JLG E300A, E300AJ & E300AJP Articulating Lifts Service and Maintenance Manual (ANSI) - 3120772

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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


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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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