JLG E300AJ, E300AJP Boom Lift Service Manual
432 pages · Publication 31215001
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
What's inside
From the manual's own table of contents: 401 sections, 472 entries. See sample pages (PDF, 577 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Operating Specifications
Machine Specification E300AJ
Machine Specification E300AJP4 topics
- Capacities
- Tires
- Dimensional Data
- Lubrication Specifications
Hydraulic Oil5 topics
- Critical Stability Weights
- Major Component Weights
- Operator Maintenance
- Thread Locking Compound
- Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart1 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 Assembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Show all 401 sections
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
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 Damage
Tire Replacement
Wheel and Tire Replacement
Wheel Installation1 topic
- Spindle
Setting Wheel Bearing End Play
Specifications
Checking
Greasing Requirements3 topics
- Tilt Sensor
- Speed Sensor
- Drive Hub
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 Assembly
Main Assembly1 topic
- Drive Motor
Removal
Disassembly
Inspection
Assembly
Installation2 topics
- Swing Drive
- Swing Motor
Preparation Before Disassembly
Disassembly and Inspection
One Piece Stator Construction
Two Piece Stator Construction
Final Checks
Installation Torque1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value1 topic
- Battery Maintenance and Charging
Battery Maintenance, Quarterly
Battery Charging, Daily1 topic
- Battery Charger
Operating Instructions
Maintenance Instructions
Battery Charger Fault Codes
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
Instructions for using the Delta-Q QuiQ Programmer CTQuiQ Programming Kit
Checking/Changing the Battery Charger Algorithm10 topics
- Chassis Tilt Indicator System
- Drive Orientation System
- Hoods
- Platform Control Enable System
- Function Speed Control System
- Transport Position Interlock System
- Above Elevation (Above Horizontal) Cutout System
- Platform Load Control System
- Positive Opening Switch Systems
- Platform
Support Removal
Support Installation1 topic
- Boom Maintenance
Removal of the Main Boom
Disassembly of the Main Boom
Assembly of the Main Boom
Installation of the Main Boom8 topics
- Wear Pads
- Tilt Sensor Check
- Boom Limit Switches
- Boom Cleanliness Guidelines
- Foot Switch Adjustment
- Articulating Jib Boom
- Boom Synchronizing Procedure
- Rotary Actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding
Troubleshooting1 topic
- Powertrack Maintenance
Removing a Link
Installing a New Link
Replacing Fixed End Brackets
Replacing Moving End Brackets1 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 Connection Assembly and Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly and Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Platform Level Cylinder
Jib Lift Cylinder
Main Boom Lift Cylinder
Master Cylinder
Tower Boom Lift Cylinder
Steer Cylinder
Telescope Cylinder1 topic
- Cylinder Removal And Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Phase Check Cartridge1 topic
- Pressure Setting Procedure
Adjustments made at the Main Valve Bank
Adjustments made at the Boom Function Valve Bank1 topic
- Initial Hydraulic Pump Start-up Procedure
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 Parameters Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings
- Machine Orientation When performing test
Test Notes
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test5 topics
- Calibrating Steer
- Calibrating Tilt Sensor
- Calibrating Load Sensing
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions1 topic
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
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
- Wiring Harness Connector Labels
Connector Labels
Component Labels2 topics
- Electrical Harness
- Electrical Schematics
Maintenance and Lubrication Diagram
Hydraulic Oil Operation Chart
Spindle Assembly
Chassis Component Location
Steering Installation
Drive Components
Frame Mounted Electrical Connection
Relay
System Fuses
Brake Fuses
Drive Fuses
Main Assembly - Sheet 1 of 2
Main Assembly - Sheet 2 of 2
Output Carrier
Planet Gear
Input Carrier
Hub Spindle
Drive Hub - Sheet 1 of 2
Drive Hub - Sheet 2 of 2
Cup Pressing Tool
Drive Motor
Swing Components
Swing Drive - Exploded View
Swing Motor - Cutaway
Swing Motor - Exploded View
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Boom Placement
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Battery Charger
Battery Boxes
QuiQ Programming Kit
Hoods
