JLG 4045R Use and care manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
®
AS/NZS GB
ANSI
Model(s)
4045R
3121760
March 12, 2019 - Rev F
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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. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
3121760 a
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed various
compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard compliance
information.
This manual is a very important tool! Keep it with the machine at all times.
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.
Refer to www.JLG.com for Warranty, Production Registration, and other machine-related documentation.
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SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
b3121760
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-
GROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED,
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN
ORANGE BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST
UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
NOTICE
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY
OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROP-
ERTY.
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.
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SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
3121760 c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CON-
TACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTA-
TIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH
MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
NOTICE
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT
THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
NOTICE
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES
WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE
HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
E-mail: [e-mail]
For:
•Accident Reporting
•Product Safety Publica-
tions
•Current Owner Updates
•Questions Regarding
Product Safety
•Standards and Regulations
Compliance Information
•Questions Regarding Special
Product Applications
•Questions Regarding Prod-
uct Modifications
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REVISION LOG
d3121760
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
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TABLE OF CONTENTS
3121760 i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Operator Training and Knowledge. . . . . . . . . . . . . . . . . . . . . .1-2
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Crushing and Collision Hazards. . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Machine Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . .2-2
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . .2-7
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . .3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.4 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.5 MACHINE CONTROL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.6 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.7 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Ground/Platform/OFF Key Selector Switch . . . . . . . . . . . . . .3-6
Platform Lift/Lower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Inverter ON/OFF Switch (If Equipped). . . . . . . . . . . . . . . . . . .3-6
Ground Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . .3-7
Hourmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Overload Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
MDI Indicator (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3.8 PLATFORM MANUAL DESCENT CONTROL. . . . . . . . . . . . . . . . .3-9
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TABLE OF CONTENTS
ii 3121760
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.9 PLATFORM CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Platform Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . .3-12
Lift/Drive Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Forward/Reverse/Lift/Lower Direction Decal. . . . . . . . . . .3-12
Drive/Lift/Steer Joystick Control . . . . . . . . . . . . . . . . . . . . . . .3-13
Steering And Traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Traveling Forward and Reverse. . . . . . . . . . . . . . . . . . . . . . . .3-14
Raising And Lowering Platform. . . . . . . . . . . . . . . . . . . . . . . .3-14
Arm Guards (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Overload Indicator (LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Tilt Indicator Warning Light and Alarm . . . . . . . . . . . . . . . .3-16
Variable Tilt - Platform Restricted Height Indicator . . . . .3-16
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Battery Charge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
System Fault Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Indoor/Outdoor Operation Indicator . . . . . . . . . . . . . . . . . .3-18
Indoor/Outdoor Operation Mode Switch . . . . . . . . . . . . . .3-18
Low/High Drive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3.10 PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.11 PLATFORM RAILS FOLD-DOWN PROCEDURE
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Platform with Dual Rail Extension Deck . . . . . . . . . . . . . . . .3-20
Platform with Rail In Rail Extension Deck. . . . . . . . . . . . . . .3-22
3.12 PARKING AND STOWING MACHINE. . . . . . . . . . . . . . . . . . . . . .3-24
3.13 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . .3-25
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3.14 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Hydraulic Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . . 4-1
Platform Caught Overhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Righting of Tipped Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 PLATFORM MANUAL DESCENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
SECTION - 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Other Publications Available Specific to this Machine . . . 5-1
5.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Machine Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
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TABLE OF CONTENTS
3121760 iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Lubrication Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.5 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Scissor Arm - Safety Props . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-12
Delta-Q - Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Green Power - Battery Charger (China (GB) Only) . . . . . . 5-14
Eagle Performance - Battery Charger. . . . . . . . . . . . . . . . . . 5-15
Battery Maintenance and Safety Practices. . . . . . . . . . . . . 5-16
Battery Quick-Disconnect (If Equipped) . . . . . . . . . . . . . . . 5-16
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.7 DECAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.8 DIAGNOSTIC TROUBLE CODES (DTC). . . . . . . . . . . . . . . . . . . . 5-23
SECTION - 6 - ACCESSORIES
6.1 DC/AC POWER INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.2 QUIKWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6.3 WORKSTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6.4 ELECTRICIAN’S TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.6 PANEL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.7 VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Preparation and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
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TABLE OF CONTENTS
iv 3121760
