JLG 4045R Operation And Safety Manual
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JLG 4045R Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
4045R
3121760
AS/NZS GB
ANSI
®
March 12, 2019 - Rev F

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) 4045R 3121760 AS/NZS GB ANSI ® March 12, 2019 - Rev F...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 4 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating proce- dures 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 noti- fication. Contact JLG Industries, Inc. for updated information.
  • Page 5 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO THE POTEN- TIAL PERSONAL INJURY HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO AVOID POSSIBLE INJURY OR DEATH. INDICATES A POTENTIALITY HAZARDOUS SITUATION.
  • Page 6 • Questions Regarding NOTICE uct Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT Contact: THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.
  • Page 7 REVISION LOG REVISION LOG Original Issue A -June 1, 2017 Revised B - October 16, 2017 Revised C - November 3, 2017 Revised D - December 5, 2017 Revised E - June 29, 2018 - Revised Covers, Prop 65 Revised F - March 12, 2019 3121760...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS PREPARATION, INSPECTION, AND MAINTENANCE ..2-2 PRE-START INSPECTION ........2-4 GENERAL .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE PLATFORM CONTROL STATION......3-10 3.12 PARKING AND STOWING MACHINE.
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Electrical System ........5-7 Operation .
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE PLATFORM WORK LIGHTS .......6-18 LIST OF FIGURES Operation .
  • Page 12 6-15. Footswitch Installation ......6-22 4045R - Available Accessories ......6-1 6-16.

  • Page 13: Section - Paragraph, Subject Page

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally 3121760...

  • Page 14: Section 1 - Safety Precautions

    JLG Industries, Inc. (“JLG”). A maintenance program, using the information provided in this manual and the Service and Maintenance Manual,...

  • Page 15: Pre-Operation

    JLG Industries, Inc. • Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utili- zation and application of the machine.

  • Page 16: Machine Inspection

    JLG. • Check the machine for modifications to original compo- • Ensure that the ground conditions are adequate to support nents.

  • Page 17: Operation

    SECTION 1 - SAFETY PRECAUTIONS OPERATION • Do not carry materials directly on platform railing unless approved by JLG. General • When two or more persons are in the platform, the operator • Machine operation requires your full attention. Bring the shall be responsible for all machine operations.

  • Page 18: Trip And Fall Hazards

    • 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 plat- form wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine.

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards • This machine is not insulated and does not provide protec- • The minimum approach distance may be reduced if insulat- tion from contact or proximity to electrical current. ing barriers are installed to prevent contact, and the barri- •...

  • Page 20: Tipping Hazards

    Keep all loads within the confines of the Over 200 KV to 350 KV 20 (6) platform, unless authorized by JLG. Over 350 KV to 500 KV 25 (8) • Keep the chassis of the machine a minimum of 2 ft. (0.6m)
  • Page 21 SECTION 1 - SAFETY PRECAUTIONS • Wind speed can change rapidly. Always consider approach- • Do not increase the platform size with unauthorized modifi- ing weather events, the time required to lower the platform, cations or attachments. and methods to monitor current and potential wind condi- tions.

  • Page 22: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. • Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors.
  • Page 23 SECTION 1 - SAFETY PRECAUTIONS • During operation, keep all body parts inside platform rail- • Be aware of stopping distances in all drive speeds. When ing. driving in high speed, switch to low speed before stopping. Travel grades in low speed only. •...

  • Page 24: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which hauling. must be observed during maintenance of this machine. Addi- • This machine should not be towed, except in the event of tional precautions to be observed during machine mainte- emergency, malfunction, power failure, or loading/unload- nance are inserted at the appropriate points in this manual...

  • Page 25: Battery Hazards

    • Use only replacement parts or components that are • Do not contact tools or other metal objects across the bat- approved by JLG.  To be considered approved, replacement tery terminals. parts or components must be identical or equivalent to original parts or components.

