Jlg 340AJ Service Manual manuals

Jlg 340AJ Service Manual User Manual (348 pages)

Brand: Jlg | Category: Special machinery | Size: 30.44 MB |

English

Table of contents

P/N - 3121259

1

AGENERAL

3

BHYDRAULIC SYSTEM SAFETY

3

CMAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

SECTION 5 - HYDRAULICS

8

10

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

17

Major Component Weights

18

Hydraulic Oil

18

1.6 FUNCTION SPEEDS

19

Test Notes

19

SECTION 1 - SPECIFICATIONS

20

1.7 OPERATOR MAINTENANCE

21

SOCKET HEAD CAP SCREWS

26

Magni Coating (Ref 4150701)*

30

SECTION 2. GENERAL

31

2.2 SERVICE AND GUIDELINES

32

Safety and Workmanship

32

Cleanliness

32

SECTION 2 - GENERAL

33

Changing Hydraulic Oil

34

Lubrication Specifications

34

2.4 CYLINDER DRIFT TEST

34

Platform Drift

34

2-10 – JLG Lift – 3121259

40

3.1 TIRES AND WHEELS

41

Tire Replacement

41

Wheel and Tire Replacement

41

Wheel Installation

41

3-2 – JLG Lift – 3121259

42

3.6 DRIVE MOTOR

43

3-4 – JLG Lift – 3121259

44

3121259 – JLG Lift – 3-5

45

3-6 – JLG Lift – 3121259

46

3121259 – JLG Lift – 3-7

47

3-8 – JLG Lift – 3121259

48

3121259 – JLG Lift – 3-9

49

3.7 DRIVE HUB

50

Roll, Leak and Brake Testing

50

Tightening and Torquing Bolts

50

Measuring Rolling Torque

51

Main Disassembly

51

3-12 – JLG Lift – 3121259

52

Housing-Spindle Disassembly

53

3-14 – JLG Lift – 3121259

54

3121259 – JLG Lift – 3-15

55

Cover Disassembly

56

3121259 – JLG Lift – 3-17

57

Planet Gear Subassembly

58

Spindle-Brake Subassembly

59

3-20 – JLG Lift – 3121259

60

Housing-Spindle Subassembly

61

Housing-Ring Gear Subassembly

62

Cover Subassembly

63

Main Assembly

64

3121259 – JLG Lift – 3-25

65

3-26 – JLG Lift – 3121259

66

3121259 – JLG Lift – 3-27

67

3-28 – JLG Lift – 3121259

68

3121259 – JLG Lift – 3-29

69

3.8 OSCILLATING AXLE SYSTEM

70

3121259 – JLG Lift – 3-31

71

3.10 SWING MOTOR

72

3121259 – JLG Lift – 3-33

73

3-34 – JLG Lift – 3121259

74

Disassembly and Inspection

75

3-36 – JLG Lift – 3121259

76

3121259 – JLG Lift – 3-37

77

3-38 – JLG Lift – 3121259

78

3121259 – JLG Lift – 3-39

79

3-40 – JLG Lift – 3121259

80

3121259 – JLG Lift – 3-41

81

3121259 – JLG Lift – 3-43

83

3-44 – JLG Lift – 3121259

84

3121259 – JLG Lift – 3-45

85

3-46 – JLG Lift – 3121259

86

3121259 – JLG Lift – 3-47

87

One Piece Stator Construction

88

Two Piece Stator Construction

89

Final Checks

90

Installation

90

3.11 SWING DRIVE

90

3121259 – JLG Lift – 3-51

91

3-52 – JLG Lift – 3121259

92

M20x2.5 Thread

93

3-54 – JLG Lift – 3121259

94

Wear Tolerance

96

Swing Bearing Torque Value

96

3121259 – JLG Lift – 3-59

99

Assembly

100

FROM LAST JIB

101

(ORIENTATION LOOKING TOWARDS

102

LOWER UPRIGHT)

