Jlg E300 Service Manual Uživatelský manuál

Service and Maintenance ManualModelE300AJE300AJPS/N 0300138358to PresentP/N - 3121253October 24, 2013

vi – JLG Lift – 3121253LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121253986712345781. Tower Lift Cylinder2. Tower Upright3. Upper Upright4. Upper Lift Cylinder5. Maste

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-3NOTE: The telescope cylinder weighs approximately 53 lbs.(24 kg).6. Using a suitable lifting de

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121253Installation of the Main BoomNOTE: The main boom assembly weighs approximately 475lbs. (216 kg)

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-58. Connect all the hose/line couplings on the side ofthe boom as tagged during removal. Install

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 312125313. Using JLG P/N 0100011 thread locking compoundor equivalent, install the retaining bolt, kee

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-7Use JLG P/N 0100011 Thread Locking Compound or equivalent*******Figure 4-2. Boom Thread Lockin

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121253AAAABBBBFigure 4-3. Boom Torque ValuesA - Torque35 ft.lbs. (48 Nm)B - Torque 85 ft.lbs. (116

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-911010732849651. Link2. Level Link3. Lower Boom4. Mid Boom5. Timing Link6. Upper Upright7. Tower

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121253Use JLG P/N 0100011 Thread Locking Compound or equivalent***********Figure 4-5. Lower Boom Th

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-11AABBBBBBBBFigure 4-6. Lower Boom Torque ValuesA - Torque35 ft.lbs. (48 Nm)B - Torque 85 ft.

3121253 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121253116623345783524Figure 4-7. AJP Jib1. Platform Rotator2. Jib Rotator3. Upper Jib Link4. Jib Li

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-13A,E,FB,E,FAC,FD,FAAAABCDEFTorque to 35 ft.lbs. (48 Nm)Torque to 85 ft.lbs. (115 Nm)Torque to 2

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3121253NOTE: UPPER BOOM ANGLE TO BE 1° BELOWHORIZONTAL TO 3° ABOVE HORIZONTALTO ACTIVATE SWITCH. UPP

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-154.2 POWERTRACK MAINTENANCERemoving a LinkNOTE: Hoses shown in the powertrack are for example o

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31212533. To remove a link, the rivets holding the links togethermust be removed. Use a right-angle p

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-175. After grinding it may be neccesary to help the rivetout by using a center punch with a hamm

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31212537. Remove the link from the other section of the pow-ertrack using a screwdriver. Installing a

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-192. Spread apart the half-shear (female) end of the newlink and slide the peanut end of the tra

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 31212534. Pull the moving end out over the track so that thenew connection is positioned in the curve

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-21NOTE: When installing snap rings make sure they areseated in pin groove and closed properly.8.

viii – JLG Lift – 3121253LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 31212539. Pull up on the other end of the round bar and slidethe new poly roller onto the bar. 10. In

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-23Replacing Fixed End Brackets1. Remove the rivets the same way as shown under thelink removal i

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31212533. Take the new bracket and install bracket center pinand snap ring. Repeat on the other brack

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-25MOVE THE CABLES/HOSES OUT OF THE WAY DURING THEGRINDING PROCESS TO PROTECT THEM. KEEP THE HOSE

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 31212533. Install radius pins into their original locations andinstall snap rings. Repeat with other

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-274.3 BOOM CLEANLINESS GUIDELINESThe following are guidelines for internal boom cleanlinessfor m

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 31212534.7 ROTARY ACTUATORTheory of OperationThe rotary actuator is a simple mechanism that uses thes

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-29PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3121253PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-31Disassembly1. Remove the capscrews (113) over end cap lock pins(109). 2. Using a 1/8” (3.18mm)

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATATable 1-1. Operating spec

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 31212536. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-3310. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 312125316. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-35Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31212532. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-37Each T-seal has 2 back-up rings (see drawing for ori-entation). Beginning with the inner seal

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31212539. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-3914. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3121253Installing Counterbalance ValveRefer to Figure 4-12., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-41Figure 4-12. Rotator Counterbalance Valve

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31212531.3 CAPACITIES1.4 TIRES1.5 HYDRAULIC OILNOTE: Refer to Figure 1-1., Hydraulic Oil Specifications.NOT

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 3121253Installation and BleedingAfter installation of the actuator on the equipment, it isimportant t

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-43TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 3121253NOTES:

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121253Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-35.2 HYDRAULIC CYLINDERSDisassemblyNOTE: Disassembly of the cylinder should be performed ona clean work s

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121253123810911254763121316*221917*****21211415192018**231. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper5

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-51617141221242221131512323232325476831110918*20**19*****1. Tube Assembly2. Rod Assembly3. Gland4. Dust Wi

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31212535476381110916151711716131412161621. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper5. Retaining Ring6.

