JLG 340AJ Manuals

Manuals and User Guides for JLG 340AJ. We have 2 JLG 340AJ manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG 340AJ Service And Maintenance Manual (371 pages)

Brand: JLG | Category: Boom Lifts | Size: 34 MB

Hydraulic System Safety
3
Safe Maintenance
3
General
3
Table of Contents
5
Section 1 - Specifications

19
- Operating Specifications
  19
- Dimensional Data
  19
- Capacities
  19
- Tires
  19
- Engine Data
  19
  - Major Component Weights
    20
  - Hydraulic Oil
    20
- Function Speeds
  21
  - Test Notes
    21
  - Operator Maintenance and Lubrication Diagram
    22
- Operator Maintenance
  23
- Torque Chart
  26
- Machine Preparation, Inspection, and Maintenance
  31
General

31
- Pre-Start Inspection
  31
- Pre-Delivery Inspection and Frequent Inspection
  31
- Annual Machine Inspection
  31
- Preventive Maintenance
  31
- Service and Guidelines
  32
  - General
    32
  - Safety and Workmanship
    32
  - Cleanliness
    32
  - Components Removal and Installation
    32
  - Bearings
    33
  - Gaskets
    33
  - Bolt Usage and Torque Application
    33
  - Hydraulic Lines and Electrical Wiring
    33
  - Component Disassembly and Reassembly
    33
  - Pressure-Fit Parts
    33
  - Hydraulic System
    33
- Lubrication and Information
  34
  - Changing Hydraulic Oil
    34
  - Battery
    34
  - Lubrication and Servicing
    34
  - Hydraulic System
    34
  - Lubrication Specifications
    34
- Cylinder Drift
  35
  - Cylinder Leakage Test
    35
  - Theory
    35
  - Cylinder Thermal Drift
    35
- Pins and Composite Bearing Repair Guidelines
  36
- Welding on JLG Equipment
  36
- Drive Orientation System
  44
- Beyond Transport Position - Drive Speed Cutback System
  44
- Drive/Steer - Boom Function Interlock System (CE ONLY)
  44
- Drive System
  44
- 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
    
    Drive Hub Assembly
    68
    
    Bearing Pressing Tool
    69
    
    Drift Pin for Lining up Thrustwashers with Output Planet Gear
    70
    
    Bearing Nut Wrench
    71
- Oscillating Axle System
  72
  - Oscillating Axle Bleeding Procedure
    72
  - Oscillating Axle
    73
- Chassis Tilt Indicator System
  74
- Swing Motor
  74
  - Preparation before Disassembly
    76
    
    Swing Motor Removal and Installation
    76
    
    Swing Motor Disassembly and Inspection
    77
    
    Swing Motor Assembly
    84
  - One Piece Stator Construction
    90
  - Two Piece Stator Construction
    91
  - Final Checks
    92
  - Installation
    92
    
    Swing Drive Removal
    92
    
    Swing Drive Installation
    97
  - Swing Bearing Torque Value
    98
  - Turntable Bearing Mounting Bolt Condition Check
    98
  - Wear Tolerance
    98
    
    Swing Bearing Disassembly
    100
    
    Swing Gear Assembly
    101
  - Assembly
    102
  - Cable Installation and Identification
    103
- Engine Operating States
  111
- Engine Start Conditions
  112
- Engine RPM Levels
  112
  - Idle RPM
    112
  - MID Engine RPM
    112
  - Engine Stop RPM
    112
- Engine Controls
  113
  - Multi-Function RPM
    113
  - High Engine RPM
    113
  - Ambient Air Temperature Sensor/Fuel Level Sensor
    113
  - Generator RPM
    113
- Engine Startup Procedure (Kubota)
  114
- Kubota Engine
  115
  - Engine Oil Pressure Switch
    115
  - Engine Speed Sensor
    115
  - Coolant Sensor
    116
  - Glow Plugs
    116
  - Engine Speed Actuators
    117
    
    Engine Throttle Actuator
    117
    
    Proportional Fuel Rack Actuator
    118
  - Alternator Excitation
    118
  - Fuel Pump
    118
  - Shutdown
    118
  - Engine Start
    118
  - Kubota Engine Diagrams
    119
- GM Dual Fuel Engine
  123
  - Communications with the JLG Control System
    123
  - Engine Start
    123
  - Oil Pressure
    123
  - Engine Speed
    123
  - Coolant Temperature
    123
  - Fuel Select
    123
  - DTC to SPN/FMI Cross Reference Chart
    130
- Fuel Reserve / Cut-Out System
  132
- Cold Start System (Diesel Engine)
  132
- Generator
  132
- Counterweight
  133
Section 4 - Boom & Platform

