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JLG 4045R Service Manual

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

Table of Contents

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JLG 4045R Specifications

General IconGeneral
Platform Capacity705 lb / 320 kg
Weight7, 500 lb / 3, 402 kg
Drive Speed3.5 mph
Gradeability25%
Power SourceElectric
Drive Speed - Elevated0.5 mph
Drive Speed - Lowered3.5 mph
Max Travel Speed3.5 mph
Platform Height40 ft
Working Height46 ft
Overall Length9.08 ft / 2.77 m
Maximum Working Height46 ft
Platform Length8 ft
Machine Length9.08 ft / 2.77 m

Summary

Introduction and Safety Precautions

General Safety Precautions

General safety precautions for operating and maintaining the Mobile Elevating Work Platform (MEWP).

Section 1: Specifications

1.1 Machine Specifications

Details operating specifications for the 4045R model, including platform, driving, and chassis data.

1.2 Limit Switch Activation

Explains the function of tilt alarm and high drive speed cutout limit switches.

1.3 Lubrication Specifications

Provides information on lubrication capacities and hydraulic oil types and specifications.

1.4 Hydraulic Pressure Settings

Lists hydraulic pressure settings for main, lift, and steer relief valves.

1.5 Hydraulic Cylinder Specifications

Details specifications for lift and steer cylinders, including bore diameter and stroke.

1.6 Serial Number Location

Indicates the location of the serial number plate for machine identification.

1.7 Critical Stability Weights

Lists critical stability weights for components like batteries and wheel assemblies.

1.8 Major Component Weights

Provides weights for major machine components like platform and arm assembly.

1.9 Torque Requirements

Details torque requirements for fasteners and refers to torque charts.

Section 2: General Information

2.1 Machine Preparation, Inspection, and Maintenance

Outlines essential information for operating and maintaining the machine safely and efficiently.

2.2 Preventive Maintenance Schedule

Details scheduled inspections and maintenance tasks based on intervals and codes.

2.3 Service Maintenance Components

Describes key components requiring service, such as scissor arm safety props.

2.4 Service and Guidelines

Provides general guidelines for servicing, including safety, cleanliness, and component handling.

2.5 Lubrication and Information

Covers lubrication requirements, hydraulic oil, and changing procedures.

2.6 Cylinder Drift Test

Explains the procedure for measuring acceptable cylinder drift.

2.7 Pins and Composite Bearing Repair Guidelines

Offers guidelines for repairing pins and composite bearings.

Section 3: Chassis & Scissor Arms

3.1 Component Compartments

Identifies components located in the left and right side compartments.

3.2 Battery Removal and Maintenance

Details procedures for removing, maintaining, and disconnecting batteries.

3.3 Battery Charging

Explains battery charging procedures for different charger types and safety precautions.

3.4 DC/AC Power Inverter Installation

Provides instructions for installing an optional DC/AC power inverter.

3.5 Logic Control Module Installation

Guides on accessing, removing, and installing the logic control module.

3.6 Main Power Contactor Relay and Pump Control Module

Locates and describes the main power contactor relay and pump control module.

3.7 Pump Control Module

Details removal and installation procedures for the pump control module.

3.8 Ground Control Station - Folding Cover

Covers component location, removal, and installation for the folding ground control station.

3.9 Ground Control Station - Fixed Cover

Covers component location, removal, and installation for the fixed ground control station.

3.10 Platform Control Station

Overviews control station components and provides installation/removal instructions.

3.11 Tilt Sensor Installation

Guides on removing and installing the tilt sensor and its wiring.

3.12 Elevation Sensor

Explains the function and installation of the elevation sensor.

3.13 Pot-Hole Protection System Components

Details components and adjustment procedures for the Pot-Hole Protection System.

3.14 Steer and Spindle Assembly Components

Illustrates steer and spindle assembly installation and related components.

3.15 Arms and Platform Positioning and Support

Provides instructions for positioning and supporting arms and platform.

3.16 Platform Removal

Outlines procedures for safely removing the platform.

3.17 Scissor Arms Removal

Details methods for removing scissor arm assemblies.

