JLG 340 AJ Service & Maintenance Manual (3121259) – PDF DOWNLOAD (Eng)

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JLG 340 AJ Service & Maintenance Manual (3121259) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 340 AJ Service & Maintenance Manual (3121259) – PDF DOWNLOAD

Section 1. Specifications.................................................. 17
	1.1 Operating Specifications........................................... 17
	1.2 Dimensional Data................................................... 17
	1.3 Capacities......................................................... 17
	1.4 Tires.............................................................. 17
	1.5 Engine Data........................................................ 18
	1.6 Hydraulic Oil...................................................... 18
		Major Component Weights............................................ 19
	1.7 Function Speeds.................................................... 20
		Test Notes......................................................... 20
	1.8 Operator Maintenance............................................... 22
Section 2. General......................................................... 31
	2.1 Machine Preparation, Inspection, and Maintenance................... 31
		General............................................................ 31
		Preparation, Inspection, and Maintenance........................... 31
		Pre-Start Inspection............................................... 31
		Pre-Delivery Inspection and Frequent Inspection.................... 31
		Annual Machine Inspection.......................................... 31
		Preventive Maintenance............................................. 31
	2.2 Service and Guidelines............................................. 32
		General............................................................ 32
		Safety and Workmanship............................................. 32
		Cleanliness........................................................ 32
		Components Removal and Installation................................ 32
		Component Disassembly and Reassembly............................... 33
		Pressure-Fit Parts................................................. 33
		Bearings........................................................... 33
		Gaskets............................................................ 33
		Bolt Usage and Torque Application.................................. 33
		Hydraulic Lines and Electrical Wiring.............................. 33
		Hydraulic System................................................... 33
		Lubrication........................................................ 34
		Battery............................................................ 34
		Lubrication and Servicing.......................................... 34
	2.3 Lubrication and Information........................................ 34
		Hydraulic System................................................... 34
		Hydraulic Oil...................................................... 34
		Changing Hydraulic Oil............................................. 34
		Lubrication Specifications......................................... 34
	2.4 Cylinder Drift..................................................... 35
		Theory............................................................. 35
		Cylinder Leakage Test.............................................. 35
		Cylinder Thermal Drift............................................. 35
	2.5 Pins and Composite Bearing Repair Guidelines....................... 36
	2.6 Welding on JLG Equipment........................................... 36
		Do the Following When Welding on JLG Equipment..................... 36
		Do NOT Do the Following When Welding on JLG Equipment.............. 36
Section 3. Chassis & Turntable............................................. 43
	3.1 Tires and Wheels................................................... 43
		Tire Replacement................................................... 43
		Wheel and Tire Replacement......................................... 43
		Wheel Installation................................................. 43
	3.2 Drive Orientation System........................................... 44
	3.3 Beyond Transport Position - Drive Speed Cutback System............. 44
	3.4 Drive/Steer - Boom Function Interlock System (CE ONLY)............. 44
	3.5 Drive System....................................................... 44
	3.6 Drive Motor........................................................ 45
		Disassembly........................................................ 45
		Assembly........................................................... 45
	3.7 Drive Hub.......................................................... 52
		Roll, Leak and Brake Testing....................................... 52
		Tightening and Torquing Bolts...................................... 52
		Measuring Rolling Torque........................................... 53
		Main Disassembly................................................... 53
		Housing-Spindle Disassembly........................................ 55
		Spindle-Brake Subassembly Disassembly.............................. 57
		Cover Disassembly.................................................. 58
		Planet Gear Subassembly............................................ 60
		Spindle-Brake Subassembly.......................................... 61
		Housing-Spindle Subassembly........................................ 63
		Housing-Ring Gear Subassembly...................................... 64
		Cover Subassembly.................................................. 65
		Main Assembly...................................................... 66
		Integral Brake Check Procedure..................................... 67
	3.8 Oscillating Axle System............................................ 72
		Oscillating Axle Bleeding Procedure................................ 72
	3.9 Chassis Tilt Indicator System...................................... 74
	3.10 Swing Motor....................................................... 74
		Removal............................................................ 76
		Preparation Before Disassembly..................................... 76
		Disassembly and Inspection......................................... 77
		Assembly........................................................... 84
		One Piece Stator Construction...................................... 90
		Two Piece Stator Construction...................................... 91
