JLG 740AJ Boom Lift Service Manual
554 pages · Publication 3121651
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- Models
- 740AJ
- Serial coverage
- 0300185828 to Present
- Manual type
- Service Manual
- Pages
- 554
- Publication
- 3121651
- Condition
- Brand new
What's inside
From the manual's own table of contents: 546 sections, 631 entries. See sample pages (PDF, 593 KB)
General
Hydraulic System Safety
Maintenance6 topics
- Operating specifications
- Dimensional Data
- Capacities
- Engine Data
- Tires
- Component Data
Drive System
Swing System
Auxiliary Power Pump3 topics
- Torque Requirements
- Hydraulic Oil
- Major Component Weights
Critical Stability Weights1 topic
- Operator Maintenance
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief1 topic
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Show all 546 sections
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Theory
Cylinder Leakage Test
Cylinder Thermal Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation2 topics
- Tow Bar (If Equipped)
- Wheel Drive Assembly
Removal
Installation1 topic
- Drive Hub
Disassembly
Cleaning and Inspection
Repair
Assembly1 topic
- Drive Brake
Inspection1 topic
- Drive Motor
Description
Initial Start-up Procedures
Troubleshooting
Shaft Seal Replacement
Loop Flushing Valve1 topic
- Swing Hub
Roll, Leak And Brake Testing
Tightening and Torquing Bolts
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Motor
Disassembly and Inspection
One Piece Stator Construction2 topics
- Swing Hub Removal
- Swing Hub Installation
Procedure for Setting Swing Gear Backlash
Swing Drive Lubrication1 topic
- TABLE OF CONTENTS Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values4 topics
- Tilt Indicator System
- Spark Arrester Cleaning Instructions
- Rotary Coupling
- Generator
Maintenance Schedule
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
Generator Disassembly and Assembly
Lead Connection List for Generator3 topics
- Auxiliary Power System
- Deutz Engine
- Deutz Engine - TD2011L04
Glow Plugs
Check Oil Level
Replacing Engine Oil
Replacing the Oil Filter
Replacing the Primary Fuel Filter1 topic
- Deutz Engine - TD2.9L4
Replacing the Primary Fuel Filters1 topic
- Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline2 topics
- Deutz EMR 2
- GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing the Engine Oil
Coolant Fill Procedure - Dual Fuel Engine1 topic
- 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 Injector Rail
Fuel Injector1 topic
- GM Engine Fuel System Repair
Propane Fuel System Leak Test
Electronic Pressure Regulator (EPR) Assembly Replacement
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- Air Compressor
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 Systems2 topics
- Counterweight
- Platform
Platform Valve Removal
Platform Valve Installation
Support Removal
Support Installation2 topics
- Rotator and Slave Cylinder
- Boom System
Switch Systems
Above Elevation (Above Horizontal) Cutout System
Transport Position Interlock System (CE only)
Platform Control Enable System
Function Speed Control System
Platform
Main Lift End Stroke Dampening System
QuikStick Lift System
Tower Boom Sequence Valve System
Upright Level Override System
Ground Control Keyswitch System2 topics
- Main Boom Powertrack
- Powertrack Maintenance
Flat Bar Removal
Round Bar/Poly Bar Removal
Removing and Installing Links
Installing a New Flat Bar
Installing a New Round Bar/Poly Roller
Replacing a Fixed End Bracket
Replacing a Moving End Bracket
Replacing a One Piece Bracket4 topics
- Boom Cleanliness Guidelines
- Main Boom Assembly
- Upright
- Tower Boom Assembly
Tower Out of Sync2 topics
- Articulating Jib
- Upright Monitoring System
Re-Synchronizing Upright
Calibration
Calibration Faults
Function Check
Service Mode/Tower Boom Retrieval1 topic
- UMS Troubleshooting and Fault Messages
Backward Stability Concern Message
Forward Stability Concern Message
Auto Detection Input Low Message
UMS Sensor Communications Lost
Out of Usable Range Message
UMS Sensor Not Calibrated Message
UMS Sensor Faulted Message
Incompatible Software Detected Message2 topics
- Sequence for Hose Replacement in the Tower Boom
- Limit Switches Adjustment
Main Boom Horizontal Limit Switch
Tower Boom Horizontal Limit Switch1 topic
- Boom Valve Adjustment
Main Boom1 topic
- Rotator Assembly
Theory of Operation
Required Tools
Making a Seal Tool
Before Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Bolt-On External Fall Arrest System
Bolt-On External Fall Arrest System Types
Inspection Before Use
Inspecting Line Tenser
Inspecting Slip Indicator
Annual Inspection and Certification1 topic
- Skyguard
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic cylinders
Slave Cylinder
Upright Level Cylinder
Jib Lift Cylinder
Main Boom Lift Cylinder
Tower Boom Lift Cylinder