135
- Boom and Platform
  135
- Transport Position Sensing System
  135
- Boom Maintenance
  135
  - Disassembly of the Main Boom
    135
- Platform Control Enable System
  135
  - Assembly of the Main Boom
    137
    
    Boom Inspection
    137
    
    Main Boom Assembly Diagram
    139
    
    Jib/ Platform Support Diagram
    140
- Boom Cleanliness Guidelines
  141
- Boom Hydraulic Lines Diagram
  142
- Rotary Actuator
  144
  - Theory of Operation
    144
  - Making a Seal Tool
    145
  - Tools Required
    145
    
    Rotary Actuator Disassembly
    146
    
    Rotary Actuator - Exploded View
    148
    
    Rotary Actuator Inspection
    151
    
    Rotary Actuator Assembly
    152
  - Greasing Thrust Washers
    156
  - Installing Counterbalance Valve
    156
  - Testing the Actuator
    156
    
    Rotator Counterbalance Valve
    157
    
    Rotary Actuator Installation and Bleeding
    158
    
    Boom and Platform Troubleshooting
    159
    
    Platform Support Torque Values
    160
- Lubricating O-Rings in the Hydraulic System
  161
  - Cup and Brush
    161
  - Dip Method
    162
  - Spray Method
    162
  - Brush-On Method
    162
- Hydraulic Cylinders
  163
  - Cylinders Disassembly and Assembly
    163
  - Disassembly and Assembly Instructions
    163
  - General Information
    163
  - Inspection after Assembly
    163
  - Standard of Maintenance
    163
  - Acceptable Oil Leakage on Cylinder Rod
    164
  - Disassembly Procedure
    166
  - Assembly
    169
    
    Tower Lift Cylinder
    172
    
    Upper Lift Cylinder
    173
    
    Master Cylinder
    174
    
    Level Cylinder
    175
    
    Jib Cylinder
    176
    
    Steer Cylinder
    177
    
    Telescope Cylinder
    178
    
    Axle Lockout Cylinder
    179
    
    Hydraulic Tank
    180
    
    Valve Installation
    181
    
    Main Pump/Charge Filter Hydraulic Lines Diagram
    183
    
    Main Pump/Main Valve Hydraulic Lines Diagram
    184
    
    Drive Pump to Main Valve/Tank Hydraulic Lines
    185
    
    Main Control Valve Torque Specifications
    186
    
    Main Control Valve Identification
    187
    
    Flow Divider Valve Torque Specifications
    188
    
    Flow Divider Valve Identification
    189
    
    Fly Boom Control Valve Identification
    192
    
    Upright Control Valve Identification
    193
- Drive Pump
  194
  - Description
    194
  - Case Drain and Heat Exchanger
    195
  - High Pressure Relief Valve (HPRV) and Charge Check
    195
  - The System Circuit
    195
  - Charge Pressure Relief Valve
    196
  - Drive Pump Hydraulic Schematic
    196
  - Electrical Displacement Control (EDC)
    197
    
    Symbol Chart (Drive Pump)
    198
    
    Drive Pump Disassembly
    199
    
    EDC Control Disassembly
    200
    
    Pressure Limiter Removal
    201
    
    Charge Pressure Relief Valve Removal
    201
    
    High Pressure Relief Valve Removal
    201
    
    Endcap Removal
    202
    
    Cylinder Block Kit Removal
    202
    
    Servo Sleeve Removal
    202
    
    Servo Piston Removal
    203
    
    Swashplate and Swashplate Bearing Removal
    203
    
    Servo Piston Disassembly
    203
    
    Drive Pump Inspection
    204
    
    Block Spring Removal
    204
    
    Drive Pump Assembly
    208
    
    Shaft and Seatl Installation
    208
    
    Swashplate Bearings and Swashplate Installation
    208
    
    Servo Piston Reassembly
    209
    
    Servo Piston Installation
    209
    
    Servo Cylinder Installation
    209
    
    Cylinder Kit Reassembly
    210
    
    Cylinder Kit Installation
    210
    
    Timing Pin and Endcap Bushing Installation
    211
    
    Valve Plate and Endcap Installation
    211
    
    Charge Pump Installation
    212
    
    End Cover Installation
    213
    
    Charge Pressure Relief Valve Installation
    213
    
    HPRV Valve Installation
    213
    
    Optional Displacement Limiter Installation
    214
    
    EDC Control Assembly
    214
    
    EDC Control Installation
    215
  - Port Locations and Gauge Installation
    216
  - Fastener Size and Torque Chart
    217
  - Plug Size and Torque Chart
    217
    
