Jlg 340AJ Service Manual User Manual Page 262
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SECTION 6 - JLG CONTROL SYSTEM
6-18 – JLG Lift – 3121259
Valve and Actuator Outputs Engine Proportional Throttle Actuator No STB/OC
No STG; energize and verify current path
Engine High Speed Throttle Actuator No STB/OC for relay
No STG; energize to verify
Drive Forward Valve No STB/OC
No STG; energize and verify current path
Drive Reverse Valve No STB/OC
No STG; energize and verify current path
Swing Left Valve No STB/OC
No STG; energize and verify current path
Swing Right Valve No STB/OC
No STG; energize and verify current path
Tow er Li ft Up Va lve No ST B/ OC
No STG; energize and verify current path
Tower Lift Down Valve No STB/OC
Do not check STG
Lift Up Valve No STB/OC
No STG; energize and verify current path
Lift Down Valve No STB/OC
Do not check STG
Flow Control Valve No STB/OC
No STG; energize and verify current path
Telescope In Valve No STB/OC
No STG; energize Tele In and Out simultaneously
Telescope Out Valve No STB/OC
No STG; energize Tele In and Out simultaneously
Level Up Valve No STB/OC
No STG; energize Level Up and Down simultaneously
Level Down Valve No STB/OC
No STG; energize Level Up and Down simultaneously
Platform Station
Digital and Functional Switch Inputs (Platform
Module communicates and Ground Module veri-
fies)
Engine Start Open; de-energized
Emergency Descent Open; de-energized
Drive Speed Select Open or Closed, but not both Max Speed and Max Torque
Horn Open; de-energized
Tower Lift Up Open; de-energized
Tower Lift Down Open; de-energized
Telescope In Open; de-energized
Telescope Out Open; de-energized
Jib Up Open; de-energized
Jib Down Open; de-energized
Level Up Open; de-energized
Level Down Open; de-energized
Rotate Left Open; de-energized
Rotate Right Open; de-energized
Table 6-5. System Startup Checks
Item Checked Function Condition/Action
- 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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