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6.8 PLATFORM WORK LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6.9 PLATFORM RAIL PADDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6.10 ANTI-VANDALISM PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6.11 RAIL MOUNTED PLATFORM EXTENSION HANDLES . . . . . . .6-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6.12 FOOTSWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6.13 MAGNETIC GATE LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3-1. Location of Machine Controls. . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3. MDI Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4. Location of Manual Descent Control . . . . . . . . . . . . . . . . . . 3-9
3-5. Platform Control Station (Module P/N 1001224873) . .3-10
3-5. Platform Control Station (Module P/N 1001228112) . .3-11
3-6. Grade and Sideslope Definition. . . . . . . . . . . . . . . . . . . . . .3-15
3-7. Platform Deck Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-8. Platform with Dual Rail Extension - Fold Down
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-9. Platform with Rail in Rail Extension - Fold Down
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-10. Securing Control Station to Platform. . . . . . . . . . . . . . . . .3-24
3-11. Fork Lift Pockets - Location . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-12. Lifting Machine Using Spreader Bar and Lift Lug
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-13. Tie Down and Lift Lug Locations . . . . . . . . . . . . . . . . . . . . .3-27
3-14. Hydraulic Brakes - Manual Disengage . . . . . . . . . . . . . . . .3-28
4-1. Location of Manual Descent Control . . . . . . . . . . . . . . . . . . 4-2
5-1. Hydraulic Oil Operating Temperature Chart . . . . . . . . . . . 5-9
5-2. Scissor Arm - Safety Props . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-3. Hydraulic Oil Check Procedure. . . . . . . . . . . . . . . . . . . . . . .5-13
5-4. Hydraulic Oil Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
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TABLE OF CONTENTS
3121760 v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5-5. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-6. Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-7. Machine Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
6-1. DC/AC Power Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-2. JLG QuickWelder Installation. . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-3. JLG QuickWelder Components. . . . . . . . . . . . . . . . . . . . . . . .6-6
6-4. Workstation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-5. Electrician’s Tree Installation . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-6. Pipe Rack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-7. Panel Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-8. Machinist’s Vise Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-9. Work Lights Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-10. Work Light Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-11. Platform Rail Padding Components . . . . . . . . . . . . . . . . . 6-19
6-12. A-VP Covers Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-13. A-VP Covers Closed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-14. Platform Extension Handles Installation . . . . . . . . . . . . . 6-21
6-15. Footswitch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-16. Magnetic Gate Latch Installation . . . . . . . . . . . . . . . . . . . . 6-23
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . . . . . . . 1-7
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . . 1-8
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
2-2 High Drive Cutout Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-3 Tilt Activation Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
5-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-5 OEM Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-8 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-10 Machine Decal Installation Chart - 4045R . . . . . . . . . . . . 5-21
5-11 Diagnostic Trouble Codes (DTC). . . . . . . . . . . . . . . . . . . . . 5-24
6-1 4045R - Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Options/Accessories Relationship Table . . . . . . . . . . . . . . 6-2
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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TABLE OF CONTENTS
vi 3121760
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This Page Left Blank Intentionally
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SECTION 1 - SAFETY PRECAUTIONS
3121760 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper
and safe machine usage and maintenance. In order to pro-
mote proper machine usage, it is mandatory that a daily
routine is established based on the content of this manual.
A maintenance program, using the information provided
in this manual and the Service and Maintenance Manual,
must also be established by a qualified person and must
be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine
must not accept operating responsibility until this manual
has been read, training is accomplished, and operation of
the machine has been completed under the supervision of
an experienced and qualified operator.
These sections contain the responsibilities of the owner,
user, operator, lessor, and lessee concerning safety, train-
ing, inspection, maintenance, application, and operation.If
there are any questions with regard to safety, training,
inspection, maintenance, application, and operation,
please contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MAN-
UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
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SECTION 1 - SAFETY PRECAUTIONS
1-2 3121760
1.2 PRE-OPERATION
Operator Training and Knowledge
•Read, understand, and study the Operation and Safety
Manual in its entirety before operating the machine. For
clarification, questions, or additional information regarding
any portions of this manual, contact JLG Industries, Inc.
•An operator must not accept operating responsibilities
until adequate training has been given by competent and
authorized persons.
•Allow only those authorized and qualified personnel to
operate the machine who have demonstrated that they
understand the safe and proper operation and mainte-
nance of the unit.
•Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, and operating instructions on the machine and in
this manual.
•Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined
by JLG.
•All operating personnel must be familiar with the emer-
gency controls and emergency operation of the machine as
specified in this manual.
•Read, understand, and obey all applicable employer, local,
and governmental regulations as they pertain to your utili-
zation and application of the machine.
Workplace Inspection
•Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the
machine.
•Do not operate or raise the platform from a position on
trucks, trailers, railway cars, floating vessels, scaffolds or
other equipment unless the application is approved in writ-
ing by JLG.
•Before operation, check work area for overhead hazards
such as electric lines, bridge cranes, and other potential
overhead obstructions.
•Check operating surfaces for holes, bumps, drop-offs,
obstructions, debris, concealed holes, and other potential
hazards.
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SECTION 1 - SAFETY PRECAUTIONS
3121760 1-3
•Check the work area for hazardous locations. Do not oper-
ate the machine in hazardous environments unless
approved for that purpose by JLG.
•Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel.
•This machine can be operated in nominal ambient temper-
atures of 0oF to 104oF (-20oC to 40oC). Consult JLG to opti-
mize operation outside of this temperature range.