  • Page 26: Section 2 - User Responsibilities, Machine Preparation And Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION PERSONNEL TRAINING 8. Means to avoid the hazards of unprotected electrical conductors. The Mobile Elevating Work Platform (MEWP) is a personnel han- 9. Selection of the appropriate MEWPs and available options dling device, so it is necessary that it be operated and main- for the work to be performed considering specific job tained only by trained personnel.

  • Page 27: Machine Familiarization

    NOTE: Responsibilities for familiarization may vary by region. Table 2-1 explains the periodic machine inspections and main- tenance recommended by JLG Industries, Inc. Consult local reg- Only properly trained personnel who have received unit-spe- cific familiarization shall operate a MEWP. The user shall deter- ulations for further requirements for MEWPs.
  • Page 28 NOTE: Inspection forms are available from JLG. Use the Service and 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 SPECIFIC JLG PRODUCT MODEL.

  • Page 29: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION PRE-START INSPECTION 3. Decals and Placards – Check all for cleanliness and legibility. Ensure none of the decals and placards are The Pre-Start Inspection should include each of the following: missing. Ensure all illegible decals and placards are cleaned or replaced.
  • Page 30 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 10. Platform Gate - Keep gate and surrounding area clean and unobstructed. Check that gate closes properly and is not bent or damaged. During operation keep gate closed. Self-Closing Swing Gate 3121760...
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 11. Lanyard Anchorage Points - JLG Industries, Inc. recommends personnel in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point (1). Lanyard Attach Points...

  • Page 32: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION DAILY WALK-AROUND INSPECTION 3. Hydraulic Pump/Motor, Control Valve Installation - No unsupported wires or hoses; no damaged or broken Begin the “Walk-Around Inspection” at item 1, see Figure 2-1. wires - See Inspection Note. Continue checking each item in sequence for the conditions 4.

  • Page 33: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection (Side Compartment Doors Open) 3121760...

  • Page 34: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION FUNCTION CHECK Perform the Function Check as follows: 1. From the Ground Control Panel with no load in the platform: (See Figure 3-2. on page 3-5) a. Ensure that the key selector switch and the plat- Platform Elevated - Pot-Hole Bars Fully Lowered form lift switch operates properly.
  • Page 35 31 ft. - max. 9.4 - max. Table 2-2. High Drive Cutout Height 2.00 ° - outdoor 23 - 25 ft. 7 - 7.6 m 4045R 3.50° HIGH DRIVE SPEED 2.00° - indoor 27 - 31 ft. 8.2 - 9.4 m...
  • Page 36 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 37: Section 3 - Machine Controls, Indicators And Operation

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION GENERAL DESCRIPTION This machine is a Mobile Elevating Work Platform (MEWP) used NOTICE to position personnel, along with their necessary tools and THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICA- materials at work locations.

  • Page 38: Operating Characteristics And Limitations

    2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 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 39: Machine Control Locations

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION MACHINE CONTROL LOCATIONS 1. Ground Control Station 2. Platform Control Station 3. Platform Manual Descent Control (T-Handle) 4. AC Plug - At Rear of Machine - For Platform AC Receptacle Outlet Box 5.

  • Page 40: Battery Charging

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION BATTERY CHARGING 3. After connecting the charger to an AC outlet at the start of the charging cycle, check the LED indicators on NOTE: Be sure that machine is parked in a well ventilated area the charger for normal operation or if a fault has before charging begins.

  • Page 41: Ground Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION GROUND CONTROL STATION Figure 3-2. Ground Control Station 1. Ground/Platform/OFF Key Selector Switch 5. Hourmeter 2. Platform Lift/Lower Switch 6. Overload Indicator 7. MDI - Indicator (If Equipped) 3. Inverter ON/OFF Switch (If Equipped) 4.

  • Page 42: Ground/Platform/Off Key Selector Switch

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform Lift/Lower Switch A three position, momentary contact lift DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN control switch provides raising and lowering THE PLATFORM EXCEPT IN AN EMERGENCY. of the platform from the Ground Control Station.

