Jlg 340AJ Service Manual User Manual Page 33
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- TROUBLESHOOTING
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SECTION 2 - GENERAL
3121259 β JLG Lift β 2-3
Component Disassembly and Reassembly
When disassembling or reassembling a component, complete
the procedural steps in sequence. Do not partially disassemble
or assemble one part, then start on another. Always recheck
your work to assure that nothing has been overlooked. Do not
make any adjustments, other than those recommended, with-
out obtaining proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use a molybdenum disul-
fide base compound or equivalent to lubricate the mating sur-
face.
Bearings
1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing.
2. Discard bearings if the races and balls (or rollers) are pit-
ted, scored, or burned.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer or
bore, apply pressure to the outer race. If the bearing is to
be installed on a shaft, apply pressure to the inner race.
Gaskets
Check that holes in gaskets align with openings in the mating
parts. If it becomes necessary to hand-fabricate a gasket, use
gasket material or stock of equivalent material and thickness.
Be sure to cut holes in the right location, as blank gaskets can
cause serious system damage.
Bolt Usage and Torque Application
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1. Always use new replacement hardware when installing
locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.
2. Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Chart Sec-
tion 1.)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as well
as their receptacles, when disconnecting or removing them
from the unit. This will assure that they are correctly rein-
stalled.
Hydraulic System
1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.
2. Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid
assembly.
Lubrication
Service applicable components with the amount, type, and
grade of lubricant recommended in this manual, at the speci-
fied intervals. When recommended lubricants are not avail-
able, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.
Battery
Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
sion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and servic-
ing are shown in the Lubrication Chart in Section 1.
2.3 LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting the
pump to cavitate due to insufficient system warm-up or
leaks in the pump supply (suction) lines.
- 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 β JLG Lift β 3121259 40
- 3.1 TIRES AND WHEELS 41
- Tire Replacement 41
- Wheel and Tire Replacement 41
- Wheel Installation 41
- 3-2 β JLG Lift β 3121259 42
- 3.6 DRIVE MOTOR 43
- 3-4 β JLG Lift β 3121259 44
- 3121259 β JLG Lift β 3-5 45
- 3-6 β JLG Lift β 3121259 46
- 3121259 β JLG Lift β 3-7 47
- 3-8 β JLG Lift β 3121259 48
- 3121259 β JLG Lift β 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 β JLG Lift β 3121259 52
- Housing-Spindle Disassembly 53
- 3-14 β JLG Lift β 3121259 54
- 3121259 β JLG Lift β 3-15 55
- Cover Disassembly 56
