sound when the platform is loaded beyond rated load.
  • Page 122 Table 6-7. LSS Troubleshooting (Continued) LIFT CYLINDER HEAD PRESSURE 2 – OUT OF For the 4045R, this fault is triggered when the upper lift cylinder head pressure reading is high. This occurs when RANGE HIGH (8525) ground module V3-15 exceeds 4.75V for 500mS. Check the wire harness that connects to the lift cylinder for short circuits (crushed).

  • Page 123: Diagnostic Trouble Codes

    For example: a “211” on page 7-3 - Power Up would be indicated by 2 flashes, a pause, then 1 flash, a pause, then would keep repeating until the fault is cleared. The more detailed three digit code numbers in the DTC column of the following tables are only indicated on a JLG hand- held diagnostic analyzer.

  • Page 124: Dtc Check Tables

    SECTION 7 - DIAGNOSTIC TROUBLE CODES DTC CHECK TABLES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code EVERYTHING OK None None • No Motion restrictions Platform Mode and no Faults are active. GROUND MODE OK None None •...
  • Page 125 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code POWER CYCLE None • No Motion restrictions This Help Message is issued at each power-up. This serves to indicate which messages have been recorded in the failure log since the last power-up event.
  • Page 126 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code FUNCTION PROBLEM – STEER RIGHT None • DriveState = PREVENTED Steer Right Switch in the Platform Control Box was PERMANENTLY SELECTED closed during power-up.
  • Page 127 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 23198 PRESSURE SENSOR 2 OUT OF RANGE • OverloadState= TRUE A short to Battery was detected on the the HIGH PRSTR_SIG2 or reading was >22mA. The Ground module should disable the VSHORT FET to protect the board components.
  • Page 128 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code AMBIENT TEMPERATURE SENSOR – PF: Continuous 2_4 • Drive and Lift Restrictions The temperature as communicated by the tempera- OUT OF RANGE LOW ture/tilt sensor is less than -40 degrees Celsius.
  • Page 129 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 2512 ELEV ANGLE SENSOR NOT DETECTING None • LiftUpState = PREVENTED The input voltage from the Elevation Angle Sensor CHANGE • PlatformHeightValue that measures lower arm motion did not increment/ assumed to be Full Elevation decrement properly while the vehicle was lifting...
  • Page 130 MODEL CHANGED – HYDRAULICS SUS- None • DriveState = PREVENTED The user changed the Model Selection using the JLG PENDED – CYCLE EMS • LiftUpState = PREVENTED Analyzer. All functions are being prevented until the •...
  • Page 131 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code OPEN CIRCUIT LINE CONTACTOR None • DriveState = PREVENTED The vehicle's Main Line Contactor did not close when • LiftUpState = PREVENTED energized.
  • Page 132 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 3213 POWER MODULE MAIN CONTACTOR - None • DriveState = PREVENTED Curtis Code 31: Coil 1 Driver Open/Short SHORT TO GROUND OR OPEN CIRCUIT •...
  • Page 133 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 33320 DRIVE REVERSE VALVE – OPEN CIRCUIT None • Disable Output Open Circuit detected on DRIVE_REV_VLV • DriveState = PREVENTED 33321 DRIVE REVERSE VALVE – SHORT TO None •...
  • Page 134 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code LIFT DOWN VALVE – OPEN CIRCUIT None • Disable Highside Output Open Circuit detected on LIFT_DN_VLV • Open Lowside Output • LiftDownState = PREVENTED •...
  • Page 135 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4235 POWER MODULE TOO HOT - REDUCED None • DriveState =CREEP Curtis Code 22: Controller Overtemp Cutback OPERATION • LiftUpState = CREEP Set: Heatsink temperature exceeded 185°F (85°C).
  • Page 136 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code BATTERY VOLTAGE TOO HIGH – SYSTEM None • Enter SafeMode The Ground Module measured excessively high bat- SHUTDOWN • LiftDownState = MAX tery voltage (VBAT) (>32.0V) and de-energized the Main Line Contactor and Battery Relay to protect sys- tem devices and was unable to bring voltage down to...
  • Page 137 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4473 POWER MODULE VOLTAGE TOO LOW - None • DriveState =CREEP Curtis Code 23:B+ Undervoltage Cutback REDUCED OPERATION • LiftUpState = CREEP Set: Capacitor bank voltage dropped below the Undervoltage limit with FET bridge enabled Effect: Reduced Drive Torque...
  • Page 138 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4477 BATTERY VOLTAGE TOO HIGH – FORC- None • Disable VSW, The Ground Module momentarily measured exces- ING DISCHARGE LiftDownState = PREVENTED sively high battery voltage (VBAT) (>32.0V) and LiftUpState = PREVENTED entered SafeMode.
  • Page 139 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code CANBUS FAILURE – PLATFORM MOD- None • All Platform functions Pre- In PlatformMode, the control system failed to receive vented. Normal operation messages from the Platform Module.
  • Page 140 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 8215 LSS ANGLE SENSOR – OUT OF RANGE None • LiftUpState = PREVENTED The Elevation1RawValue reading when the machine • PlatformHeightValue is at minimum elevation has deviated from the assumed to be Full Elevation Elevation1MinCalValue.
  • Page 141 • DriveState = PREVENTED The Ground Module has not been configured for the NOT CONFIGURED • LiftUpState = PREVENTED first time. Use the JLG Analyzer to adjust all Machine • LiftDownState = PREVENTED Setup and Personality settings and re-cycle power to clear difficulty.
  • Page 142 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 9952 POWER MODULE FAILURE – INTERNAL None • DriveState = PREVENTED Curtis Code 43: Pump Throttle Wiper High ERROR • LiftUpState = PREVENTED Set: Pot2 wiper voltage is lower than the high fault threshold (can be changed with the VCL funciton Setup_Pot_Faults())
  • Page 143 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 9957 POWER MODULE FAILURE – INTERNAL None • DriveState = PREVENTED Curtis Code 68: VCL Run Time Error ERROR • LiftUpState = PREVENTED Set: Runtime VCL code error condition Effect: ShutdownMotor,ShutdownMainContac- tor,ShutdownEMBrake, ShutdownThrottle, Shut-...
  • Page 144 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code FUNCTIONS LOCKED OUT - POWER None • DriveState = PREVENTED The control system will not function because the MODULE SOFTWARE VERSION •...

