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This service manual PDF download for the E300A, E300AJ & E300AJP JLG Electric Boom Lifts has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
JLG Lift E300A
JLG Lift E300AJ
JLG Lift E300AJP
TABLE OF CONTENTS :
Section 1. Specifications
1.1 Capacities
1.2 Operating specifications
1.3 Battery Charger
1.4 Drive System
1.5 Tires
1.6 Hydraulic Filter
1.7 Hydraulic Pump/Electric Motor Assembly
1.8 Dimensional Data
1.9 Function Speeds
1.10 Torque Specifications
1.11 Pressure Settings
1.12 Cylinder Specifications
1.13 Major Component Weights
1.14 Serial Number Locations
1.15 Hydraulic Oil
1.16 Lubrication
Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Cylinder Drift Test
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Section 3. Chassis & Turntable
3.1 Tires and Wheels
3.2 Drive Hub Part No. 2780236
3.3 Drive Hub (S/N 115723 to Present)
3.4 Drive Brake – Mico
3.5 Speed Sensor Adjustment
3.6 Positrac/Tilt module
3.7 Swing Bearing
3.8 Swing Motor
3.9 Helac Rotary actuator
3.10 Battery Maintenance and Charging
Section 4. Boom & Platform
4.1 Boom Maintenance
4.2 Wear Pads
4.3 Articulating Jib (AJ/AJP)
4.4 Tilt Indicator Switch Leveling
4.5 Footswitch Adjustment
4.6 Boom Limit Switches
Section 5. Hydraulics
5.1 Lubricating O-Rings in the Hydraulic System
5.2 Cylinders – Theory of Operation
5.3 Cylinder Checking Procedures
5.4 Cylinder Repair
5.5 Cylinder Removal And Installation
5.6 Lower Lift Cylinder Bleeding Procedure
5.7 Pressure Settings
5.8 Brake/Steer Valve Hydraulic filter replacement
Section 6. JLG Control System
6.1 JLG Control System Analyzer Kit Instructions
Section 7. Basic Electrical Information & Schematics
7.1 General
7.2 Multimeter Basics
7.3 Applying Silicone Dielectric Compound to Electrical Connections
7.4 AMP Connector
7.5 Deutsch Connectors
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3120772
Total Pages : 174
This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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Section A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General
B Hydraulic System Safety
C Maintenance
Section 1. Specifications
1.1 Capacities
1.2 Operating specifications
1.3 Battery Charger
1.4 Drive System
1.5 Tires
1.6 Hydraulic Filter
1.7 Hydraulic Pump/Electric Motor Assembly
1.8 Dimensional Data
1.9 Function Speeds
1.10 Torque Specifications
1.11 Pressure Settings
1.12 Cylinder Specifications
1.13 Major Component Weights
Critical Stability Weights
1.14 Serial Number Locations
1.15 Hydraulic Oil
1.16 Lubrication
Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
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
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment
Section 3. Chassis & Turntable
3.1 Tires and Wheels
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation
3.2 Drive Hub Part No. 2780236
Disassembly
Disassembly of Cover
Disassembly of the first stage planetary assembly (7)
Disassembly of second stage planet gears (1)
Assembly of first stage planetary assembly (7)
Assembly of end cover unit (8)
Final Assembly
Initial Start-up And After Repairs
Oil Change Interval-Gear Drive
3.3 Drive Hub (S/N 115723 to Present)
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Cover Disassembly
Input Carrier Assembly
Output Planet Gear Assembly
Output Carrier Assembly
Hub-Spindle Assembly
Cover Subassembly
Main Assembly
3.4 Drive Brake – Mico
Disassembly
Assembly
Bleeding
3.5 Speed Sensor Adjustment
Adjustment Procedure
3.6 Positrac/Tilt module
3.7 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Checking Worm Gear End Play
Adjusting End Play
3.8 Swing Motor
Removal
Disassembly
Assembly
Shaft Timing Procedure
Installation
3.9 Helac Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Disassembly
Inspection
Assembly
3.10 Battery Maintenance and Charging
Battery Maintenance, Quarterly
Charging Sequence of Remote LED Card
Section 4. Boom & Platform
4.1 Boom Maintenance
Removal of the Boom Assembly
Disassembly of the Main Boom
Inspection
Assembly of the Main Boom
Installation of the Boom Assembly
4.2 Wear Pads
4.3 Articulating Jib (AJ/AJP)
Removal
4.4 Tilt Indicator Switch Leveling
4.5 Footswitch Adjustment
4.6 Boom Limit Switches
Section 5. Hydraulics
5.1 Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method
5.2 Cylinders – Theory of Operation
Systems Incorporating Double Acting Cylinders
5.3 Cylinder Checking Procedures
Cylinder Without Counterbalance Valves (Steer and Master)
Cylinders With Single Counterbalance Valve (Upper Lift Cylinder)
Cylinders With Dual Counterbalance Valve (Lower Lift, Telescope, and Slave Cylinders)
5.4 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
5.5 Cylinder Removal And Installation
Upper (Main) Boom Lift Cylinder Removal
Upper (Main) Boom Lift Cylinder Installation
Lower Lift Cylinder Removal
Lower Lift Cylinder Installation
Upper Boom Telescope Cylinder Removal
Upper Boom Telescope Cylinder Installation
5.6 Lower Lift Cylinder Bleeding Procedure
5.7 Pressure Settings
Main Relief at Pump
Upper Lift Down Relief
Lower Lift Down Relief
Swing Relief
Telescope In Relief
Platform Level Up Relief
Platform Level Down Relief
Steer Relief
Jib Lift (Up and Down) Relief
Jib Swing Relief
5.8 Brake/Steer Valve Hydraulic filter replacement
Section 6. JLG Control System
6.1 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 Parameters Using the Hand Held Analyzer
Machine Setup
Machine Configuration Programming Information
Machine Personality Settings
Level Vehicle Description
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test
Section 7. Basic Electrical Information & Schematics
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.3 Applying Silicone Dielectric Compound to Electrical Connections
7.4 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service – Voltage Reading
7.5 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
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JLG E300A, E300AJ & E300AJP Articulating Lifts Service and Maintenance Manual (ANSI) – 3120772.pdf