  • Page 43: Ground Emergency Stop Switch

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Ground Emergency Stop Switch MDI Indicator (If Equipped) Power is turned on by pulling the switch out, The MDI indicator or Multifunction Digital Indicator displays a and is turned off by depressing switch. A two- Battery Discharge Indicator (BDI), an LCD display which shows position, red, mushroom-shaped emergency the current hour-meter reading or Diagnostic Trouble Code(s)

  • Page 44: Mdi Indicator

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION NOTE: When more than one DTC exists, each DTC will be dis- played on the LCD for 3 seconds before changing to the next DTC. Once the last active DTC is displayed, the display will recycle indefinitely until the DTC’s are corrected.

  • Page 45: Platform Manual Descent Control

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION PLATFORM MANUAL DESCENT CONTROL The platform manual descent control is used in the event of total power failure to lower the platform using gravity. The man- ual descent control T-handle is located on the left rear of the machine, just below the platform ladder.

  • Page 46: Platform Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION PLATFORM CONTROL STATION 1. Emergency Stop Switch 2. Lift/Drive Select Switch 3. Black/White Directional Arrow 4. Steer Switch and Decal 5. Controller 6. Trigger Switch (on front of controller) 7. Overload Indicator (LSS) 8.

  • Page 47: Platform Control Station (Module P/N 1001228112)

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 1. Emergency Stop Switch 2. Lift/Drive Select Switch 3. Black/White Directional Arrow 4. Steer Switch and Decal 5. Controller 6. Trigger Switch (on front of controller) 7. Overload Indicator (LSS) 8. Tilt Indicator 9.

  • Page 48: Platform Emergency Stop Switch

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform Emergency Stop Switch This toggle switch is used to select operation of either the drive or lift function. After selecting a function, the joystick controller NOTE: Both the ground and platform emergency stop buttons must be moved in the proper direction in order to activate that must be set to ON in order to operate the machine.

  • Page 49: Drive/Lift/Steer Joystick Control

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Drive/Lift/Steer Joystick Control Steering And Traveling Trigger (Enable) Switch - This switch is located on the front of the joystick controller. The trigger switch acts as an enable and must be depressed before operating the drive, steer and lift DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM SUR- functions.

  • Page 50: Steering

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Steering Raising And Lowering Platform On the platform control station, position the 1. If the machine was shut down, place the key selector lift/drive select switch to the drive position. switch to the platform position. To steer the machine, engage trigger switch 2.

  • Page 51: Grade And Sideslope Definition

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION LEVEL Figure 3-6. Grade and Sideslope Definition 3121760 3-15...

  • Page 52: Arm Guards (If Equipped)

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Arm Guards (If Equipped) Tilt Indicator Warning Light and Alarm If the machine is equipped with electronic arm guards, the plat- A red warning light on the control panel illu- form will stop lowering at a predetermined height and the minates and an audible alarm sounds when machine’s beacons will flash at a different rate to warn ground the chassis is at or beyond the tilt cutout set-...

  • Page 53: Horn

    RED LED ON solid = batteries low, RED LED If the code cannot be cleared by the opera- ON and GREEN LEDs ON = batteries FULL charge. tor, the machine will require service by a qualified JLG mechanic. 1. On platform control consoles with module P/N 1001224873 2.

  • Page 54: Alarm

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Alarm Low/High Drive Speed This alarm mounted on the front of the platform control station The two position speed switch controls will sound for various machine conditions or warnings such as, high or low range drive speed. High speed system ready chirp or if the machine tilt warning is activated.

  • Page 55: 3.10 Platform Extension

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.10 PLATFORM EXTENSION To retract the deck: 1. Push down on the locking mechanism lever (1) using (See Figure 3-7.) your foot, hold down on the lever and slide the top This machine is equipped with an extension deck, giving the handrails (2) rearward until the locking mechanism operator better access to certain work areas.

