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340AJ Service Manual
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Jlg 340AJ Service Manual User Manual Page 106
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Table of contents
TROUBLESHOOTING
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SECTION 3 - CHASSIS & TURNTABLE
3-66
– JLG Lift –
3121259
SEE DET
AIL
S
DET
A
IL
S
SYSTEM T
ANK
TOWER LIFT CYLINDER T
ANK
TOWER LIF
T CYLINDER
PRESSURE
AC CABLE
MAIN LIFT
CYLINDER PRES
SURE
SYSTEM PRESSURE
BOOM CABLE
L
OWER BOOM HARNESS
Figure 3-44. Cable Installation and Identification - Sheet 6 of 8
1
2
...
101
102
103
104
105
106
107
108
109
110
111
...
347
348
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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