    Fasteners and Plugs (Hydraulics)
    218
    
    Drive Pump Initial Start
    220
  - Initial Startup Procedures
    220
  - Drive Pump Troubleshooting
    221
  - Pump Adjustment
    224
    
    Charge Pressure Relief Valve Adjustment
    224
    
    Pressure Limiter Adjustment
    225
  - Displacement Limiter Adjustment
    227
  - Control Neutral Adjustment
    228
  - Mechanical Neutral Adjustment
    229
    
    Servo Adjustment Side M4
    229
    
    Verify Neutral Setting
    229
  - Removing the Pump
    230
  - Electric Control Module
    230
  - Control Solenoids
    231
  - Control Module Removal/Installation
    231
  - Shaft Seal, Roller Bearing and Shaft Replacement
    231
  - Shaft Assembly Diagram
    232
  - Charge Check / HPRV
    233
  - Charge Pressure Relief Valve
    233
  - Gear Pump Disassembly
    234
  - Pressure Limiter Valve Replacement
    234
    
    Gear Pump Cutaway
    236
    
    Gear Pump Assembly
    238
    
    Gear Pump Troubleshooting
    244
    
    Low or no Flow from Gear Pump
    244
    
    Excessive Noise from Gear Pump
    244
    
    External Leakage of the Gear Pump
    244
- Pressure Setting Procedure
  245
- Oil Sampling
  245
- Oil Sampling Port
  246
Section 6 - Jlg Control System

247
- JLG Control System Analyzer Kit Instructions
  247
  - Introduction
    247
- Analyzer Menu Structure
  248
- Using the Hand Held Analyzer
  249
  - To Connect the JLG Control System Analyzer
    249
  - Changing the Access Level of the Hand Held Analyzer
    250
  - Adjusting Parameters Using the Hand Held Analyzer
    251
  - Machine Setup
    252
  - Level Vehicle Description
    252
    
    Analyzer Abbreviations
    253
    
    Control Module Location
    255
    
    Ground Module
    256
    
    Platform Module
    260
- Operator Controls and Switches
  262
  - Ground Control Switches
    262
  - Toggle Switches
    262
- Control System Startup Checks
  263
  - Analyzer Top Level Menu
    266
  - Analyzer Diagnostic Menu
    267
  - Analyzer Personalities Menu
    271
  - Analyzer Machine Setup Menu
    273
  - Analyzer Calibration Menu
    274
  - Machine Model Adjustment
    275
  - Machine Configuration Programing Information
    278
  - Machine Configuration Programming Settings
    282
- LSS System
  283
  - Diagnostic Menu
    284
  - Calibration Procedure
    285
    
    Accessory Weights
    286
    
    Pipe Rack Capacity Reductions
    288
    
    Skyglazier Capacity Reductions
    288
    
    JLG Control System Testing and Evaluation
    290
  - Testing & Evaluation
    290
  - LSS Troubleshooting Chart
    291
- Resetting the MSSO System
  292
  - JLG Control System Fault Messages
    294
  - Fault Code Troubleshooting Information
    301
  - Overload Variations
    335
Section 7 - Basic Electrical Information & Schematics

337
- Basic Electrical Information and Schematics
  337
- Multimeter Basics
  337
  - Voltage Measurement
    337
  - Backprobing
    337
- General
  337
  - Grounding
    337
  - Min/Max
    337
  - Polarity
    337
  - Scale
    337
  - Resistance Measurement
    338
  - Continuity Measurement
    338
  - Current Measurement
    339
- Applying Silicone Dielectric Compound to Electrical Connections
  339
  - Installation of Dielectric Grease
    340
  - Deutsch HD, DT, DTM, DRC Series
    340
  - AMP Seal
    340
  - AMP Mate-N-Lok
    341
  - DIN Connectors
    341
  - Exclusions
    341
    