  • Page 56: Platform Rails Fold-Down Procedure

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.11 PLATFORM RAILS FOLD-DOWN PROCEDURE (If 1. Remove platform top rail pins (four total - two front, two rear) and fold the FRONT and REAR GATE platform Equipped) rails down onto the platform deck. 2.

  • Page 57: Platform With Dual Rail Extension - Fold Down

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-8. Platform with Dual Rail Extension - Fold Down Sequence 3121760 3-21...

  • Page 58: Platform With Rail In Rail Extension Deck

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform with Rail In Rail Extension Deck To raise the rails back to the upright position, unfold the rails in the reverse sequence they were folded and replace the bail pins (See Figure 3-9.) to secure rails.

  • Page 59: Platform With Rail In Rail Extension - Fold Down

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-9. Platform with Rail in Rail Extension - Fold Down Sequence 3121760 3-23...

  • Page 60: 3.12 Parking And Stowing Machine

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.12 PARKING AND STOWING MACHINE 1. Drive the machine to a well-protected and well-venti- lated area. 2. Ensure the platform is fully lowered. NOTICE WHEN THE MACHINE IS SHUT DOWN FOR OVERNIGHT PARKING OR BATTERY CHARGING, THE EMERGENCY STOP AND POWER SELECT SWITCHES MUST BE POSITIONED TO OFF TO PREVENT DRAINING THE BATTERIES.

  • Page 61: 3.13 Machine Lifting And Tie Down

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.13 MACHINE LIFTING AND TIE DOWN Lifting The machine may be lifted using a fork lift truck. Lift only using the built-in fork lift pockets on the side of the machine, and only with the platform in the stowed position.

  • Page 62: Tie Down

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Tie Down When transporting the machine, the platform must be fully low- ered in the stowed position with the machine securely tied down to the truck or trailer deck. There are two tie-down and one lift lugs located at the front and two tie-down/lift lugs on the rear of the machine.
  • Page 63 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-13. Tie Down and Lift Lug Locations 3121760 3-27...

  • Page 64: 3.14 Towing

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.14 TOWING 5. Pump the RED knob (3) until pressure builds, approxi- mately 5 to 10 strokes. The brakes should now be It is not recommended that this machine be towed, except in released.

  • Page 65: Section 4 - Emergency Procedures

    SECTION 4 - EMERGENCY PROCEDURES SECTION 4. EMERGENCY PROCEDURES GENERAL INFORMATION Platform Caught Overhead If the platform becomes jammed or snagged in overhead This section explains the steps to be taken in case of an emer- structures or equipment, do the following: gency situation during operation.

  • Page 66: Platform Manual Descent

    SECTION 4 - EMERGENCY PROCEDURES PLATFORM MANUAL DESCENT The platform manual descent control is used in the event of total power failure to lower the platform using gravity. The man- ual descent control T-handle is located on the left rear of the machine, just below the platform ladder.

  • Page 67: Incident Notification

    SECTION 4 - 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.
  • Page 68 SECTION 4 - EMERGENCY PROCEDURES NOTES: 3121760...
  • Page 69 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 70: Section 5 - General Specifications And Maintenance

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE SECTION 5. GENERAL SPECIFICATIONS AND MAINTENANCE INTRODUCTION Other Publications Available Specific to this Machine Service and Maintenance Manual........3121761 This section of the manual provides additional necessary infor- mation to the operator for proper operation and maintenance Illustrated Parts Manual ............3121759 of this machine.

  • Page 71: Operating Specifications

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE OPERATING SPECIFICATIONS Table 5-1. Operating Specifications DESCRIPTION 4045R PLATFORM ANSI/CSA/CE/AUS/GB Maximum Platform Height (Ground to Platform Floor - Elevated) 39.3 ft. (11.9 m) 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 72 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-1. Operating Specifications (Continued) DESCRIPTION 4045R Elevated Drive Height Indoor: 39 ft. (11.9 m) 28.7 ft. (8.75 m) - ANSI/CE/CSA/GB Outdoor: 39 ft. (11.9 m) - AUS Turning Radius Inside: 0 in. (0 cm) 92 in.

