JLG 340AJ PVC 2007 Service & Maintenance Manual (31217118) – PDF DOWNLOAD
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JLG 340AJ PVC 2007 Service & Maintenance Manual (31217118) – PDF DOWNLOADJLG 340AJ PVC 2007 Service & Maintenance Manual (31217118) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 340AJ PVC 2007 Service & Maintenance Manual (31217118) – PDF DOWNLOAD
31217118 _A_340 AJ_JLG_Service Manual_English.................................. 1
Section A. Introduction - Maintenance Safety Precautions................... 3
A General.............................................................. 3
B Hydraulic System Safety.............................................. 3
C Maintenance.......................................................... 3
Table of Contents.......................................................... 5
List of Figures............................................................ 11
List of Tables............................................................. 15
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 Operator Maintenance............................................... 21
1.8 Threadlocking Compound............................................. 24
1.9 Torque Charts...................................................... 25
SAE Fastener Torque Chart.......................................... 25
SAE Fastener Torque Chart (Continued).............................. 26
SAE Fastener Torque Chart (Continued).............................. 27
SAE Fastener Torque Chart (Continued).............................. 28
SAE Fastener Torque Chart (Continued).............................. 29
SAE Fastener Torque Chart (Continued).............................. 30
Metric Fastener Torque Chart....................................... 31
Metric Fastener Torque Chart (Continued)........................... 32
Metric Fastener Torque Chart (Continued)........................... 33
Metric Fastener Torque Chart (Continued)........................... 34
Section 2. General......................................................... 35
2.1 Machine Preparation, Inspection, and Maintenance................... 35
General............................................................ 35
Preparation, Inspection, and Maintenance........................... 35
Pre-Start Inspection............................................... 35
Pre-Delivery Inspection and Frequent Inspection.................... 35
Annual Machine Inspection.......................................... 35
Preventive Maintenance............................................. 35
2.2 Service and Guidelines............................................. 36
General............................................................ 36
Safety and Workmanship............................................. 36
Cleanliness........................................................ 36
Components Removal and Installation................................ 36
Component Disassembly and Reassembly............................... 37
Pressure-Fit Parts................................................. 37
Bearings........................................................... 37
Gaskets............................................................ 37
Bolt Usage and Torque Application.................................. 37
Hydraulic Lines and Electrical Wiring.............................. 37
Hydraulic System................................................... 37
Lubrication........................................................ 38
Battery............................................................ 38
Lubrication and Servicing.......................................... 38
Hydraulic System................................................... 38
Hydraulic Oil...................................................... 38
Changing Hydraulic Oil............................................. 38
Lubrication Specifications......................................... 38
2.3 Cylinder Drift..................................................... 39
Theory............................................................. 39
Cylinder Leakage Test.............................................. 39
Cylinder Thermal Drift............................................. 39
2.4 Pins and Composite Bearing Repair Guidelines....................... 40
2.5 Welding on JLG Equipment........................................... 40
Do the Following When Welding on JLG Equipment..................... 40
Do Not Do the Following When Welding on JLG Equipment.............. 40
Section 3. Chassis & Turntable............................................. 47
3.1 Tires and Wheels................................................... 47
Tire Replacement................................................... 47
Wheel and Tire Replacement......................................... 47
Wheel Installation................................................. 47
3.2 Drive Orientation System........................................... 48
3.3 Beyond Transport Position - Drive Speed Cutback System............. 48
3.4 Drive/Steer - Boom Function Interlock System (CE ONLY)............. 48
3.5 Drive System....................................................... 48
3.6 Drive Motor........................................................ 49
Disassembly........................................................ 49
Assembly........................................................... 49
3.7 Drive Hub.......................................................... 56
Roll, Leak and Brake Testing....................................... 56
Tightening and Torquing Bolts...................................... 56
Measuring Rolling Torque........................................... 57
Main Disassembly................................................... 57
Housing-Spindle Disassembly........................................ 59
Spindle-Brake Subassembly Disassembly.............................. 61
Cover Disassembly.................................................. 62
Planet Gear Subassembly............................................ 64
Spindle-Brake Subassembly.......................................... 65
Housing-Spindle Subassembly........................................ 67
Housing-Ring Gear Subassembly...................................... 68
Cover Subassembly.................................................. 69
Main Assembly...................................................... 70
Integral Brake Check Procedure..................................... 71
3.8 Oscillating Axle System............................................ 76
Oscillating Axle Bleeding Procedure................................ 76
3.9 Chassis Tilt Indicator System...................................... 78
3.10 Swing Motor....................................................... 78
Removal............................................................ 80
Preparation Before Disassembly..................................... 80
Disassembly and Inspection......................................... 81