Drive Orientation Switch
Counterweight
Location of Components Platform Support
Platform Support Torque Values
Boom Assembly
Boom Lubrication Instructions
Power Track Hoses
Clamp Block Installation
Boom Thread Locking Compound Location
Boom Torque Values
Lower Boom
Lower Boom Thread Locking Compound Location
Lower Boom Torque Values
AJP Jib
AJP Jib Torque Values
Wear Pad Thickness
Boom Limit Switches
Location of Components - Articulating Jib Boom
Rotary Actuator (Exploded View)
Rotator - Assembly Drawing
Rotator Counterbalance Valve
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
ORB-MPP Thread
MFF-BSPP Thread
Torque Wrench Angle
FFWR Method
Cylinder Barrel Support
Cylinder Rod Support
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tower Boom Cylinder
Main Telescope Cylinder Removal
Main Control Valve - Sheet 1 of 2
Main Control Valve - Sheet 2 of 2
Boom Function Valve - Sheet 1 of 2
Boom Function Valve - Sheet 2 of 2
Hydraulic Components Location
Hydraulic Schematic (E300AJP) - Sheet 1 of 4
Hydraulic Schematic (E300AJP) - Sheet 2 of 4
Hydraulic Schematic (E300AJ) - Sheet 3 of 4
Hydraulic Schematic (E300AJ) - Sheet 4 of 4
Hand Held Analyzer
Analyzer Flow Chart, Version P1.10 - Sheet 1 of 5
Analyzer Flow Chart, Version P1.10 - Sheet 2 of 5
Analyzer Flow Chart, Version P1.10 - Sheet 3 of 5
Analyzer Flow Chart, Version P1.10 - Sheet 4 of 5
Analyzer Flow Chart, Version P1.10 - Sheet 5 of 5
Control Module Location
Analyzer Connecting Points
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
Power Module - LH
Power Module - RH
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Voltage Measurement (DC)
Current Measurement (DC)
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
Platform Console Harness - Sheet 1 of 5
Platform Console Harness - Sheet 2 of 5
Platform Console Harness - Sheet 3 of 5
Platform Console Harness - Sheet 4 of 5
Platform Console Harness - Sheet 5 of 5
Load Sensing System Harness (LSS) - Sheet 1 of 2
Load Sensing System Harness (LSS) - Sheet 2 of 2
Main Valve Harness - Sheet 1 of 3
Main Valve Harness - Sheet 2 of 3
Main Valve Harness - Sheet 3 of 3
Boom Valve Harness - Sheet 1 of 2
Boom Valve Harness - Sheet 2 of 2
Turntable Harness - Sheet 1 of 4
Turntable Harness - Sheet 2 of 4
Turntable Harness - Sheet 3 of 4
Turntable Harness - Sheet 4 of 4
Amber Beacon Harness
Ground Panel Harness - Sheet 1 of 3
Ground Panel Harness - Sheet 2 of 3
Ground Panel Harness - Sheet 3 of 3
Chassis Traction Harness - Sheet 1 of 3
Chassis Traction Harness - Sheet 2 of 3
Chassis Traction Harness - Sheet 3 of 3
Chassis Traction to Turntable Harness
Steering Sensor Harness
Inverter IGN Harness
Platform Work Light Harness
SkyGuard Harness - Sheet 1 of 2
SkyGuard Harness - Sheet 2 of 2
Security Lock Harness - Sheet 1 of 2
Security Lock Harness - Sheet 2 of 2
Skyguard (Bar) 6 Pin Harness
Eboom Clearsky CAN Harness
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
Dimensional Data - E300AJ
Dimensional Data - E300AJP
Mobil DTE 11M Specs
Mobil DTE 10 Excel 15 Specs
Mobilfluid 424 Specs
Mobil EAL 224H Specs
Mobil EAL Envirosyn H Specs
Quintolubric 888-46
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Swing Motor Troubleshooting
Battery Charger Fault Codes (Delta-Q)
Battery Algorithms
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC) Thread - Steel
37° Flare (JIC) Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24°Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Flat Face Port (MFF) - S Series - Table 3 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) -Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Main Valve Torque
Boom Function Valve Torques
Analyzer Abbreviations
Machine Configuration Programming Information - Version P1.10
Machine Configuration Programming Settings - Version P1.10
Personality Ranges/Defaults - Version P1.10
Function Speeds
Machine Setup Descriptions
JLG Control System Flash Codes
DIAGNOSTICS - Menu Descriptions
System Test Descriptions
System Test Messages
Diagnostic Trouble Codes
Wiring Harness Connector Labels
Inside this manual
Real pages from this service manual (432 pages). Open the sample pages (PDF, 574 KB)
- Specifications, page 20: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 164: SECTION 4 - BOOM & PLATFORM
- Diagram, page 272: TELESCOPE CYLINDER
- Color page, page 156: SECTION 4 - BOOM & PLATFORM
- Color page, page 267: SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the E300AJ, E300AJP 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 31215001$69.81
Added to your cart. View cart
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, 432 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).