Master Cylinder
Steer Cylinder
Main Boom Telescope Cylinder1 topic
- Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Lift Cylinder Removal
Main Lift Cylinder Installation
Upright Level Cylinder Removal
Upright Level Cylinder Installation
Tower Boom Lift Cylinder Removal
Tower Boom Lift Cylinder Installation
Slave Cylinder Removal
Slave Cylinder Installation2 topics
- Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
- Pressure Setting Procedures
Set Up the Function Pump
Adjustments Made at the Main Valve Block
Adjustments Made at the Platform Valve Block3 topics
- Hydraulic Component Start-Up Procedures and Recommendations
- Hydraulic Drive Pump Pre-fill Procedure
- Function Pump
Fluid and Filter Maintenance
Control Assembly
Plug and Fitting Sizes and Torques1 topic
- Hydrostatic Pump
Servo Controlled Piston Pump
Charge Pump Adapter Assembly
Manual Servo Control Basic Assembly
Manual Servo Control Assembly Options
Rotating Kit Assembly
Fault-logic Trouble Shooting
Start-up Procedure2 topics
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
Introduction
To Connect the JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Configuration Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings and Function Speeds
- Machine Orientation When Setting Function Speeds
Test Notes1 topic
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation2 topics
- Resetting The MSSO System
- CANbus Communications
Analyzer Diagnostics Menu Structure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Telematics Gateway
Telematics-Ready (TCU) Plug1 topic
- Electrical Schematics
Maintenance and Lubrication Diagram
Deutz 2011 Engine Dipstick
Filter Lock Assembly
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (METRIC Fasteners - Sheet 4 of 5)
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - GM
Tow Bar
Axle and Steering Installation without Tow Package
Axle and Steering Installation with Tow Package
Chassis Component Location
Turntable Component Location
Wheel Drive Installation
Drive Hub
Drive Brake
Drive Motor Cross Section
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
SwashPlate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swashplate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Removing the Shaft Seal
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Drive Assembly
Swing Motor and Brake Assembly
Swing Drive Motor
Swing Bearing Tolerance Boom Placement (Sheet 1 of 2)
Swing Bearing Tolerance Boom Placement (Sheet 2 of 2)
Swing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Removal
Swing Bearing Torque Sequence
Rotary Coupling Seal Installation
Rotary Coupling Cutaway
Rotary Coupling Port Location (9 Port)
Rotary Coupling Installation
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Generator Troubleshooting Circuit Diagram (Sheet 1 of 2)
Generator Troubleshooting Circuit Diagram (Sheet 2 of 2)
Generator Electrical Circuit Diagram
Power Board PC1 Electrical Circuit Diagram
Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2)
Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2)
Auxiliary Power System
Deutz D2011 Engine Installation - Sheet 1 of 2
Deutz D2011 Engine Installation - Sheet 2 of 2
Deutz 2.9 L4 Engine Installation - Sheet 1 of 5
Deutz 2.9 L4 Engine Installation - Sheet 2 of 5
Deutz 2.9 L4 Engine Installation - Sheet 3 of 5
Deutz 2.9 L4 Engine Installation - Sheet 4 of 5
Deutz 2.9 L4 Engine Installation - Sheet 5 of 5
Deutz Engine Dipstick
Engine Oil Viscosity
Location of the Oil Filter
Location of the Primary Fuel Filter
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Engine Oil Dip Stick
Electric Fuel Lock Off
Low Pressure Regulators
ETC throttle control device
LPG Engine Control Unit (ECM)
ECM Assembly
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Pressure Regulator Section
(TMAP) Sensor & Electronic Throttle Control (ETC)
Mixer Assembly
Air Compressor
Counterweight
Location of Components Platform Support
Platform Support Torque Values
Location of Components-Rotator and Slave Cylinder
Boom Components Location
Location of Components - Powertrack
Powertrack Installation Main Boom (Sheet 1 of 2)
Powertrack Installation Main Boom (Sheet 2 of 2)
Hose and Cables Installation Tower Boom (Sheet 1 of 2)
Hose and Cables Installation Tower Boom (Sheet 2 of 2)
Location of Components - Upright
Location of Components - Tower Boom
Location of Components - Articulating Jib
Releveling Valve
Boom Upright Positioning
UMS Sensor Location
UMS Module Location
UMS Module Pin Identification
Boom Valve and Limit Switches Location (Sheet 1 of 2)
Boom Valve and Limit Switches Location (Sheet 2 of 2)
Rotator - Exploded View
Rotator - Assembly Drawing
Rotator Counterbalance Valve
Line Tenser - Transfastener Type
Line Tenser - Shuttle Type
Slip Indicator - System OK