Assembly........................................................... 88
One Piece Stator Construction...................................... 94
Two Piece Stator Construction...................................... 95
Final Checks....................................................... 96
Installation....................................................... 96
3.11 Swing Drive....................................................... 96
Removal............................................................ 96
Installation.......................................................101
Turntable Bearing Mounting Bolt Condition Check....................102
Wear Tolerance.....................................................102
Swing Bearing Torque Value.........................................102
Disassembly........................................................104
Assembly...........................................................106
3.12 Engine Operating States...........................................116
3.13 Engine Start Conditions...........................................117
3.14 Engine RPM Levels.................................................117
Engine Stop RPM....................................................117
Idle RPM...........................................................117
Mid Engine RPM.....................................................117
Multi-Function RPM.................................................118
High Engine RPM....................................................118
Generator RPM......................................................118
3.15 Engine Controls...................................................118
Ambient Air Temperature Sensor.....................................118
Fuel Level Sensor..................................................118
3.16 Engine Startup Procedure (Kubota).................................119
3.17 Kubota Engine.....................................................120
Engine Oil Pressure Switch.........................................120
Engine Speed Sensor................................................120
Coolant Sensor.....................................................121
Glow Plugs.........................................................121
Engine Speed Actuators.............................................122
Engine Start.......................................................123
Alternator Excitation..............................................123
Fuel Pump..........................................................123
Shutdown...........................................................123
3.18 GM Dual Fuel Engine...............................................128
Communications with the JLG Control System.........................128
Engine Start.......................................................128
Oil Pressure.......................................................128
Engine Speed.......................................................128
Coolant Temperature................................................128
Fuel Select........................................................128
3.19 Fuel Reserve / Cut-Out System.....................................142
3.20 Cold Start System (Diesel Engine).................................142
3.21 Generator.........................................................142
3.22 Counterweight.....................................................143
Section 4. Boom & Platform.................................................145
4.1 Platform Control Enable System.....................................145
4.2 Platform Load Sensing System.......................................145
4.3 Ground Control Keyswitch System....................................145
4.4 Function Speed Control System......................................145
4.5 Jib Lift End Of Stroke Dampening...................................145
4.6 Emergency Decent System............................................145
4.7 Transport Position Sensing System..................................145
4.8 Platform...........................................................146
Platform/Support Removal...........................................146
Support Installation...............................................147
4.9 Main Boom Powertrack...............................................149
Removal............................................................149
Installation.......................................................149
4.10 Powertrack Maintenance............................................150
Remove Link........................................................150
Install New Link...................................................153
Replace Fixed End Brackets.........................................156
Replace Moving End Brackets........................................157
4.11 Boom Maintenance..................................................159
Disassembly of the Main Boom.......................................159
Inspection.........................................................160
Assembly of the Main Boom..........................................160
4.12 Boom Cleanliness Guidelines.......................................164
4.13 Rotary Actuator...................................................167
Theory of Operation................................................167
Tools Required.....................................................168
Disassembly........................................................169
Inspection.........................................................174
Assembly...........................................................175
Greasing Thrust Washers............................................179
Installing Counterbalance Valve....................................179
Testing the Actuator...............................................179
Installation and Bleeding..........................................181
Troubleshooting....................................................182
4.14 Skyguard®.........................................................183
Operation..........................................................183
Function Test......................................................183
Diagnostics & Troubleshooting......................................184
Section 5. Basic Hydraulic Information & Schematics........................185
5.1 Lubricating O-Rings in the Hydraulic system........................185
Cup and Brush......................................................185
Dip Method.........................................................186
Spray Method.......................................................186
Brush-on Method....................................................186
5.2 Hydraulic Cylinders................................................187
Disassembly and Assembly Instructions..............................187
General Information................................................187
Standard of Maintenance............................................187
