JLG 340AJ Service & Maintenance Manual (3121259) -PDF DOWNLOAD
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JLG 340AJ Service & Maintenance Manual (3121259) -PDF DOWNLOADJLG 340AJ Service & Maintenance Manual (3121259) -PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 340AJ 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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