JLG 4045R Manuals

Manuals and User Guides for JLG 4045R. We have 2 JLG 4045R manuals available for free PDF download: Service Maintenance Manual, Operation And Safety Manual

JLG 4045R Service Maintenance Manual (180 pages)

Brand: JLG | Category: Scissor Lifts | Size: 14.61 MB

Table of Contents
5
Subject - Section, Paragraph

13
Specifications

13
- Specification
  13
  - Platform Capacities
    14
  - Machine Dimensional Data
    14
  - Tires
    14
  - Batteries
    15
  - Motors
    15
  - Electrical System
    16
- Limit Switch Activation
  17
  - Tilt Alarm
    17
  - High Drive Speed Cutout
    17
- Lubrication
  17
  - Lubrication Capacities
    17
  - Hydraulic Oil
    17
  - Lubrication Specifications
    18
- Hydraulic Pressure Settings
  20
- Hydraulic Cylinder Specifications
  20
- Serial Number Location
  20
- Critical Stability Weights
  21
- Major Component Weights
  21
- Torque Requirements
  21
  - Torque Charts
    22
General

27
- Machine Preparation, Inspection, and Maintenance
  27
- Preventive Maintenance and Inspection Schedule
  29
  - Maintenance and Inspection Schedule Codes
    29
  - Footnotes
    31
- Service Maintenance Components
  32
  - Scissor Arm - Safety Prop
    32
  - Hydraulic Oil Check Procedure
    33
- 2.4 Service and Guidelines
  34
  - General
    34
  - Safety and Workmanship
    34
  - Cleanliness
    34
  - Components Removal and Installation
    34
  - Component Disassembly and Reassembly
    34
  - Pressure-Fit Parts
    34
  - Bearings
    34
  - Gaskets
    34
  - Bolt Usage and Torque Application
    34
  - Hydraulic Lines and Electrical Wiring
    35
  - Hydraulic System
    35
  - Lubrication
    35
  - Battery
    35
- 2.5 Lubrication and Information
  35
  - Hydraulic Oil
    35
  - Changing Hydraulic Oil
    35
- 2.6 Cylinder Drift Test
  36
  - Platform Drift
    36
  - Cylinder Drift
    36
- Pins and Composite Bearing Repair Guidelines
  36
Chassis & Scissor Arms

37
- Left and Right Side Component Compartments
  37
- Battery Removal/Maintenance
  38
  - Battery Quick-Disconnect (if Equipped)
    38
  - Battery Maintenance and Safety Practices
    39
- Battery Charging
  39
- DC/Ac Power Inverter Installation - Option
  45
- Logic Control Module Installation
  46
- Main Power Contactor Relay and Pump Control Module
  47
- Pump Control Module
  48
  - Removal
    48
  - Installation
    48
- Ground Control Station - Folding Cover
  50
  - Components Location
    50
  - Removal
    50
  - Installation
    50
- Ground Control Station - Fixed Cover
  52
  - Components Location
    52
  - Removal
    52
  - Installation
    52
- 3.10 Platform Control Station
  54
  - Installation/Removal
    55
  - Control Station Disassembly
    55
  - Joystick Controller
    57
- 3.11 Tilt Sensor Installation
  58
  - Tilt Sensor Removal
    58
- 3.12 Elevation Sensor
  59
  - Elevation Sensor Installation
    60
- 3.13 Pot-Hole Protection System Components
  61
- 3.14 Steer and Spindle Assembly Components
  62
- Arms and Platform Positioning and Support
  65
- 3.16 Platform Removal
  65
- 3.17 Scissor Arms Removal
  65
  - Removing Scissor Arm Assembly as a Complete Unit
    65
  - Removing/Installing Scissor Arms Individually
    65
Hydraulics

75
- Cylinders - Theory of Operation
  75
- Valves - Theory of Operation
  75
  - Solenoid Control Valves (Bang-Bang)
    75
  - Relief Valves
    75
  - Crossover Relief Valves
    75
  - Proportional Valve
    75
  - Manual Descent Valve
    75
- Pump/Motor
  76
  - Pump Motor Electrical Evaluation
    76
- Hydraulic Tank Installation
  78
  - Hydraulic Oil Check Procedure
    79
- Hydraulic Pump and Electric Motor Assembly
  80
  - Pump/Motor Removal
    80
  - Pump/Motor Disassembly
    81
  - Pump/Motor Assembly
    81
  - Pump/Motor Installation
    81
- Hydraulic Manifold Valve Installation
  82
- Hydraulic Manifold Assembly - Component Torque
  84
- Hydraulic Hose Routing
  85
- Lift Cylinder - Lower
  85
- Lift Cylinder - Upper
  85
- Steer Cylinder
  85
- Drive Motor Installation
  86
- Hydraulic Brake Installation
  87
  - Hydraulic Brake Release
    87
- Pressure Setting Procedure
  88
  - Main Relief
    88
  - Lift up Relief
    88
  - Steer Relief
    88
- 4.10 Cylinder Checking Procedure
  89
- 4.11 Lift Cylinder Removal/Installation
  89
- 4.12 Lower Lift Cylinder
  90
  - Disassembly
    90
  - Assembly
    90
- 4.13 Upper Lift Cylinder
  90
- 4.14 Cylinder Repair
  94
  - Disassembly
    94
  - Cleaning and Inspection
    95
  - Assembly
    95
Jlg Control System

