JLG 740AJ Service Manual User Manual
Service and maintenance manual
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Table of contents
Document Outline
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- 1.1 Capacities
- 1.2 Engine Data
- 1.3 Tires
- 1.4 Drive System
- 1.5 Swing System
- 1.6 Hydraulic Drive Pump
- 1.7 Variable Displacement Pump
- 1.8 Hydraulic Load Sense Pump
- 1.9 Auxiliary Power Pump
- 1.10 Hydraulic Filter - In-line
- 1.11 Compressor
- 1.12 Dimensional Data
- 1.13 Operating Specifications
- 1.14 Function Speeds
- 1.15 Torque Requirements
- 1.16 Lubrication
- 1.17 Cylinder Specifications
- 1.18 Major Component Weights
- 1.19 Pressure Settings
- 1.20 Critical Stability Weights
- 1.21 Operator Maintenance
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires & Wheels
- 3.2 Oscillating Axle Bleeding Procedure And Lockout Test
- 3.3 Free Wheeling Option
- 3.4 Torque Hub, Drive
- 3.5 Drive Brake - Ausco (Prior to S/N 56875)
- 3.6 Drive Brake - Mico (S/N 56875 to 83332)
- 3.7 Drive Brake (S/N 83332 to Present)
- 3.8 Drive Motor (Prior to S/N 83332)
- 3.9 Drive Motor Adjustment Procedure (Prior to S/N 83332)
- 3.10 Drive Motor (S/N 83332 to Present)
- 3.11 Swing Hub installation
- 3.12 Swing Bearing
- 3.13 Swing Hub (Prior to S/N 0300068040)
- 3.14 Swing Brake - Ausco (Prior to S/N 0300068040)
- 3.15 Swing Motor (Eaton) (Prior to S/N 0300068040)
- 3.16 Swing Hub (S/N 0300068040 to Present)
- 3.17 Swing Brake (S/N 0300068040 to Present)
- 3.18 Swing Motor (S/N 0300068040 to Present)
- 3.19 Rotary Coupling
- 3.20 Tilt Alarm Switch (Prior to S/N 0300062045)
- 3.21 Spark Arrester Cleaning Instructions
- 3.22 Generator
- 3.23 Dual Fuel System
- 3.24 EFI Engine
- 3.25 Ford LPG System (S/N 0300077500 To Present)
- 3.26 Deutz EMR 2 (S/N 85331 to Present)
- 3.27 GM Engine General Maintenance
- 3.28 GM Engine Dual Fuel System
- Fuel Filter
- Electric Lock Off
- EPR Assembly
- Low Pressure Regulator (LPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Engine Control Module
- Heated Exhaust Gas Oxygen Sensor
- Gasoline Multi Point Fuel Injection System (MPFI)
- Gasoline Fuel Pump
- Gasoline Pressure And Temperature Sensor Manifold
- Fuel Filter
- Fuel Injector Rail
- Fuel Injector
- 3.29 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Electronic Pressure Regulator (EPR) Assembly Replacement
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Electronic Throttle Control Replacement
- Mixer Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.30 GM Engine LPG Fuel System Diagnosis
- 3.31 Air Compressor
- Description
- Oil Injection
- Inlet Valve and Control Valving
- Air Filter Unit
- Oil Reservoir and Primary Oil Separation
- Secondary Spin-On Oil Coalescer/ Separator
- Spin-On Oil Filter
- Minimum Pressure Valve/Check Valve Assembly
- Hydraulic Drive System
- Compressor Cooling System
- Initial Startup
- Normal Startup Procedure
- Normal Shutdown Procedure
- Daily Operation
- General Maintenance
- Lubrication Guide
- Oil Filter Replacement
- Coalescer (Air/Oil Separator) Replacement
- Air Filter Replacement
- Belts - Tightening and Replacement
- Cooler Core Cleaning (Exterior)
- Adding/Changing Compressor Oil
- Pressure Adjustments
- Intake Control
- Minimum Pressure Valve
- Compressor Thermal Valve
- Safety Shutdown Systems
- Troubleshooting
- Section 4. Boom & Platform
- 4.1 Boom Maintenance
- 4.2 Rotator and Slave Cylinder
- 4.3 Main Boom Powertrack
- 4.4 Powertrack Maintenance
- 4.5 Main Boom Assembly
- 4.6 Upright
- 4.7 Tower Boom Assembly
- 4.8 Articulating Jib Boom
- 4.9 Limit Switches Adjustment
- 4.10 Platform
- 4.11 Wear Pads
- 4.12 Rotator - Helac (Prior to S/N 0300130881)
- 4.13 Rotator Assembly (S/N 0300130881 to Present)
- 4.14 Drive Card Setup Procedures
- 4.15 Foot Switch Adjustment
- 4.16 Upright Monitoring System
- 4.17 UMS Troubleshooting and Fault Messages - Non-ADE Machines
- Tower Lift Down Permanently closed
- Backward Stability Concern Message
- Forward Stability Concern Message
- UMS Out of Usable Range Message
- Battery voltage < 9.0 Volts
- Battery voltage > 16.0 Volts
- UMS Sensor Not Calibrated Message
- UMS Sensor Faulted
- Tower Lift Down Output Short to Ground or Open Circuit
- Tower Lift Down Output Short to Battery
- Platform Indicator Output Short to Ground or Open Circuit
- Platform Indicator Output Short to Battery
- Ground Indicator Output Short to Ground
- Ground Indicator Output Short to Battery
- Turntable Sensor Not Calibrated Message
- Turntable Sensor Faulted
- EEPROM checksums failure
- 4.18 UMS Troubleshooting and Fault Messages - ADE Machines
- 4.19 Use and Care of Fall Arrest System
- Section 5. Hydraulics
- 5.1 Lubricating O-Rings in the Hydraulic System
- 5.2 Valves - Theory Of Operation
- 5.3 Cylinders - Theory Of Operation
- 5.4 Cylinder Checking Procedure
- 5.5 Cylinder Repair
- 5.6 Cylinder Removal And Installation
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Slave Cylinder Removal
- Slave Cylinder Installation
- 5.7 Hydraulic Pump W/hayes Pump drive Coupling Lubrication
- 5.8 Pressure Setting Procedures
- 5.9 Hydraulic oil change-out procedure
- 5.10 Hydraulic Component Start-Up Procedures and Recommendations
- 5.11 Rexroth Variable Displacement Pump (Prior to S/N 0300121643)
- 5.12 Sauer Piston Pump S/N 0300121643 to Present
- Section 6. JLG Control System
- 6.1 Introduction
- 6.2 CANbus Communications
- 6.3 To Connect the JLG Control System Analyzer
- 6.4 Using the Analyzer
- 6.5 Changing the Access Level of the Hand Held Analyzer
- 6.6 Adjusting Parameters Using the Hand Held Analyzer
- 6.7 Machine Setup
- 6.8 Level Vehicle Description
- 6.9 Machine Personality Settings
- Section 7. Basic Electrical Information & schematics