Machine Inspection
•Do not operate this machine until the inspections and func-
tional checks have been performed as specified in Section 2
of this manual.
•Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the machine’s Service and
Maintenance Manual.
•Ensure all safety devices are operating properly. Modifica-
tion of these devices is a safety violation.
MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH
PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
•Do not operate any machine on which the safety or instruc-
tion placards or decals are missing or illegible.
•Check the machine for modifications to original compo-
nents. Ensure that any modifications have been approved
by JLG.
•Avoid accumulation of debris on platform floor. Keep mud,
oil, grease, and other slippery substances from footwear
and platform floor.
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SECTION 1 - SAFETY PRECAUTIONS
1-4 3121760
1.3 OPERATION
General
•Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell
phones, two-way radios, etc. that will distract your attention
from safely operating the machine.
•Do not use the machine for any purpose other than posi-
tioning personnel, their tools, and equipment.
•Before operation, the user must be familiar with the
machine capabilities and operating characteristics of all
functions.
•Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from ser-
vice and notify the proper authorities.
•Do not remove, modify, or disable any safety devices.
•Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and stop
before moving the switch to the next function. Operate
controls with slow and even pressure.
•Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
•Do not carry materials directly on platform railing unless
approved by JLG.
•When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
•Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
•Do not assist a stuck or disabled machine by pushing or
pulling except by pulling at the chassis tie-down lugs.
•Fully lower platform and shut off all power before leaving
machine.
•Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair
unrestrained which may become caught or entangled in
equipment.
•Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
•Hydraulic cylinders are subject to thermal expansion and
contraction. This may result in changes to the platform
position while the machine is stationary. Factors affecting
thermal movement can include the length of time the
machine will remain stationary, hydraulic oil temperature,
ambient air temperature and platform position.
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SECTION 1 - SAFETY PRECAUTIONS
3121760 1-5
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. For further information regarding fall protection
requirements on JLG products, contact JLG Industries, Inc.
•Identify the designated lanyard anchorage point(s) at the
platform and securely attach the lanyard. Attach only one
(1) lanyard per lanyard anchorage point.
•Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the machine when entering
or leaving the platform. Always maintain “three point con-
tact” with the machine, using two hands and one foot or
two feet and one hand at all times during entry and exit.
.
•Keep both feet firmly positioned on the platform floor at all
times. Never position ladders, boxes, steps, planks, or simi-
lar items on unit to provide additional reach for any pur-
pose.
•Never use the scissor arm assembly to gain access to or
leave the platform.
•Keep oil, mud, and slippery substances cleaned from foot-
wear and the platform floor.
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SECTION 1 - SAFETY PRECAUTIONS
1-6 3121760
Electrocution Hazards
•This machine is not insulated and does not provide protec-
tion from contact or proximity to electrical current.
•Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-1.
•Allow for machine movement and electrical line swaying.
•Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up
to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
•The minimum approach distance may be reduced if insulat-
ing barriers are installed to prevent contact, and the barri-
ers are rated for the voltage of the line being guarded.
These barriers shall not be part of (or attached to) the
machine. The minimum approach distance shall be reduced
to a distance within the designed working dimensions of
the insulating barrier. This determination shall be made by
a qualified person in accordance with the employer, local,
or governmental requirements for work practices near
energized equipment.
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SECTION 1 - SAFETY PRECAUTIONS
3121760 1-7
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).
ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-
ERWISE.
Tipping Hazards
•Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
•The user must be familiar with the operating surface before
driving. Do not exceed the allowable sideslope and grade
while driving.
•Do not elevate platform or drive with platform elevated
while on or near a sloping, uneven, or soft surface. Ensure
machine is positioned on a smooth, firm surface within the
limits of the maximum operating slope before elevating
platform or driving with the platform in the elevated posi-
tion.
•Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
•Never exceed the maximum platform capacity as specified
on the platform. Keep all loads within the confines of the
platform, unless authorized by JLG.
•Keep the chassis of the machine a minimum of 2 ft. (0.6m)
from holes, bumps, drop-offs, obstructions, debris, con-
cealed holes, and other potential hazards at the ground
level.
•Do not operate the machine when wind conditions exceed
specifications shown in Section 5, Table 5-2 or as shown on
the capacity placard on the platform billboard. Factors
affecting wind speed are; platform elevation, surrounding
structures, local weather events, and approaching storms.
•Wind speed can be significantly greater at height than at
ground level.
Table 1-1. Minimum Approach Distances (M.A.D.)
VOLTAGE RANGE
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0to50KV 10(3)
Over50KV to200 KV 15(5)
Over200KVto350KV 20 (6)
Over350KVto500KV 25 (8)
Over500KVto750KV 35 (11)
Over750KVto1000KV 45 (14)
NOTE: This requirement shall apply except where employer, local or govern-
mental regulations are more stringent.
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