Bolt-On External Fall Arrest System Components - Transfastener Type
Bolt-On External Fall Arrest System Components - Shuttle Type
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Tapered Bushing Installation
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Piston Seal Kit Installation
Rod Assembly Installation
Spanner Nut Removal
Main Boom Telescopic Cylinder
Components Main Boom and Tower Boom
Main Control Valve Pressure Adjustments (SN 0300185828 through 0300194175)
Main Control Valve Pressure Adjustments (SN 0300194176 to Present)
Main Valve Components (SN 0300194176 to Present) - Sheet 1 of 2
Main Valve Components (SN 0300194176 to Present) - Sheet 2 of 2
Valve Component Torque (SN 0300194176 to Present) - Sheet 1 of 2
Valve Component Torque (SN 0300194176 to Present) - Sheet 2 of 2
Platform Control Valve Identification
Platform Control Valve Component Torque
Gauge Port Locations
Load Sensing Control Adjustment
Pressure Compensation Control Adjustment
Shaft Seal and Retaining Ring
Plug Locations, Sizes, and Torques
Endcover Inspection
Housing Inspection
Servo Piston Installation
Bearing or Bushing Inspection
Manual Servo Control Basic Assembly Option
Neutral Lockout Switch Assembly
Gauge Locations
Fault- logic Troubleshooting
Hydraulic Schematic - Sheet 1 of 6
Hydraulic Schematic - Sheet 2 of 6
Hydraulic Schematic - Sheet 3 of 6
Hydraulic Schematic - Sheet 4 of 6
Hydraulic Schematic - Sheet 5 of 6
Hydraulic Schematic - Sheet 6 of 6
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart Version 6.X Software -Sheet 1 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 2 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 3 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 4 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 5 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 6 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 7 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 8 of 8
Fault Code Light Location
Analyzer Connecting Points
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female Contacts
Use of Seal Plugs
Brad-Harrison M12
Phoenix Contact M12
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Telematics Gateway Harness - Sheet 1 of 3
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Electrical Components Installation - Sheet 1 of 2
Electrical Components Installation - Sheet 2 of 2
Electrical Schematic GM - Sheet 1 of 2
Electrical Schematic GM - Sheet 2 of 2
Electrical Schematic - Sheet 1 of 14
Electrical Schematic - Sheet 2 of 14
Electrical Schematic - Sheet 3 of 14
Electrical Schematic - Sheet 4 of 14
Electrical Schematic - Sheet 5 of 14
Electrical Schematic - Sheet 6 of 14
Electrical Schematic - Sheet 7 of 14
Electrical Schematic - Sheet 8 of 14
Electrical Schematic - Sheet 9 of 14
Electrical Schematic - Sheet 10 of 14
Electrical Schematic - Sheet 11 of 14
Electrical Schematic - Sheet 12 of 14
Electrical Schematic - Sheet 13 of 14
Electrical Schematic - Sheet 14 of 14
Operating Specifications
Dimensional Data
Capacities
Deutz D2011L04 Specifications
Deutz TD 2.9 Specifications
GM 3.0L Specifications
Tire Specifications
Drive System Specifications
Swing System Specifications
Auxiliary Power Pump Specifications
Torque Requirements
Mobilfluid 424 Specs
Mobil DTE 10 Excel 32 Specs
Mobil EAL 224 H Specs
UCon Hydrolube HP-5046 Specs
Major Component Weights
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Coupling Port Information Table (9 port)
LPG Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
Engine Fault Codes
Deutz Trouble Codes - EMR4 (TD2.9 Engine)
Prime Lubricant Characteristics
Air Compressor Troubleshooting
SkyGuard Function Table
Symbols Used
Gauge and Port information
Fluid and Filter Change Interval
Excessive Noise and/ or Vibration
Actuator Response is Sluggish
Low Pump Output Flow
Pressure or Flow Instability
System Pressure Not Reaching Pressure Compensator Setting
High Inlet Vacuum
Analyzer Abbreviations
Machine Configuration Programming Information
Machine Configuration Programming Settings
Machine Personality Settings
Function Speeds
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
ADJUSTMENTS - Personality Descriptions
Diagnostic Trouble Code Chart
Inside this manual
Real pages from this service manual (554 pages). Open the sample pages (PDF, 591 KB)
- Specifications, page 25: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 473: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 537: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 287: SECTION 4 - BOOM & PLATFORM
- Color page, page 522: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 740AJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121651$69.85
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 554 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
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