102

ROTATED 28.5° CW

102

3121259 – JLG Lift – 3-63

103

3-64 – JLG Lift – 3121259

104

3121259 – JLG Lift – 3-65

105

(3) LIMIT SWITCHES ARE PART

105

OF LOWER BOOM HARNESS

105

SWITCH SW152 OF

105

LOWER BOOM HARNESS

105

3-66 – JLG Lift – 3121259

106

3121259 – JLG Lift – 3-67

107

SEE DETAIL

108

3121259 – JLG Lift – 3-69

109

3.13 ENGINE START CONDITIONS

110

3.14 ENGINE RPM LEVELS

110

Engine Stop RPM

110

Idle RPM

110

Mid Engine RPM

110

3121259 – JLG Lift – 3-71

111

3-72 – JLG Lift – 3121259

112

3.17 KUBOTA ENGINE

113

Engine Oil Pressure Switch

113

Engine Speed Sensor

113

Coolant Sensor

114

Glow Plugs

114

Engine Speed Actuators

115

Engine Start

116

Alternator Excitation

116

Fuel Pump

116

Shutdown

116

3121259 – JLG Lift – 3-77

117

3-78 – JLG Lift – 3121259

118

3121259 – JLG Lift – 3-79

119

3-80 – JLG Lift – 3121259

120

3121259 – JLG Lift – 3-81

121

3-82 – JLG Lift – 3121259

122

3121259 – JLG Lift – 3-83

123

3-84 – JLG Lift – 3121259

124

3121259 – JLG Lift – 3-85

125

3-86 – JLG Lift – 3121259

126

LP MIXER PURGE POINT

127

HOSE FROM CARBON CANISTER

127

3-88 – JLG Lift – 3121259

128

3121259 – JLG Lift – 3-89

129

VOLTAGE REGULATOR

130

CONTROL BOX

130

GENERATOR

130

ASSEMBLY

130

3.22 COUNTERWEIGHT

131

3-92 – JLG Lift – 3121259

132

4.3 BOOM MAINTENANCE

133

Disassembly of the Main Boom

133

4-2 – JLG Lift – 3121259

134

Inspection

135

Assembly of the Main Boom

135

4-4 – JLG Lift – 3121259

136

3121259 – JLG Lift – 4-5

137

4-6 – JLG Lift – 3121259

138

3121259 – JLG Lift – 4-7

139

4-8 – JLG Lift – 3121259

140

3121259 – JLG Lift – 4-9

141

4.5 ROTARY ACTUATOR

142

Theory of Operation

142

Tools Required

143

Disassembly

144

3121259 – JLG Lift – 4-13

145

4-14 – JLG Lift – 3121259

146

3121259 – JLG Lift – 4-15

147

4-16 – JLG Lift – 3121259

148

3121259 – JLG Lift – 4-19

151

4-20 – JLG Lift – 3121259

152

3121259 – JLG Lift – 4-21

153

Greasing Thrust Washers

154

Testing the Actuator

154

3121259 – JLG Lift – 4-23

155

Installation and Bleeding

156

Troubleshooting

157

4-26 – JLG Lift – 3121259

158

SECTION 5. HYDRAULICS

159

Dip Method

160

Spray Method

160

Brush-on Method

160

5.2 HYDRAULIC CYLINDERS

161

General Information

161

Standard of Maintenance

161

Inspection After Assembly

161

SECTION 5 - HYDRAULICS

162

Disassembly Procedure

164

JIG FOR

168

DUST WIPER

168

3121259 – JLG Lift – 5-21

179

3121259 – JLG Lift – 5-23

181

5-24 – JLG Lift – 3121259

182

3121259 – JLG Lift – 5-25

183

3121259 – JLG Lift – 5-29

187

5-30 – JLG Lift – 3121259

188

5.3 DRIVE PUMP

192

Description

192

The System Circuit

193

Charge Pressure Relief Valve

194

Plug Size and Torque Chart

215

Initial Startup Procedures

218

Pump Adjustment

222

Control Neutral Adjustment

226

Mechanical Neutral Adjustment

227

Removing the Pump

228

Electric Control Module

228

Control Solenoids

229

Charge Check / HPRV

231

5.4 GEAR PUMP

232

5.6 OIL SAMPLING

243

Procedure

243

INSTRUCTIONS

245

Introduction

245

6.2 ANALYZER MENU STRUCTURE

246

Using the Analyzer

247

Analyzer

248

Machine Setup

250