		Final Checks....................................................... 92
		Installation....................................................... 92
	3.11 Swing Drive....................................................... 92
		Removal............................................................ 92
		Installation....................................................... 97
		Turntable Bearing Mounting Bolt Condition Check.................... 98
		Wear Tolerance..................................................... 98
		Swing Bearing Torque Value......................................... 98
		Disassembly........................................................100
		Assembly...........................................................102
	3.12 Engine Operating States...........................................112
	3.13 Engine Start Conditions...........................................113
	3.14 Engine RPM Levels.................................................113
		Engine Stop RPM....................................................113
		Idle RPM...........................................................113
		Mid Engine RPM.....................................................113
		Multi-Function RPM.................................................114
		High Engine RPM....................................................114
		Generator RPM......................................................114
	3.15 Engine Controls...................................................114
		Ambient Air Temperature Sensor.....................................114
		Fuel Level Sensor..................................................114
	3.16 Engine Startup Procedure (Kubota).................................115
	3.17 Kubota Engine.....................................................116
		Engine Oil Pressure Switch.........................................116
		Engine Speed Sensor................................................116
		Coolant Sensor.....................................................117
		Glow Plugs.........................................................117
		Engine Speed Actuators.............................................118
		Engine Start.......................................................119
		Alternator Excitation..............................................119
		Fuel Pump..........................................................119
		Shutdown...........................................................119
	3.18 GM Dual Fuel Engine...............................................124
		Communications with the JLG Control System.........................124
		Engine Start.......................................................124
		Oil Pressure.......................................................124
		Engine Speed.......................................................124
		Coolant Temperature................................................124
		Fuel Select........................................................124
	3.19 Fuel Reserve / Cut-Out System.....................................138
	3.20 Cold Start System (Diesel Engine).................................138
	3.21 Generator.........................................................138
	3.22 Counterweight.....................................................139
Section 4. Boom & Platform.................................................141
	4.1 Platform Control Enable System.....................................141
	4.2 Transport Position Sensing System..................................141
	4.3 Platform...........................................................142
		Platform/Support Removal...........................................142
		Support Installation...............................................143
	4.4 Main Boom Powertrack...............................................145
		Removal............................................................145
		Installation.......................................................145
	4.5 Powertrack Maintenance.............................................146
		Remove Link........................................................146
		Install New Link...................................................149
		Replace Fixed End Brackets.........................................152
		Replace Moving End Brackets........................................153
	4.6 Boom Maintenance...................................................155
		Disassembly of the Main Boom.......................................155
		Inspection.........................................................156
		Assembly of the Main Boom..........................................156
	4.7 Boom Cleanliness Guidelines........................................160
	4.8 Rotary Actuator....................................................163
		Theory of Operation................................................163
		Tools Required.....................................................164
		Disassembly........................................................165
		Inspection.........................................................170
		Assembly...........................................................171
		Greasing Thrust Washers............................................175
		Installing Counterbalance Valve....................................175
		Testing the Actuator...............................................175
		Installation and Bleeding..........................................177
		Troubleshooting....................................................178
	4.9 Skyguard®..........................................................179
		Operation..........................................................179
		Function Test......................................................179
		Diagnostics & Troubleshooting......................................180
Section 5. Basic Hydraulic Information & Schematics........................181
	5.1 Lubricating O-Rings in the Hydraulic System........................181
		Cup and Brush......................................................181
		Dip Method.........................................................182
		Spray Method.......................................................182
		Brush-on Method....................................................182
	5.2 Hydraulic Cylinders................................................183
		Disassembly and Assembly Instructions..............................183
		General Information................................................183
		Standard of Maintenance............................................183
		Inspection After Assembly..........................................183