  • Page 73: Platform Capacities

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Platform Capacities Table 5-2. Platform Capacities MAXIMUM MAX. SIDE FORCE MAXIMUM MAXIMUM MAXIMUM CAPACITY ALLOWED (Platform Fully MAXIMUM PERSONS SPECIFICATION OPERATING PLATFORM OPERATING ENVIRONMENT ON PLATFORM ALLOWED IN PLATFORM Extended HEIGHT CAPACITY WIND SPEED EXTENSION @ Max.

  • Page 74: Machine Dimensional Data

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Machine Dimensional Data Tires Table 5-3. Dimensions Table 5-4. Tire Specifications DESCRIPTION 4045R DESCRIPTION 4045R Platform Height - Elevated 39.3 ft. (12 m) Size 16 in. x 5 in. (Ground to Platform Floor) (40.6 cm x12.7 cm)

  • Page 75: Batteries

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Batteries Table 5-5. OEM Battery Specifications 4045R DESCRIPTION Lead Acid Voltage (24V System - Series) 12V per battery Amp Hour Rating 150 Amp Hour @ 185 Amp Hour @ 150 Amp Hour @ 20 Hr.

  • Page 76: Electrical System

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Electrical System Table 5-6. Battery Charger Specifications DESCRIPTION 4045R 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...

  • Page 77: Critical Stability Weights

    Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or AGM: 352 lb. (160 kg) MIL-Spec MIL-L-2105. JLG Recommends - Mobil - Mobilfluid 424 Mobil EAL ENVIRONSYN H 32 Mobil SHC HYDRAULIC EAL 32 EAL and SHC are compatible with each other.

  • Page 78: Hydraulic Oil Operating Temperature Chart

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 1001219909-C Figure 5-1. Hydraulic Oil Operating Temperature Chart 3121760...

  • Page 79: Operator Maintenance

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE OPERATOR MAINTENANCE To engage the safety props: 1. From the Ground Control Station, raise the platform Scissor Arm - Safety Props (See Figure 5-2.) far enough to allow the safety props to be engaged. 2.

  • Page 80: Scissor Arm - Safety Props

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Prop Engaged Prop Disengaged Figure 5-2. Scissor Arm - Safety Props (One each side of machine) 3121760 5-11...

  • Page 81: Hydraulic Oil Check Procedure

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Hydraulic Oil Check Procedure 2. If additional oil is required, swing compartment door open and wipe all dirt and debris from the filler/filter (See Figure 5-3., and 5-4.) cap (4) area. Remove filler cap and add proper grade Lube Point(s) - Hydraulic Reservoir of oil.

  • Page 82: Hydraulic Oil Check Procedure

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Figure 5-4. Hydraulic Oil Fill Procedure Figure 5-3. Hydraulic Oil Check Procedure 3121760 5-13...

  • Page 83: Delta-Q - Battery Charger

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Delta-Q - Battery Charger Green Power - Battery Charger (China (GB) Only) All chargers are located at rear of machine inside chassis. 1. AC Voltage Input Cable 2. Charge Indicator LEDs 1. AC Voltage Input Plug 2.

  • Page 84: Eagle Performance - Battery Charger

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Eagle Performance - Battery Charger 1. AC Voltage Input Cable 2. Charge Indicator LEDs • Battery Type Indicator - (YELLOW LED ON) • Battery Charging - (30%-60%-90% RED LED ON) • Charge Complete - (GREEN LED ON) •...

  • Page 85: Battery Maintenance And Safety Practices

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Battery Maintenance and Safety Practices BATTERY FLUID LEVEL OF FULLY FILLER CAP CHARGED BATTERY VENT TUBE NOTE: These instructions are for unsealed (wet) batteries only. If machine is equipped with sealed batteries, no mainte- nance other than cleaning corroded battery terminals is 1/8 "...

