JLG R4045 Boom Lift Service Manual
188 pages · Publication 31217183
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- Models
- R4045
- Manual type
- Service Manual
- Pages
- 188
- Publication
- 31217183
- Condition
- Brand new
What's inside
From the manual's own table of contents: 239 sections, 314 entries. See sample pages (PDF, 529 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Operating Specifications
Machine Specifications
Platform Capacities
Machine Dimensional Data
Tires
Batteries
Motors1 topic
- Limit Switch Activation
Tilt Alarm
High Drive Speed Cutout1 topic
- Lubrication
Lubrication Capacities
Hydraulic Oil
Lubrication Specifications8 topics
- Hydraulic Pressure Settings
- Hydraulic Cylinder Specifications
- Serial Number Location
- Critical Stability Weights
- Major Component Weights
- Torque Requirements
- Thread Locking Compound
- Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart1 topic
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Preventive Maintenance and Inspection Schedule
Maintenance and Inspection Schedule Codes1 topic
- Service Maintenance Components
Scissor Arm - Safety Prop
Hydraulic Oil Check Procedure1 topic
- TABLE OF CONTENTS Service and Guidelines
Show all 239 sections
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery1 topic
- Lubrication and Information
Changing Hydraulic Oil1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift3 topics
- Pins and Composite Bearing Repair Guidelines
- Left and Right Side component compartments
- Battery Removal/Maintenance
Battery Quick-Disconnect
Battery Maintenance and Safety Practices1 topic
- Battery Charging
Delta-Q - Battery Charger
Green Power - Battery Charger (China (GB) Only)
Eagle Performance - Battery Charger
Battery Charger Maintenance4 topics
- DC/AC Power Inverter Installation - Option
- Logic Control Module Installation
- Main Power Contactor Relay and Pump Control Module
- Pump Control Module
Removal
Installation1 topic
- Ground Control Station - Folding Cover
Components Location2 topics
- Ground Control Station - Fixed Cover
- Platform Control Station
Installation/Removal
Control Station Disassembly
Joystick Controller1 topic
- Tilt Sensor Installation
Tilt Sensor Removal
Tilt Sensor Installation1 topic
- Elevation Sensor
Elevation Sensor Installation2 topics
- Pot-Hole Protection System Components
- TABLE OF CONTENTS Steer and Spindle Assembly Components
Drive Motor Covers Installation - Option
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation3 topics
- Arms and Platform Positioning and Support
- Platform Removal
- Scissor Arms Removal
Removing Scissor Arm Assembly as a Complete Unit
Removing/Installing Scissor Arms Individually2 topics
- Cylinders - Theory of Operation
- Valves - Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves
Proportional Valve
Manual Descent Valve1 topic
- Pump/Motor
Pump Motor Electrical Evaluation2 topics
- Hydraulic Tank Installation
- Hydraulic Pump and Electric Motor Assembly
Pump/Motor Removal
Pump/Motor Disassembly
Pump/Motor Assembly
Pump/Motor Installation3 topics
- Hydraulic Manifold Valve Installation
- Drive Motor Installation
- Hydraulic Brake Installation
Hydraulic Brake Release1 topic
- Pressure Setting Procedure
Machine Model Pressure setting
Main Relief
Lift Up Relief
Steer Relief3 topics
- Cylinder Checking Procedure
- Lift Cylinder Removal/Installation
- Lower Lift Cylinder
Disassembly
Assembly2 topics
- Upper Lift Cylinder
- Cylinder Repair
Cleaning and Inspection1 topic
- Hand Held Analyzer
Diagnostic Port
To Connect the Hand Held Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup2 topics
- Joystick Calibration
- Tilt Sensor Calibration
Tilt Sensor Failure Troubleshooting6 topics
- Elevation Sensor Calibration
- Updating Software
- Machine ConfiguRation Programming Information
- Machine Model Adjustment (Personality Settings)
- Theory of Operation
- Analyzer Information
Personalities Menu
Diagnostic Menu2 topics
- Calibration Preparation
- Calibration and Verification Procedures
Empty Platform (Load 0%) Calibration
Loaded Platform (Load 110%) Calibration
Verify Load
Partial Height Calibration4 topics
- Testing
- LSS Connector Pin Assignments
- LSS Troubleshooting
- Introduction
System Fault/DTC Indication4 topics
- Diagnostic Trouble Codes (DTC)
- DTC Check Tables
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
Continuity Measurement Over Long Distances
Requirements
Procedure2 topics
- TABLE OF CONTENTS Applying Silicone Dielectric Compound To Amp Connectors
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions1 topic
- AMP Connector
Wedge Lock