Section 4: Hydraulics

4.1 Cylinders - Theory of Operation

Explains the principles of double-acting and single-acting hydraulic cylinders.

4.2 Valves - Theory of Operation

Describes the function of various hydraulic valves like solenoid, relief, and proportional valves.

4.3 Pump/Motor Operation

Explains pump motor operation, electrical evaluation, and troubleshooting.

4.4 Hydraulic Tank Installation

Provides instructions and diagrams for installing the hydraulic tank.

4.5 Hydraulic Pump and Electric Motor Assembly

Details the removal, disassembly, assembly, and installation of the hydraulic pump/motor.

4.6 Hydraulic Manifold Valve Installation

Guides on installing the hydraulic manifold valve assembly and its schematic.

4.7 Drive Motor Installation

Provides instructions for installing the hydraulic drive motor.

4.8 Hydraulic Brake Installation

Explains the installation and manual disengagement of hydraulic brakes.

4.9 Pressure Setting Procedure

Details the process for setting hydraulic pressure relief valves using an analyzer.

4.10 Cylinder Checking Procedure

Describes how to check cylinders for proper operation and leakage.

4.11 Lift Cylinder Removal/Installation

Outlines the procedure for removing and installing the lift cylinder.

4.12 Lower Lift Cylinder Service

Provides disassembly and assembly steps for the lower lift cylinder.

4.13 Upper Lift Cylinder Service

Provides disassembly and assembly steps for the upper lift cylinder.

4.14 Cylinder Repair Procedures

Offers general procedures for cylinder repair, including disassembly and cleaning.

Section 5: JLG Control System

5.1 Hand Held Analyzer Operation

Introduces the hand-held analyzer, its display, controls, and connection procedure.

5.2 Joystick Calibration

Details the procedure for calibrating the joystick if it is replaced.

5.3 Tilt Sensor Calibration

Explains how to calibrate the tilt sensor and troubleshoot common issues.

5.4 Elevation Sensor Calibration

Guides on calibrating the elevation sensor and its relation to LSS.

5.5 Updating Software

Provides instructions for updating the power control module software.

5.6 Machine Configuration Programming

Lists machine configuration settings and their default values.

5.7 Machine Model Adjustment (Personality Settings)

Explains how to adjust machine model and personality settings for optimal performance.

Section 6: LSS (Load Sensing System) Service

6.1 LSS Theory of Operation

Explains how the Load Sensing System measures load and prevents overload situations.

6.2 Analyzer Information for LSS

Details the analyzer's personalities and diagnostic menus for LSS.

6.3 LSS Calibration Preparation

Outlines necessary preparations before performing LSS calibration.

6.4 LSS Calibration and Verification Procedures

Provides procedures for empty, loaded platform, and LSS verification calibrations.

6.5 LSS Testing

Describes how to test the LSS functionality with specific load conditions.

6.6 LSS Connector Pin Assignments

Lists pin assignments for LSS pressure transducers.

6.7 LSS Troubleshooting

Offers possible resolutions for common LSS calibration and operation issues.

Section 7: Diagnostic Trouble Codes

7.1 Introduction to DTCs

Introduces diagnostic trouble codes (DTCs) and how they are indicated.

7.2 Diagnostic Trouble Codes (DTC)

Explains DTC sorting and troubleshooting approach.

7.3 DTC Check Tables

Provides tables listing DTCs, their messages, actions, and triggers.

Section 8: General Electrical Information & Schematics

8.1 General Electrical Information

Introduces schematics for locating and correcting operating problems.

8.2 Multimeter Basics

Covers multimeter usage, grounding, backprobing, polarity, and scale.

8.3 AMP Connector Dielectric Compound Application

Details the application of dielectric compound to AMP connectors.

8.5 Working with Deutsch Connectors

Provides installation and removal instructions for Deutsch DT/DTP and HD30/HDP20 series connectors.

8.6 Switch Testing

Explains basic checks for switches and limit switches.

8.7 Electrical Schematics

Contains electrical schematic diagrams for various machine systems.

8.8 Hydraulic Schematics

Includes hydraulic schematic diagrams for system analysis.

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