  • Page 86: Tire Wear And Damage

    JLG as an approved replacement. Please refer to the JLG Parts • If more than one discrepancy exists in any quadrant of the Manual for the part number of the approved tires for a partic- wheel (within 90 degrees of one another).

  • Page 87: Wheel Installation

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque. WHEEL SLOTTED NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, A BROKEN NUT, AND POSSIBLE SEPARA- TION OF WHEEL FROM THE AXLE.

  • Page 88: Supplemental Information

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A).

  • Page 89: Decal Installation

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE DECAL INSTALLATION Figure 5-7. Machine Decal Installation (See Table 5-10.) 5-20 3121760...

  • Page 90: Machine Decal Installation

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-10. Machine Decal Installation Chart - 4045R ENGLISH ENG/KOR ENG/CHI SPA/POR ENG/SPA ENG/FRE ITEM (1001222124) (1001222125) (1001222126) (1001222127) (1001222128) (1001222129) (1001222130) (1001222131) 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701640 1701640...

  • Page 91: Machine Decal Installation Chart - 4045R

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-10. Machine Decal Installation Chart - 4045R ENGLISH ENG/KOR ENG/CHI SPA/POR ENG/SPA ENG/FRE ITEM (1001222124) (1001222125) (1001222126) (1001222127) (1001222128) (1001222129) (1001222130) (1001222131) 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 1001212290 1001213442 1001213442...

  • Page 92: 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 hand- held diagnostic analyzer connected to the machine, or on the Ground Control Station - MDI indicator, if equipped.

  • Page 93: Diagnostic Trouble Codes (Dtc)

    SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. 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 94 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code FUNCTIONS LOCKED OUT – SYSTEM None None • Enter SafeMode • A period of time elapsed without activity and the Control Sys- POWERED DOWN •...
  • Page 95 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 2210 TRIGGER CLOSED TOO LONG WHILE IN None • TriggerState = FALSE there- • Trigger Switch on the Platform Control Box was closed for NEUTRAL fore more than five seconds while the Joystick (accelerator) was in...
  • Page 96 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. 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 closed PERMANENTLY SELECTED during power-up.
  • Page 97 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code PLATFORM OVERLOADED PF: 5000ms • Drive and Lift Restrictions • While the Load Sensing System is enabled, the Platform Load ON/2000ms measured by the Load Sensing System is excessive.
  • Page 98 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 2568 TEMPERATURE CUTOUT ACTIVE - AMBI- If Transport- • Drive and Lift Restrictions • The temperature as communicated by the temperature sensor ENT TEMPERATURE TOO LOW Mode = TRUE located on the temperature/tilt sensor is less than or equal to...
  • Page 99 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code MASTER MODULE TEMPERATURE – None • Normal operation • The Ground Module's internal temperature sensor is out of OUT OF RANGE range.
  • Page 100 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4424 POWER MODULE VOLTAGE TOO LOW - None • DriveState = PREVENTED • Severe B+ Undervoltage Set: Capacitor bank voltage MODULE SHUTDOWN •...
  • Page 101 SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4477 BATTERY VOLTAGE TOO HIGH – FORC- None Lift Down = PREVENTED • The Ground Module momentarily measured excessively high ING DISCHARGE Lift Up = PREVENTED battery voltage (VBAT) (>32.0V) and entered SafeMode.
  • Page 102 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 103: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. 4045R - Available Accessories ACCESSORY ANSI China      DC/AC Inverter      Quick Welder      Workstation (Unpowered)   ...
  • Page 104 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table REQUIRED COMPATIBLE WITH INTERCHANGABLE ACCESSORY INCOMPATIBLE WITH ITEM ( Note 1) WITH (Note 2) DC/AC Inverter — — — Quick Welder Fire Extin- Inverter, Workstation, Pipe Racks, Panel Carrier, Platform Work Lights, Electrician’s Tree, Rail Padding Anti-Vandal Package, Fire Extinguisher, Machinist’s Vise, Extension —...
  • Page 105 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table (Continued) REQUIRED COMPATIBLE WITH INTERCHANGABLE ACCESSORY INCOMPATIBLE WITH ITEM ( Note 1) WITH (Note 2) Workstation, Electrician’s Tree, Pipe Platform Work Lights Inverter, Quik Welder, Anti-Vandal Package, Fire Extinguisher, Machin- — ist’s Vise, Extension Handles, OH Protection, Footswitch, Dual Rails, Racks, Panel Carrier, Rail Padding —...