- 3121259 β JLG Lift β 3-17 57
- Planet Gear Subassembly 58
- Spindle-Brake Subassembly 59
- 3-20 β JLG Lift β 3121259 60
- Housing-Spindle Subassembly 61
- Housing-Ring Gear Subassembly 62
- Cover Subassembly 63
- Main Assembly 64
- 3121259 β JLG Lift β 3-25 65
- 3-26 β JLG Lift β 3121259 66
- 3121259 β JLG Lift β 3-27 67
- 3-28 β JLG Lift β 3121259 68
- 3121259 β JLG Lift β 3-29 69
- 3.8 OSCILLATING AXLE SYSTEM 70
- 3121259 β JLG Lift β 3-31 71
- 3.10 SWING MOTOR 72
- 3121259 β JLG Lift β 3-33 73
- 3-34 β JLG Lift β 3121259 74
- Disassembly and Inspection 75
- 3-36 β JLG Lift β 3121259 76
- 3121259 β JLG Lift β 3-37 77
- 3-38 β JLG Lift β 3121259 78
- 3121259 β JLG Lift β 3-39 79
- 3-40 β JLG Lift β 3121259 80
- 3121259 β JLG Lift β 3-41 81
- 3121259 β JLG Lift β 3-43 83
- 3-44 β JLG Lift β 3121259 84
- 3121259 β JLG Lift β 3-45 85
- 3-46 β JLG Lift β 3121259 86
- 3121259 β JLG Lift β 3-47 87
- One Piece Stator Construction 88
- Two Piece Stator Construction 89
- Final Checks 90
- Installation 90
- 3.11 SWING DRIVE 90
- 3121259 β JLG Lift β 3-51 91
- 3-52 β JLG Lift β 3121259 92
- M20x2.5 Thread 93
- 3-54 β JLG Lift β 3121259 94
- Wear Tolerance 96
- Swing Bearing Torque Value 96
- 3121259 β JLG Lift β 3-59 99
- Assembly 100
- FROM LAST JIB 101
- (ORIENTATION LOOKING TOWARDS 102
- LOWER UPRIGHT) 102
- ROTATED 28.5Β° CW 102
- 3121259 β JLG Lift β 3-63 103
- 3-64 β JLG Lift β 3121259 104
- 3121259 β JLG Lift β 3-65 105
- (3) LIMIT SWITCHES ARE PART 105
- OF LOWER BOOM HARNESS 105
- SWITCH SW152 OF 105
- LOWER BOOM HARNESS 105
- 3-66 β JLG Lift β 3121259 106
- 3121259 β JLG Lift β 3-67 107
- SEE DETAIL 108
- 3121259 β JLG Lift β 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 β JLG Lift β 3-71 111
- 3-72 β JLG Lift β 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 β JLG Lift β 3-77 117
- 3-78 β JLG Lift β 3121259 118
- 3121259 β JLG Lift β 3-79 119
- 3-80 β JLG Lift β 3121259 120
- 3121259 β JLG Lift β 3-81 121
- 3-82 β JLG Lift β 3121259 122
- 3121259 β JLG Lift β 3-83 123
- 3-84 β JLG Lift β 3121259 124
- 3121259 β JLG Lift β 3-85 125
- 3-86 β JLG Lift β 3121259 126
- LP MIXER PURGE POINT 127
- HOSE FROM CARBON CANISTER 127
- 3-88 β JLG Lift β 3121259 128
- 3121259 β JLG Lift β 3-89 129
- VOLTAGE REGULATOR 130
- CONTROL BOX 130
- GENERATOR 130
- ASSEMBLY 130
- 3.22 COUNTERWEIGHT 131
- 3-92 β JLG Lift β 3121259 132
- 4.3 BOOM MAINTENANCE 133
- Disassembly of the Main Boom 133
- 4-2 β JLG Lift β 3121259 134
- Inspection 135
- Assembly of the Main Boom 135
- 4-4 β JLG Lift β 3121259 136
- 3121259 β JLG Lift β 4-5 137
- 4-6 β JLG Lift β 3121259 138
- 3121259 β JLG Lift β 4-7 139
- 4-8 β JLG Lift β 3121259 140
- 3121259 β JLG Lift β 4-9 141
- 4.5 ROTARY ACTUATOR 142
- Theory of Operation 142
- Tools Required 143
- Disassembly 144
- 3121259 β JLG Lift β 4-13 145
- 4-14 β JLG Lift β 3121259 146
- 3121259 β JLG Lift β 4-15 147
- 4-16 β JLG Lift β 3121259 148
- 3121259 β JLG Lift β 4-19 151
- 4-20 β JLG Lift β 3121259 152
- 3121259 β JLG Lift β 4-21 153
- Greasing Thrust Washers 154
- Testing the Actuator 154
- 3121259 β JLG Lift β 4-23 155
- Installation and Bleeding 156
- Troubleshooting 157