    Brad Harrison/Phoenix Contact M12
    342
    
    Amp Junior Timer
    342
    
    Sealed Enclosures
    342
- AMP Connector
  343
  - Assembly
    343
    
    Spec Connectors
    343
    
    Connector Assembly Diagrams
    344
    
    Connector Disassembly
    345
  - Service - Voltage Reading
    345
  - Wedge Lock
    345
  - Connector Installation
    346
- Deutsch Connectors
  347
  - DT/DTP Series Assembly
    347
  - DT/DTP Series Disassembly
    347
  - HD30/HDP20 Series Assembly
    348
  - HD30/HDP20 Series Disassembly
    348
    
    Electrical Schematic
    350
    
    Hydraulic Schematic
    366

JLG 340AJ Operation And Safety Manual (118 pages)

Boom Lift

Brand: JLG | Category: Lifting Systems | Size: 6 MB

Table of Contents
7
Section 1 - Safety Precautions

15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    17
- Operation
  17
  - General
    17
  - Trip and Fall Hazards
    18
  - Electrocution Hazards
    19
  - Tipping Hazards
    21
  - Crushing and Collision Hazards
    24
- Towing, Lifting, and Hauling
  25
- Maintenance
  25
  - Maintenance Hazards
    25
  - Battery Hazards
    27
Section 2. User Responsibilities, Machine Preparation, and Inspection

29
- 2.1 Personnel Training
  29
  - Operator Training
    29
  - Training Supervision
    29
  - Operator Responsibility
    29
- 2.2 Preparation, Inspection, and Maintenance
  30
  - Pre-Start Inspection
    32
  - Function Check
    33
  - Skyguard Function Test
    34
  - General
    37
- Oscillating Axle Lockout Test (if Equipped)
  39
Section 3 - Machine Controls and Indicators

41
- General
  41
- Controls and Indicators
  41
  - Ground Control Station
    42
  - Ground Control Indicator Panel
    47
  - Platform Station
    49
  - Platform Control Indicator Panel
    53
Section 4 - Machine Operation

57
- Description
  57
- Boom Operating Characteristics and Limitations
  58
  - Capacities
    58
  - Stability
    58
  - Engine Operation
    58
  - Starting Procedure
    58
  - Shutdown Procedure
    59
  - Fuel Reserve / Shut-Off System
    59
  - Engines Only)
    59
- Traveling (Driving)
  62
  - Traveling Forward and Reverse
    64
- Steering
  64
- Platform
  64
  - Platform Level Adjustment
    64
  - Platform Rotation
    64
- Boom
  65
- Function Speed Control
  66
- Machine Safety System Override (Msso)(Ce
  66
- 4.10 Skyguard Operation
  67
- Dual Fuel System (Gas Engine Only)
  67
  - Changing from Gasoline to LP Gas
    67
  - Changing from LP Gas to Gasoline
    67
- Shut down and Park
  68
  - Storage Position
    68
- 4.13 Lifting and Tie down
  71
  - Lifting
    71
  - Tie down
    71
Section 5 - Emergency Procedures

87
- General
  87
- Incident Notification
  87
- Emergency Operation
  87
  - Operator Unable to Control Machine
    87
  - Platform or Boom Caught Overhead
    88
- Auxiliary Descent System
  88
- Manual Swing Override
  88
- Emergency Towing Procedures
  90
- Machine Safety System Override (Msso)
  91
Section 6 - General Specifications & Operator Maintenance

93
- Introduction
  93
- Operating Specifications and Performance
  93
  - Data
    93
  - Operating Specifications
    93
  - Dimensional Data
    94
  - Capacities
    94
  - Tires
    95
  - Engine Data
    95
  - Hydraulic Oil
    96
  - Major Component Weights
    101
- Operator Maintenance
  105
- Tires & Wheels
  110
  - Tire Replacement
    110
  - Wheel and Tire Replacement
    111
  - Wheel Installation
    111
- Supplemental Information
  112
Section 7 - Inspection and Repair Log

113

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More JLG Manuals

JLG 340AJ Manuals

JLG 340AJ Service And Maintenance Manual (371 pages)

Table of Contents

Section 1 - Specifications

General

Section 4 - Boom & Platform

Section 6 - Jlg Control System

Section 7 - Basic Electrical Information & Schematics

JLG 340AJ Operation And Safety Manual (118 pages)

Table of Contents

Section 1 - Safety Precautions

Section 2. User Responsibilities, Machine Preparation, and Inspection

Section 3 - Machine Controls and Indicators

Section 4 - Machine Operation

Section 5 - Emergency Procedures

Section 6 - General Specifications & Operator Maintenance

Section 7 - Inspection and Repair Log

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