  • Page 106: Dc/Ac Power Inverter

    SECTION 6 - ACCESSORIES DC/AC POWER INVERTER DESCRIPTION SPECIFICATION The DC to AC Power Inverter is used to covert DC voltage Electrical System Voltage (DC) from the onboard system batteries to AC voltage for use at Power Inverter: Power Bright the platform AC output receptacle.

  • Page 107: Preparation And Inspection

    • Do not allow water or other liquids to contact the QUIKWELDER™ inverter. The JLG QuikWelder™ is a self-contained Miller wire-feed Preparation and Inspection welder. It is able to weld light to heavy gauge steel with a single welder and has twice the power of a 110-volt plug- •...

  • Page 108: Jlg Quickwelder Installation

    SECTION 6 - ACCESSORIES 1. Power Input Cable 4. Welder 2. Welder Leads 5. Wire Rod Spool 1. QuikWelder Assembly 2. Fire Extinguisher 3. ON/OFF Switch 6. Decal (Weight) Figure 6-2. JLG QuickWelder Installation Figure 6-3. JLG QuickWelder Components 3121760...

  • Page 109: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Ensure the power cable is connected to the battery and routed through the arm-stack with the platform cable. Operation THIS ACCESSORY AFFECTS THE OVERALL PLATFORM CAPACITY. REFER TO THE CAPACITY DECAL AND ADJUST ACCORDINGLY. 1.

  • Page 110: Workstation

    SECTION 6 - ACCESSORIES WORKSTATION The WorkStation offers additional space for storage of tools and objects as well as an adjustable work surface. 1. Workstation Assembly Figure 6-4. Workstation Installation NOTE: The WorkStation can be attached anywhere in the plat- form unless the machine is equipped with another acces- 3121760...

  • Page 111: Safety Precautions

    SECTION 6 - ACCESSORIES sory, at which point the WorkStation must be attached on Preparation and Inspection the opposite side. • Ensure the WorkStation is secured to the platform. Safety Precautions • Check for any missing or damaged components. Replace if necessary. •...

  • Page 112: Electrician's Tree

    SECTION 6 - ACCESSORIES 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. 1. Electrician’s Tree Assembly 3. Decal (Weight) 2.

  • Page 113: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Operation 1. Remove release pins and rotate the rack from the stowed position. THIS ACCESSORY AFFECTS THE OVERALL PLATFORM CAPACITY. REFER TO THE 2. Pull the hitch pin for the spool rod to be loaded. CAPACITY DECAL ON THE ACCESSORY AND ADJUST ACCORDINGLY.

  • Page 114: Pipe Racks

    SECTION 6 - ACCESSORIES PIPE RACKS The Pipe Racks provide a way to store pipe or conduit inside the platform in order to prevent rail damage and optimize platform utility when transporting material to an elevated site. It consists of two racks, attached to the plat- form handrails, with adjustable straps that secure the load in place.

  • Page 115: Safety Precautions

    • Replace missing or illegible decals. MULTIPLE MATERIAL-HANDLING ACCESSORIES CAN BE INSTALLED BUT ONLY • Replace any torn or frayed straps. ONE MAY BE LOADED AT A TIME UNLESS APPROVED BY JLG INDUSTRIES, INC. Operation 1. To prepare racks for loading, remove work/stow lock- THIS ACCESSORY AFFECTS THE OVERALL PLATFORM CAPACITY.