99
- Hand Held Analyzer
  99
  - Diagnostic Port
    99
  - To Connect the Hand Held Analyzer
    99
  - Using the Analyzer
    101
  - Changing the Access Level of the Hand Held Analyzer
    102
  - Adjusting Parameters Using the Hand Held Analyzer
    103
  - Machine Setup
    103
- Joystick Calibration
  104
- Tilt Sensor Calibration
  104
  - Tilt Sensor Failure Troubleshooting
    104
- Elevation Sensor Calibration
  105
- Updating Software
  105
- Machine Configuration Programming Information
  110
- Machine Model Adjustment (Personality Settings)
  111
Lss (Load Sensing System) Service

113
- Theory of Operation
  113
- LSS Component Locations
  114
- Analyzer Information
  115
  - Personalities Menu
    115
  - Diagnostic Menu
    115
- Calibration Preparation
  117
- Calibration and Verification Procedures
  118
  - Empty Platform (Load 0%) Calibration
    118
  - Loaded Platform (Load 110%) Calibration
    118
  - LSS Verification
    118
  - Partial Height Calibration
    119
- Testing
  119
- Lss Connector Pin Assignments
  120
- Lss Troubleshooting
  121
Diagnostic Trouble Codes

123
- Introduction
  123
  - System Fault/Dtc Indication
    123
- Diagnostic Trouble Codes (Dtc)
  123
- Dtc Check Tables
  124
General Electrical Information & Schematics

145
- General
  145
- Multimeter Basics
  145
  - Grounding
    145
  - Backprobing
    145
  - Min/Max
    145
  - Polarity
    145
  - Scale
    145
  - Voltage Measurement
    146
  - Resistance Measurement
    146
  - Voltage Measurement (DC)
    146
  - Continuity Measurement
    147
  - Current Measurement
    147
  - Current Measurement (DC)
    147
  - Continuity Measurement over Long Distances
    148
  - Requirements
    148
  - Procedure
    148
- Applying Silicone Dielectric Compound to Amp Connectors
  149
  - Installation of Dielectric Grease
    149
  - Deutsch HD, DT, DTM, DRC Series
    150
  - AMP Seal
    150
  - AMP Mate-N-Lok
    151
  - DIN Connectors
    152
  - Exclusions
    152
- Amp Connector
  155
  - Assembly
    156
  - Connector Assembly (2 of 4)
    156
  - Disassembly
    157
  - Wedge Lock
    158
  - Service - Voltage Reading
    159
- Working with Deutsch Connectors
  160
  - DT/DTP Series Assembly
    160
  - DT/DTP Series Disassembly
    160
  - HD30/HDP20 Series Assembly
    160
  - HD30/HDP20 Series Disassembly
    161
- Switches
  162
  - Basic Check
    162
  - Limit Switches
    162
  - Automatic Switches
    163
  - Switch Wiring - Low Side, High Side
    163
- Electrical Schematics
  164
- Electrical Schematic
  164
- Hydraulic Schematics
  176
- Hydraulic Schematic
  176

JLG 4045R Operation And Safety Manual (131 pages)