  • Page 145: General Electrical Information & Schematics

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CON- TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

  • Page 146: Voltage Measurement

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 8-1. Voltage Measurement (DC) Figure 8-2. Resistance Measurement • If meter is not auto ranging, set it to the correct • First test meter and leads by touching leads range (See multimeter’s operation manual).

  • Page 147: Continuity Measurement

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 8-3. Continuity Measurement Figure 8-4. Current Measurement (DC) • Some meters require a separate button press to • Set up the meter for the expected current range. enable audible continuity testing.

  • Page 148: Continuity Measurement Over Long Distances

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness.

  • Page 149: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. •...

  • Page 150: Deutsch Hd, Dt, Dtm, Drc Series

    Apply dielectric grease to the female contact. If trapped air prevents the connector from latching, pierce one of the unused wire seals. After assembly, install a seal plug (JLG #4460905) in that location to prevent moisture ingress. Note that seal plugs may be installed by the wire harness manufacturer if an unused wire seal becomes compromised (wire inserted in the wrong cavity during assembly and then corrected).

  • Page 151: Amp Mate-N-Lok

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-6. Use of Seal Plugs AMP Mate-N-Lok This connector system is widely used inside enclosures for general-purpose interconnect. Follow the general guidance for installation. 3121761...

  • Page 152: Din Connectors

    Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required). The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 connector system.
  • Page 153 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-8. Phoenix Contact M12 – No Dielectric Grease ENGINE CONTROL UNIT CONNECTORS Many times, these types of connectors use back-seals for moisture integrity. However, the low-force contacts cannot dis- place dielectric grease and create electrical contact. It is possible to use solvents (i.e. contact cleaner or mineral spirits) for the removal of improperly applied dielectric grease.
  • Page 154 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SEALED ENCLOSURES Application of dielectric grease is not required in properly sealed enclosures. To meet criteria, the enclosure must be rated to at least IP66 (dust tight; protected from powerful jets of water). The enclosure must be fitted with a high quality, contin- uous gasket and all wiring must pass through cable entrances.

  • Page 155: Amp Connector

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS MOLEX CMC SERIES CONNECTORS The CMC connector family is a sealed, high-density connection system using matte-seal technology for CP 0.635 and 1.50 mm terminals. To guarantee IP6K7 and IP6K9 sealing, a seal plug option is used. However, the low-force contacts cannot displace dielectric grease and create electrical contact.

  • Page 156: Assembly

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 8-10. Connector Assembly (1 of 4)). Pro- ceed as follows: Figure 8-10. Connector Assembly (1 of 4) 1.

  • Page 157: Disassembly

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-12. Connector Assembly (3 of 4) Figure 8-13. Connector Assembly (4 of 4) Disassembly 1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 2.

  • Page 158: Wedge Lock

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-14. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. Wedge Lock The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife.

  • Page 159: Service - Voltage Reading

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector sys- tem.

  • Page 160: Working With Deutsch Connectors

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 8-16. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

  • Page 161: Hd30/Hdp20 Series Disassembly

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-19. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing. HD30/HDP20 Series Disassembly Figure 8-20. HD/HDP Contact Removal 1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 2.

  • Page 162: Switches

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Induc- tive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch.

  • Page 163: Automatic Switches

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.

  • Page 164: Electrical Schematics

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS ARMSTACK POWER 1001200627_E - Sht. 3 of 9 Figure 8-22. Electrical Schematic 8-20 3121761...
  • Page 165 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ARMSTACK POWER 1001200627_E - Sht. 3 of 9 Figure 8-22. Electrical Schematic 3121761 8-21...
  • Page 166 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 4 of 9 Figure 8-22. Electrical Schematic 8-22 3121761...
  • Page 167 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 4 of 9 Figure 8-22. Electrical Schematic 3121761 8-23...
  • Page 168 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 5 of 9 Figure 8-22. Electrical Schematic 8-24 3121761...
  • Page 169 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 5 of 9 Figure 8-22. Electrical Schematic 3121761 8-25...
  • Page 170 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E-Sht. 6 of 9 Figure 8-22. Electrical Schematic 8-26 3121761...
  • Page 171 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E-Sht. 6 of 9 Figure 8-22. Electrical Schematic 3121761 8-27...
  • Page 172 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 7 of 9 Figure 8-22. Electrical Schematic 8-28 3121761...
  • Page 173 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 7 of 9 Figure 8-22. Electrical Schematic 3121761 8-29...
  • Page 174 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 8 of 9 Figure 8-22. Electrical Schematic 8-30 3121761...
  • Page 175 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001200627_E - Sht. 8 of 9 Figure 8-22. Electrical Schematic 3121761 8-31...

  • Page 176: Hydraulic Schematics

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HYDRAULIC SCHEMATICS 1001213345_B Figure 8-23. Hydraulic Schematic 8-32 3121761...
  • Page 177 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001213345_B Figure 8-23. Hydraulic Schematic 3121761 8-33...
  • Page 178 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 8-34 3121761...
  • Page 180 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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