Service - Voltage Reading1 topic
- Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side2 topics
- Electrical Schematics
- Hydraulic Schematics
Hydraulic Oil Operating Temperature Specifications
Machine Component Locations
Battery Cable Connections
Battery Fluid Level
Logic Module Components
Logic Module CO02 - Harness Connector Identification
Main Power Contactor Relay and Pump Controller Module Location
Hydraulic Pump Control - Power Connections
Ground Control Station - Folding Cover
Ground Control Station Removal
Ground Control Station - Rear of Panel
Ground Control Station - Fixed Cover
Platform Control Station Installation
Platform Control Station Disassembly
Platform Control Station Components - Internal
Joystick
Elevation Sensor Location
Pot-Hole-Protection Assembly
Steer and Spindle Assembly Installation
Drive Motor Cover Installation - Option
Arms and Platform Positioning with Overhead Support
Platform Assembly - Installation/Removal
Scissor Arm Assembly
Scissor Arm Assembly - Pin Configuration
Scissor Arm Assembly - Cable Routing
Scissor Arm Assembly - Cable Routing (FTSW)
Scissor Arm Assembly - Cable Routing (Coiled)
Scissor Arm Assembly - Cable Routing (Coiled) (FTSW)
Scissor Arm Assembly - Cable Routing w/o AC Cable (GB Market)
Scissor Arm Assembly - Cable Routing (Coiled) w/o AC Cable (GB Market)
Hydraulic Tank Installation
Hydraulic Pump - Motor Components
Hydraulic Manifold Assembly - Installation
Hydraulic Manifold Assembly - Schematic
Hydraulic Manifold Assembly - Component Location
Hydraulic Manifold Assembly - Component Torque
Hydraulic Hose Routing
Drive Motor - Installation
Rear Hydraulic Brake - Installation
Hydraulic Brakes - Manual Disengage
Lift Cylinder - Lower
Lift Cylinder - Upper
Steer Cylinder
Cylinder Barrel Support
Cylinder Rod Support
Gar-Max Bearing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Rod Assembly Installation
Hand Held Analyzer
Diagnostic Port Location
Analyzer Software P1.13.2 - Sheet 1 of 4
Analyzer Software P1.13.2 - Sheet 2 of 4
Analyzer Software P1.13.2 - Sheet 3 of 4
Analyzer Software P1.13.2 - Sheet 4 of 4
LSS Component Locations
Voltage Measurement (DC)
Current Measurement (DC)
AMP Connector
Connector Assembly (1 of 4)
Connector Assembly (2 of 4)
Connector Assembly (3 of 4)
Connector Assembly (4 of 4)
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Schematic - Sheet 1 of 16
Electrical Schematic - Sheet 2 of 16
Electrical Schematic - Sheet 3 of 16
Electrical Schematic - Sheet 4 of 16
Electrical Schematic - Sheet 5 of 16
Electrical Schematic - Sheet 6 of 16
Electrical Schematic - Sheet 7 of 16
Electrical Schematic - Sheet 8 of 16
Electrical Schematic - Sheet 9 of 16
Electrical Schematic - Sheet 10 of 16
Electrical Schematic - Sheet 11 of 16
Electrical Schematic - Sheet 12 of 16
Electrical Schematic - Sheet 13 of 16
Electrical Schematic - Sheet 14 of 16
Electrical Schematic - Sheet 15 of 16
Electrical Schematic - Sheet 16 of 16
Hydraulic Schematic - Sheet 1 of 2
Hydraulic Schematic - Sheet 2 of 2
Standard UTTO Hydraulic Fluid Specs
Premium Hydraulic Fluid (VG 15) Specs
Biodegradable Synthetic Hydraulic Fluid (VG 32) Specs
Inspection and Maintenance Responsibilities
Preventive Maintenance & Inspection Schedule
Battery Charger Specifications
Diagnostic Trouble Codes (Delta Q Battery Charger)
Fault Codes (Green Power)
Fault Codes (Eagle Battery Charger)
Pump Control Module Specifications
Pump Power Module Terminal Functions (CO117-J1)
Joystick Specifications
Connector Chart
Tilt Sensor Wiring Pin Assignment
Valve Pressure Per Machine Model
Machine Configuration Programming Information - Version P1.13.2
Machine Model Adjustment (Personality Settings) - Version P1.13.2
Personalities Menu Description
Diagnostic Menu Descriptions
Calibrations Menu
Platform 110% Calibration Weight
Platform 100% Calibration Weight
Platform 120% Calibration Weight
Connections for R4045 Lift Cylinder Rod Pressure Transducer
Connections for R4045 Lower & Upper Lift Cylinder Head Pressure Transducer
LSS Troubleshooting
Diagnostic Trouble Codes (DTC)
Inside this manual
Real pages from this service manual (188 pages). Open the sample pages (PDF, 527 KB)
- Specifications, page 14: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 148: SECTION 7 - DIAGNOSTIC TROUBLE CODES
- Diagram, page 182: SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 156: SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the R4045 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 31217183$69.97
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 188 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).