		Disassembly Procedure..............................................186
		Assembly...........................................................189
	5.3 Drive Pump.........................................................215
		Description........................................................215
		The System Circuit.................................................216
		High Pressure Relief Valve (HPRV) and Charge Check.................216
		Charge Pressure Relief Valve.......................................217
		Electrical Displacement Control (EDC)..............................218
		Disassembly........................................................220
		Inspection.........................................................225
		Assembly...........................................................229
		Port Locations and Gauge Installation..............................237
		Fastener Size and Torque Chart.....................................238
		Plug Size and Torque Chart.........................................238
		Initial Startup Procedures.........................................241
		Troubleshooting....................................................242
		Pump Adjustment....................................................245
		Displacement Limiter Adjustment....................................248
		Control Neutral Adjustment.........................................249
		Mechanical Neutral Adjustment......................................250
		Removing the Pump..................................................251
		Electric Control Module............................................251
		Control Solenoids..................................................252
		Shaft Seal, Roller Bearing and Shaft Replacement...................252
		Charge Check / HPRV................................................254
		Charge Pressure Relief Valve.......................................254
		Pressure Limiter Valve Replacement.................................255
	5.4 Gear Pump..........................................................255
		Disassembly........................................................255
		Troubleshooting....................................................265
	5.5 Pressure Setting Procedure.........................................266
	5.6 Oil Sampling.......................................................266
		Procedure..........................................................266
Section 6. JLG Control System..............................................269
	6.1 JLG Control System Analyzer Kit Instructions.......................269
		Introduction.......................................................269
	6.2 Analyzer Menu Structure............................................270
	6.3 Using the Hand Held Analyzer.......................................271
		To Connect the JLG Control System Analyzer.........................271
		Using the Analyzer.................................................271
		Changing the Access Level of the Hand Held Analyzer................272
		Adjusting Parameters Using the Hand Held Analyzer..................273
		Machine Setup......................................................274
		Level Vehicle Description..........................................274
	6.4 Operator Controls and Switches.....................................284
		Ground Control Switches............................................284
		Platform Control Switches..........................................284
	6.5 Control System Startup Checks......................................285
	6.6 LSS System.........................................................307
		Diagnostic Menu....................................................308
		Calibration Procedure..............................................309
		Testing & Evaluation...............................................314
		Troubleshooting....................................................315
	6.7 Resetting The MSSO System..........................................316
	6.8 System Fault Messages..............................................318
Section 7. Basic Electrical Information & Schematics.......................361
	7.1 General............................................................361
	7.2 Multimeter Basics..................................................361
		Grounding..........................................................361
		Backprobing........................................................361
		Min/Max............................................................361
		Polarity...........................................................361
		Scale..............................................................361
		Voltage Measurement................................................361
		Resistance Measurement.............................................362
		Continuity Measurement.............................................362
		Current Measurement................................................363
	7.3 Applying Silicone Dielectric Compound to Electrical Connections....363
		Installation of Dielectric Grease..................................364
		Deutsch HD, DT, DTM, DRC Series....................................364
		AMP Seal...........................................................364
		AMP Mate-N-Lok.....................................................365
		DIN Connectors.....................................................365
		Exclusions.........................................................366
	7.4 AMP Connector......................................................368
		Applying Silicone Dielectric Compound to AMP Connectors............368
		Assembly...........................................................368
		Disassembly........................................................370
		Wedge Lock.........................................................370
		Service - Voltage Reading..........................................370
	7.5 Deutsch Connectors.................................................372
		DT/DTP Series Assembly.............................................372
		DT/DTP Series Disassembly..........................................372
		HD30/HDP20 Series Assembly.........................................373
		HD30/HDP20 Series Disassembly......................................373
	7.6 Telematics Gateway.................................................374
		Telematics-Ready (TCU) Plug........................................374
	7.7 Electrical Schematics..............................................379

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