- 4-26 β JLG Lift β 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 β JLG Lift β 5-21 179
- 3121259 β JLG Lift β 5-23 181
- 5-24 β JLG Lift β 3121259 182
- 3121259 β JLG Lift β 5-25 183
- 3121259 β JLG Lift β 5-29 187
- 5-30 β JLG Lift β 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 β JLG Lift β 6-7 251
- 6-8 β JLG Lift β 3121259 252
- PLATFORM MODULE 253
- GROUND MODULE 253
- 6-10 β JLG Lift β 3121259 254
- 3121259 β JLG Lift β 6-11 255
- 6-12 β JLG Lift β 3121259 256
- 3121259 β JLG Lift β 6-13 257
- 6-14 β JLG Lift β 3121259 258
- 3121259 β JLG Lift β 6-15 259
- Ground Control Switches 260
- Platform Control Switches 260
- 3121259 β JLG Lift β 6-17 261
- 6-18 β JLG Lift β 3121259 262
- 3121259 β JLG Lift β 6-19 263
- ANALYZER 264
- 3121259 β JLG Lift β 6-21 265
- 6-22 β JLG Lift β 3121259 266
- 3121259 β JLG Lift β 6-23 267
- 6-24 β JLG Lift β 3121259 268
- 3121259 β JLG Lift β 6-25 269
- 6-26 β JLG Lift β 3121259 270
- 3121259 β JLG Lift β 6-27 271
- 6-28 β JLG Lift β 3121259 272
- 3121259 β JLG Lift β 6-29 273
- 6-30 β JLG Lift β 3121259 274
- 3121259 β JLG Lift β 6-31 275
- 6-32 β JLG Lift β 3121259 276
- 6.6 SYSTEM FAULT MESSAGES 277
- 6-34 β JLG Lift β 3121259 278
- 3121259 β JLG Lift β 6-35 279
- 6-36 β JLG Lift β 3121259 280
- 3121259 β JLG Lift β 6-37 281
- 6-38 β JLG Lift β 3121259 282
- 3121259 β JLG Lift β 6-39 283
- 6-40 β JLG Lift β 3121259 284
- 3121259 β JLG Lift β 6-41 285
- 6-42 β JLG Lift β 3121259 286
- 3121259 β JLG Lift β 6-43 287
- 6-44 β JLG Lift β 3121259 288
- 3121259 β JLG Lift β 6-45 289
- 6-46 β JLG Lift β 3121259 290
- 3121259 β JLG Lift β 6-47 291
- 6-48 β JLG Lift β 3121259 292
- 3121259 β JLG Lift β 6-49 293
- 6-50 β JLG Lift β 3121259 294
- 3121259 β JLG Lift β 6-51 295
- 6-52 β JLG Lift β 3121259 296
- 3121259 β JLG Lift β 6-53 297
- 6-54 β JLG Lift β 3121259 298
- 3121259 β JLG Lift β 6-55 299
- 6-56 β JLG Lift β 3121259 300
- 3121259 β JLG Lift β 6-57 301
- 6-58 β JLG Lift β 3121259 302
- 3121259 β JLG Lift β 6-59 303
- 6-60 β JLG Lift β 3121259 304
- 3121259 β JLG Lift β 6-61 305
- 6-62 β JLG Lift β 3121259 306
- 3121259 β JLG Lift β 6-63 307
- 6-64 β JLG Lift β 3121259 308
- 3121259 β JLG Lift β 6-65 309
- 6-66 β JLG Lift β 3121259 310
- 3121259 β JLG Lift β 6-67 311
- 6-68 β JLG Lift β 3121259 312
- 3121259 β JLG Lift β 6-69 313
- 6-70 β JLG Lift β 3121259 314
- 3121259 β JLG Lift β 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 β JLG Lift β 3121259 320
- AMP JUNIOR TIMER 320
- SEALED ENCLOSURES 320
- 7.4 AMP CONNECTOR 321
- 7-8 β JLG Lift β 3121259 322
- Wedge Lock 323
- Service - Voltage Reading 323
- 7-10 β JLG Lift β 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 β JLG Lift β 7-13 327
- 7-14 β JLG Lift β 3121259 328
- 00111963-G 329
- 7-16 β JLG Lift β 3121259 330
- 1001119638-G 331
- 7-18 β JLG Lift β 3121259 332
- 7-20 β JLG Lift β 3121259 334
- KUBOTA ENGINE HARNESS 336
- GENERATOR HARNESS 337
- GM ENGINE HARNESS 338
- 7-26 β JLG Lift β 3121259 340
- 3121259 β JLG Lift β 7-29 343
- 7-30 β JLG Lift β 3121259 344
- 1001120020-C 345
- 7-32 β JLG Lift β 3121259 346
- JLG Worldwide Locations 348
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