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-71314121521191925476381110917*1612018*201616161. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper5. Reta

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-3MOBIL DTE 11MMOBIL DTE 10 EXCEL 15MOBILFLUID 424QUINTOLUBRIC 888-46MOBIL EAL ENVIRONSYN H32MOBIL EAL

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31212532119**2122232120*18**21216175476381091113141215124241. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-9181825476381191014131215141619*2019*21117171. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper5. Retain

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31212531412151161618181717254310911876131. Tube Assembly2. Rod Assembly3. Gland4. Dust Wiper5. Retaining Ring6

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-11242413141215121617547638109112118**20*2119**212223211. Tube Assembly2. Rod Assembly3. Gland4. Dust Wipe

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31212534. Withdraw the O-ring and back up ring carefully asnot to damage the seals. 5. It is impossible to dis

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-134. Push the piston to the rod assembly to the end ofthe thread and then install the piston nut. Whenins

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31212535.3 PRESSURE SETTING PROCEDUREAdjustments made at the Main Valve BankMAIN PRESSURE RELIEF VALVE – 3000

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-15STEER RIGHT – 1400 PSI (97 BAR))1. Install pressure gauge at port MP of Main ValveBank.2. Activate Stee

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3121253Adjustments made at the Boom Function Valve BankJIB LIFT UP – 2000 PSI (138 BAR)1. Install pressure gau

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-17PLATFORM LEVEL UP – 3000 PSI (207 BAR)1. Refer to the Main Pressure Relief Valve procedureand temporari

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31212531.7 FUNCTION SPEEDSTest Notes1. Stop watch should be started with the function, notwith the controll

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3121253• at end of platform level up hose (do not use this loca-tion if port 15 was chosen in step 2.)4. Activ

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-194. After loosening relief valve jam nut, adjust valveclockwise to increase pressure or counterclockwise

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3121253TT-SWG-LT(INSIDE COIL)TT-SWG-RT(OUTSIDE COIL)BRK-PRES-SWTWR-LFT-UPFLOW-CNTLBRAKEMAIN-LFT-UPSTEER-RT(OUT

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-21511113112111178644491101010121414131414Table 5-3. Main Valve Torques# Description Ft. Lbs. Nm # Descrip

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121253JIB-DN(INSIDE COIL)TELE-IN(INSIDE COIL)TELE-OUT(OUTSIDE COIL)PLTF-ROT-RT(OUTSIDE COIL)PLTF-ROT-LT(INSID

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-232226193781111111111111111111113AJPONLY16E300AJP6121013161213131313133435131513E300AJTable 5-4. Boom Fun

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121253ccBADBTorque Ft-Lbs. NmA 14-18 19-24.5B 17-23 23-31C 6-9 8-12D 16-20 22-27ELECTRICMOTOR &PUMPPUMPHA

SECTION 5 - HYDRAULICS3121253 – JLG Lift – 5-255.4 INITIAL HYDRAULIC PUMP START-UP PROCEDUREThis procedure must be used when the hydraulic pump orpump

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 31212536. Continue activating the platform rotate switchmomentarily until the assistant sees a clear, uniforms

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-51563,4265Figure 1-2. Operator Maintenance and Lubrication Diagram

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121253The JLG Control System controller has a built in LED toindicate any faults. The system stores re

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-3The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121253Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter the first dig

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-5Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121253Figure 6-2. Platform Control Module Location - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-7POSITIONMATINGCONNECTORMATINGTERMINALPIN TYPEFUNCTIONJ144603214460226 1ANALYZER PWR (12V)POWER O

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121253Figure 6-4. Ground Control Module Location - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-9POSITIONMATINGCONNECTORTERMINAL PIN TYPEFUNCTIONJ144603214460226 1 N/C N/C N/C4460226 2 CAN HIGH

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121253Figure 6-6. Power Module Location - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-11CONNECTOR PIN TAGNAME FUNCTION TYPEJ11 PLTEMS PLATFORM EMS VBAT INPUT2 GNDEMS GROUND EMS VBAT I

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212531.8 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-2., Operator Ma

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121253CONNECTOR PIN TAG NAME FUNCTION TYPEJ21N/CN/C N/C N/C2CANHCAN HIGH SERIAL I/O3CANLCAN LOW SERIA

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-13Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGIT

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121253S/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWEDSW SWITCH or SOFTW

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-15MENU: HELP:PRESS ENTERHELP: (001) SYSTEM OKLOG: (XXX)XX:XXXXXXXXXXXXXMENU:

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121253MENU:ACTIVATE TESTSACTIVATE TESTS : YES:ENTER,NO:ESCMENU:ACCESS LEVEL 1ACCESS LEVEL: CODE 000

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-17MENU: MACHINE SETUPMODEL NUMBER: 1=3002TILT: 1=5Deg2DRIVE CUTOUT: 0=CHA

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121253Table 6-2. Machine Configuration Programming InformationConfiguration Digit Number DescriptionD