Brand: JLG | Category: Boom Lifts | Size: 12.26 MB

Table of Contents
8
Section - Paragraph, Subject Page
13
Table of Contents
13
Section 1 - Safety Precautions
14
General
14
Pre-Operation
15
Operator Training and Knowledge
15
Workplace Inspection
15
Machine Inspection
16
Operation
17
General
17
Trip and Fall Hazards
18
Electrocution Hazards
19
Tipping Hazards
20
Minimum Approach Distances (M.A.D.)
20
Crushing and Collision Hazards
22
Towing, Lifting, and Hauling
24
Maintenance
24
Maintenance Hazards
24
Battery Hazards
25
Section 2 - User Responsibilities, Machine Preparation and Inspection
26
Personnel Training
26
Operator Training
26
Training Supervision
26
Operator Responsibility
26
Machine Familiarization
27
Preparation, Inspection, and Maintenance
27
Pre-Start Inspection
29
Daily Walk-Around Inspection
32
Daily Walk-Around Inspection
33
Function Check
34
Section 3 - Machine Controls, Indicators and Operation
37
General
37
Description
37
Operating Characteristics and Limitations
38
Placards
38
Capacities
38
Stability
38
Platform Loading
38
Machine Control Locations
39
Location of Machine Controls
39
Battery Charging
40
Ground Control Station
41
Ground/Platform/Off Key Selector Switch
42
Platform Lift/Lower Switch
42
Inverter ON/OFF Switch (if Equipped)
42
Ground Emergency Stop Switch
43
Hourmeter
43
Overload Indicator
43
MDI Indicator (if Equipped)
43
MDI Indicator
44
Platform Manual Descent Control
45
Location of Manual Descent Control
45
Platform Control Station
46
Platform Control Station (Module P/N 1001224873)
46
Platform Control Station (Module P/N 1001228112)
47
Platform Emergency Stop Switch
48
Lift/Drive Select Switch
48
Forward/Reverse/Lift/Lower Direction Decal
48
Drive/Lift/Steer Joystick Control
49
Steering and Traveling
49
Steering
50
Traveling Forward and Reverse
50
Raising and Lowering Platform
50
Grade and Sideslope Definition
51
Arm Guards (if Equipped)
52
Overload Indicator (LSS)
52
Tilt Indicator Warning Light and Alarm
52
Variable Tilt - Platform Restricted Height Indicator
52
Horn
53
Battery Charge Indicator
53
System Fault Indicator
53
Alarm
54
Indoor/Outdoor Operation Indicator
54
Indoor/Outdoor Operation Mode Switch
54
Low/High Drive Speed
54
3.10 Platform Extension
55
Platform Deck Extension
55
Platform Rails Fold-Down Procedure
56
Platform with Dual Rail Extension Deck
56
Platform with Dual Rail Extension - Fold down
57
Platform with Rail in Rail Extension Deck
58
Platform with Rail in Rail Extension - Fold down
59
3.12 Parking and Stowing Machine
60
3.13 Machine Lifting and Tie down
61
Lifting
61
Fork Lift Pockets - Location
61
Tie down
62
3.14 Towing
64
Hydraulic Brake Release
64
Hydraulic Brakes - Manual Disengage
64
Section 4 - Emergency Procedures
65
General Information
65
Emergency Operation
65
Operator Unable to Control Machine
65
Platform Caught Overhead
65
Righting of Tipped Machine
65
Platform Manual Descent
66
Incident Notification
67
Section 5 - General Specifications and Maintenance
70
Introduction
70
Other Publications Available Specific to this Machine
70
Operating Specifications
71
Platform Capacities
73
Machine Dimensional Data
74
Tires
74
Batteries
75
Electrical System
76
Battery Charger Specifications
76
Critical Stability Weights
77
Lubrication
77
Lubrication Capacities
77
Lubrication Specifications
77
Hydraulic Oil Operating Temperature Chart
78
Operator Maintenance
79
Scissor Arm - Safety Props
79
Scissor Arm - Safety Props
80
Hydraulic Oil Check Procedure
81
Hydraulic Oil Check Procedure
82
Hydraulic Oil Fill Procedure
82
Delta-Q - Battery Charger
83
Green Power - Battery Charger (China (GB) Only)
83
Eagle Performance - Battery Charger
84
Battery Maintenance and Safety Practices
85
Battery Quick-Disconnect (if Equipped)
85
Battery Fluid Level
85
Tire Wear and Damage
86
Wheel and Tire Replacement
86
Wheel Installation
87
Supplemental Information
88
Decal Installation
89
Machine Decal Installation
90
Machine Decal Installation Chart - 4045R
91
Diagnostic Trouble Codes (Dtc)
92
Diagnostic Trouble Codes (DTC)
93
Section 6 - Accessories
103
DC/Ac Power Inverter
106
Safety Precautions
106
Preparation and Inspection
107
Operation
107
Quikwelder
107
JLG Quickwelder Installation
108
JLG Quickwelder Components
108
Safety Precautions
109
Preparation and Inspection
109
Operation
109
Workstation
110
Workstation Installation
110
Safety Precautions
111
Preparation and Inspection
111
Operation
111
Electrician's Tree
112
Electrician's Tree Installation
112
Safety Precautions
113
Preparation and Inspection
113
Operation
113
Pipe Racks
114
Pipe Rack Installation
114
Safety Precautions
115
Preparation and Inspection
115
Operation
115
Panel Carrier
116
Panel Carrier Installation
116
Safety Precautions
117
Preparation and Inspection
117
Operation
117
Vise
118
Machinist's Vise Installation
118
Safety Precautions
119
Preparation and Inspection
119
Operation
119
Platform Work Lights
120
Operation
120
Work Lights Installation
120
Platform Rail Padding
121
Platform Rail Padding Components
121
6.10 Anti-Vandalism Package
122
A-VP Covers Open
122
6.11 Rail Mounted Platform Extension Handles
123
Operation
123
Platform Extension Handles Installation
123
Operation
124
6.13 Magnetic Gate Latch
125
Operation
125
Magnetic Gate Latch Installation
125
Section 7. Inspection and Repair Log
127
Inspection and Repair Log
127

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Boom Lifts Lifting Systems Scissor Lifts Construction Equipment Forklifts

More JLG Manuals

JLG 4045R Manuals

JLG 4045R Service Maintenance Manual (180 pages)

Table of Contents

Subject - Section, Paragraph

Specifications

General

Chassis & Scissor Arms

Hydraulics

Jlg Control System

Lss (Load Sensing System) Service

Diagnostic Trouble Codes

General Electrical Information & Schematics

JLG 4045R Operation And Safety Manual (131 pages)

Table of Contents

Related Products

JLG Categories