Level Vehicle Description

250

3121259 – JLG Lift – 6-7

251

6-8 – JLG Lift – 3121259

252

PLATFORM MODULE

253

GROUND MODULE

253

6-10 – JLG Lift – 3121259

254

3121259 – JLG Lift – 6-11

255

6-12 – JLG Lift – 3121259

256

3121259 – JLG Lift – 6-13

257

6-14 – JLG Lift – 3121259

258

3121259 – JLG Lift – 6-15

259

Ground Control Switches

260

Platform Control Switches

260

3121259 – JLG Lift – 6-17

261

6-18 – JLG Lift – 3121259

262

3121259 – JLG Lift – 6-19

263

ANALYZER

264

3121259 – JLG Lift – 6-21

265

6-22 – JLG Lift – 3121259

266

3121259 – JLG Lift – 6-23

267

6-24 – JLG Lift – 3121259

268

3121259 – JLG Lift – 6-25

269

6-26 – JLG Lift – 3121259

270

3121259 – JLG Lift – 6-27

271

6-28 – JLG Lift – 3121259

272

3121259 – JLG Lift – 6-29

273

6-30 – JLG Lift – 3121259

274

3121259 – JLG Lift – 6-31

275

6-32 – JLG Lift – 3121259

276

6.6 SYSTEM FAULT MESSAGES

277

6-34 – JLG Lift – 3121259

278

3121259 – JLG Lift – 6-35

279

6-36 – JLG Lift – 3121259

280

3121259 – JLG Lift – 6-37

281

6-38 – JLG Lift – 3121259

282

3121259 – JLG Lift – 6-39

283

6-40 – JLG Lift – 3121259

284

3121259 – JLG Lift – 6-41

285

6-42 – JLG Lift – 3121259

286

3121259 – JLG Lift – 6-43

287

6-44 – JLG Lift – 3121259

288

3121259 – JLG Lift – 6-45

289

6-46 – JLG Lift – 3121259

290

3121259 – JLG Lift – 6-47

291

6-48 – JLG Lift – 3121259

292

3121259 – JLG Lift – 6-49

293

6-50 – JLG Lift – 3121259

294

3121259 – JLG Lift – 6-51

295

6-52 – JLG Lift – 3121259

296

3121259 – JLG Lift – 6-53

297

6-54 – JLG Lift – 3121259

298

3121259 – JLG Lift – 6-55

299

6-56 – JLG Lift – 3121259

300

3121259 – JLG Lift – 6-57

301

6-58 – JLG Lift – 3121259

302

3121259 – JLG Lift – 6-59

303

6-60 – JLG Lift – 3121259

304

3121259 – JLG Lift – 6-61

305

6-62 – JLG Lift – 3121259

306

3121259 – JLG Lift – 6-63

307

6-64 – JLG Lift – 3121259

308

3121259 – JLG Lift – 6-65

309

6-66 – JLG Lift – 3121259

310

3121259 – JLG Lift – 6-67

311

6-68 – JLG Lift – 3121259

312

3121259 – JLG Lift – 6-69

313

6-70 – JLG Lift – 3121259

314

3121259 – JLG Lift – 7-1

315

Resistance Measurement

316

Continuity Measurement

316

Current Measurement

317

TO ELECTRICAL CONNECTIONS

317

AMP Seal

318

AMP Mate-N-Lok

319

DIN Connectors

319

Exclusions

319

7-6 – JLG Lift – 3121259

320

AMP JUNIOR TIMER

320

SEALED ENCLOSURES

320

7.4 AMP CONNECTOR

321

7-8 – JLG Lift – 3121259

322

Wedge Lock

323

Service - Voltage Reading

323

7-10 – JLG Lift – 3121259

324

7.5 DEUTSCH CONNECTORS

325

DT/DTP Series Assembly

325

DT/DTP Series Disassembly

325

HD30/HDP20 Series Assembly

326

HD30/HDP20 Series Disassembly

326

3121259 – JLG Lift – 7-13

327

7-14 – JLG Lift – 3121259

328

00111963-G

329

7-16 – JLG Lift – 3121259

330

1001119638-G

331

7-18 – JLG Lift – 3121259

332

7-20 – JLG Lift – 3121259

334

KUBOTA ENGINE HARNESS

336

GENERATOR HARNESS

337

GM ENGINE HARNESS

338

7-26 – JLG Lift – 3121259

340

3121259 – JLG Lift – 7-29

343

7-30 – JLG Lift – 3121259

344

1001120020-C

345

7-32 – JLG Lift – 3121259

346

JLG Worldwide Locations

348

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