Inspection After Assembly..........................................187
Disassembly Procedure..............................................190
Assembly...........................................................193
5.3 Drive Pump.........................................................218
Description........................................................218
The System Circuit.................................................219
High Pressure Relief Valve (HPRV) and Charge Check.................219
Charge Pressure Relief Valve.......................................220
Electrical Displacement Control (EDC)..............................221
Disassembly........................................................223
Inspection.........................................................228
Assembly...........................................................232
Port Locations and Gauge Installation..............................240
Fastener Size and Torque Chart.....................................241
Plug Size and Torque Chart.........................................241
Initial Startup Procedures.........................................244
Troubleshooting....................................................245
Pump Adjustment....................................................248
Displacement Limiter Adjustment....................................251
Control Neutral Adjustment.........................................252
Mechanical Neutral Adjustment......................................253
Removing the Pump..................................................254
Electric Control Module............................................254
Control Solenoids..................................................255
Shaft Seal, Roller Bearing and Shaft Replacement...................255
Charge Check / HPRV................................................257
Charge Pressure Relief Valve.......................................257
Pressure Limiter Valve Replacement.................................258
5.4 Gear Pump..........................................................258
Disassembly........................................................258
Troubleshooting....................................................268
5.5 Pressure Setting Procedure.........................................269
5.6 Oil Sampling.......................................................269
Procedure..........................................................269
5.7 Hydraulic Schematic................................................272
Section 6. JLG Control System..............................................275
6.1 JLG Control System Analyzer Kit Instructions.......................275
Introduction.......................................................275
6.2 Analyzer Menu Structure............................................276
6.3 Using the Hand Held Analyzer.......................................277
To Connect the JLG Control System Analyzer.........................277
Using the Analyzer.................................................277
Changing the Access Level of the Hand Held Analyzer................278
Adjusting Parameters Using the Hand Held Analyzer..................279
Machine Setup......................................................280
Level Vehicle Description..........................................280
6.4 Operator Controls and Switches.....................................290
Ground Control Switches............................................290
Platform Control Switches..........................................290
6.5 Control System Startup Checks......................................291
6.6 Machine Orientation When Performing Test...........................305
Test Notes.........................................................305
6.7 LSS System.........................................................312
6.8 MSSO (Machine Safety System Override)..............................312
Diagnostic Menu....................................................313
Calibration Procedure..............................................314
Testing & Evaluation...............................................319
Troubleshooting....................................................320
6.9 Resetting The MSSO System..........................................321
6.10 System Fault Messages.............................................323
Section 7. Basic Electrical Information & Schematics.......................365
7.1 General............................................................365
7.2 Multimeter Basics..................................................365
Grounding..........................................................365
Backprobing........................................................365
Min/Max............................................................365
Polarity...........................................................365
Scale..............................................................365
Voltage Measurement................................................365
Resistance Measurement.............................................366
Continuity Measurement.............................................366
Current Measurement................................................367
7.3 Applying Silicone Dielectric Compound to Electrical Connections....367
7.4 Dielectric Grease Application......................................368
Installation.......................................................368
AMP Mate-N-Lok.....................................................368
AMP Faston.........................................................368
AMP Micro-Fit......................................................368
AMP Mini Fit Jr....................................................369
Mini Fit Sr........................................................369
DIN Connectors.....................................................369
Exceptions.........................................................369
7.5 AMP Connector......................................................370
Applying Silicone Dielectric Compound to AMP Connectors............370
Assembly...........................................................370
Disassembly........................................................372
Wedge Lock.........................................................372
Service - Voltage Reading..........................................372
7.6 Deutsch Connectors.................................................374
DT/DTP Series Assembly.............................................374
DT/DTP Series Disassembly..........................................374
HD30/HDP20 Series Assembly.........................................375
HD30/HDP20 Series Disassembly......................................375
7.7 Telematics Gateway.................................................376
Telematics-Ready (TCU) Plug........................................376
7.8 Electrical Schematics..............................................411
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