  • Page 116: Panel Carrier

    SECTION 6 - ACCESSORIES PANEL CARRIER The Panel Carrier can transport flat sheets or panels to an elevated site by positioning them in a channel on the out- side of the platform. It consists of a carrier tray that runs parallel to the length of the platform and an adjustable bracket mounted to the handrail to hold material in place.

  • Page 117: Safety Precautions

    Replace if necessary. MULTIPLE MATERIAL-HANDLING ACCESSORIES CAN BE INSTALLED BUT ONLY ONE MAY BE LOADED AT A TIME UNLESS APPROVED BY JLG INDUSTRIES, INC. • Check for loose nuts and bolts. If necessary, torque according to the Torque Chart specifications in Sec- THIS ACCESSORY AFFECTS THE OVERALL PLATFORM CAPACITY.

  • Page 118: Vise

    SECTION 6 - ACCESSORIES VISE The Vise allows the operator to secure material for assem- bling, disassembling, drilling, etc., while working from the platform. 1. Vise Assembly 3. Attach Pins 2. Capacity Decal (Weight) Figure 6-8. Machinist’s Vise Installation NOTE: If the WorkStation is installed, it must be mounted to the opposite side of the platform from the Vise.

  • Page 119: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Operation 1. Load material into the Vise. 2. Tighten the handle until secure. THIS ACCESSORY AFFECTS THE OVERALL CAPACITY OF THE PLATFORM. REFER 3. Begin working. TO THE CAPACITY DECAL AND ADJUST ACCORDINGLY. • Do not drive machine with material in the Vise. Preparation and Inspection •...

  • Page 120: Platform Work Lights

    SECTION 6 - ACCESSORIES PLATFORM WORK LIGHTS The Platform Work Lights accessory consists of two 24V lights that mount to the platform railings. 1. ON/OFF Switch 3. Mounting Bracket 2. Handle Figure 6-10. Work Light Components Operation Flip the On/Off switch to operate. Use the handle on the 1.

  • Page 121: Platform Rail Padding

    SECTION 6 - ACCESSORIES PLATFORM RAIL PADDING The Platform Rail Padding provides bumpers to the platform rails in order to prevent damage to the platform itself as well as objects it may come in contact with during operation. 1. Extension Platform - Rail Padding 3.

  • Page 122: 6.10 Anti-Vandalism Package

    SECTION 6 - ACCESSORIES 6.10 ANTI-VANDALISM PACKAGE The Anti-Vandalism Package consists of two lockable cov- ers for the Platform and Ground Control Stations that pre- vent unauthorized use of the machine. Locks are not provided with this kit. 1. Platform Covers Closed 2.

  • Page 123: 6.11 Rail Mounted Platform Extension Handles

    SECTION 6 - ACCESSORIES 6.11 RAIL MOUNTED PLATFORM EXTENSION HANDLES The platform extension handles accessory 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 it’s stowed position.

  • Page 124: Operation

    SECTION 6 - ACCESSORIES 6.12 FOOTSWITCH The footswitch accessory when installed in the platform acts as another enable switch in the function control cir- cuit. Operation The footswitch must be depressed in sequence with the platform control trigger switch to enable operation of machine functions when using the platform controls.

  • Page 125: 6.13 Magnetic Gate Latch

    SECTION 6 - ACCESSORIES 6.13 MAGNETIC GATE LATCH The platform magnetic gate latch accessory if installed helps ensure the platform gate is securely latched when closed. Operation Grasp handle and swing gate open. 1. Magnetic Gate Latch Assembly Figure 6-16. Magnetic Gate Latch Installation 3121760 6-23...
  • Page 126 SECTION 6 - ACCESSORIES NOTES: 6-24 3121760...

  • Page 127: Section 7. Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log DATE COMMENTS 3121760...
  • Page 128 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log DATE COMMENTS 3121760...
  • Page 131 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

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