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-197(Platform Alarm)01No - Sounds continuously when above elevation and tilted only.Fault Code - S

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121253Table 6-3. Personality Ranges/DefaultsAdjustmentAdjustmentRangeDefaultValueDRIVEACCEL 0.5 to 5

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-21MIN OUT 0 to 50% 16%MAX OUT 0 to 100% 35%PLATFORM LEVELACCEL 0.5 to 5 sec 1.0sDECEL 0.1 to 3 se

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-73. Hydraulic TankLube Point(s) - Fill CapCapacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full MarkLub

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121253 Table 6-4. E300 Diagnostic Fault CodesDTCFlash CodeFault Message Description 001 00 EVERYTHING

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-232252 22 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTEDInput was CLOSED during startup225

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 31212532514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is be

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-2533364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward co

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 312125377 6 7 7 STALL ED P UMP MOTOR OR POWER WIRING ERR OR T he p ower module pum p MOSFET prote

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-2799133 99 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardwar

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121253System Self TestThe system self test is utilized to locate typical problems.See Table 6-5, Syst

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-29Table 6-6. System Test MessagesRUNNING Initial display when system test is run; certain “criti

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121253TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 6 - JLG CONTROL SYSTEM3121253 – JLG Lift – 6-31CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121253Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121253TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121253Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31212533. Anderson connectors for the battery boxes and bat-tery chargers sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-5AMP Mate-N-LokFollow the installation instructions.DIN ConnectorsThis

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121253BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact m

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-77.4 AMP CONNECTORAssemblyCheck to be sure the wedge lock is in the op

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31212533. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-9Disassembly5. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-9Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121253Figure 7-13. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-117.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121253HD30/HDP20 Series Assembly8. Grasp contact about 25mm behind the con

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-13This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121253PLATFORMCONTROLBOXDRIVEORIENTATIONSWITCHGROUNDCONTROLBOXFOOTSWITCHPL

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-15ALARMMAIN VALVE300AMP FUSE(UL Only)PUMPBATTERIESMAIN BOOMLIMIT SWITC

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121253132411137910TOWERLIFT UPPINK 25-1PINK 26-1BROWN 13-1BROWN 14-1WHITE

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-17SEEZONEB-7SEE ZONE G-5J53 PINACDCGENERATORAC PROVIDEDIN PLATFORM&

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121253Figure 7-24. Hydraulic Schematic - E300AJ - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-19Figure 7-25. Hydraulic Schematic - E300AJ - Sheet 2 of 21001112910-

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121253Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121253Figure 7-26. Hydraulic Schematic - E300AJP - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121253 – JLG Lift – 7-21Figure 7-27. Hydraulic Schematic - E300AJP - Sheet 2 of 21001112910

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121253NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-11Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121253Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7))Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS3121253 – JLG Lift – 1-13Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121253Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 2 - GENERAL3121253 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31212532.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121253 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

INTRODUCTION3121253 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - GENERAL2-4 – JLG Lift – 31212532. The design and manufacturing tolerances of thecomponent working parts are very close, therefore,even the

SECTION 2 - GENERAL3121253 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 2 - GENERAL2-6 – JLG Lift – 3121253Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3121253 – JLG Lift – 2-7Functions/Controls9Platform Controls 55 66Ground Controls 55 66Function Control Locks, Guards, or Detents 1

SECTION 2 - GENERAL2-8 – JLG Lift – 3121253All Decals/Placards Installed, Secure, Legible 21 21 21Walk-Around Inspection Performed 21Annual Machine In

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire Wear and DamageInspect tires da

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3121253RIGHT SIDE VIEW WITH HUB REMOVED2******3546231Figure 3-1. Steering Installation* Torq u

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-3874Note 1Note 2532*1*61. Drive Motor2. Gasket3. Drive Brake4. Drive Hub5. Gasket6. Speed Se

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31212533.2 SPINDLESetting Wheel Bearing End PlayBE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT.1. Tig

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-51. Dust Cap2. Cotter Pin3. Spindle Nut4. Spindle Washer5. Stud Nut6. Bearing Cone7. Hub8. B

INTRODUCTIONA-2 – JLG Lift – 3121253REVISON LOGOriginal Issue - October 27, 2009Revised - February 3, 2010Revised - August 23, 2012Revised - October 2

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 31212533.3 DRIVE HUBRoll and Leak TestingTorque-Hub units should always be roll and leak testedbef

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-7NOTE: On units with a ratio 48:1, the Sun Gear (11) and theInput Shaft (9) will need to be

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121253Figure 3-5. Main Disassembly Drawing 21F. Ring Gear1G. Housing4. Output Carrier Sub

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-9Output Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31212535. Remove 4 Thrust Washers (4B), 28 Needle Rollers(4C) and the Thrust Spacer (4D) from the

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-11Input Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121253Hub-Spindle Disassembly1. Place unit on bench with Spindle (1 A) end down.2. Remove Retain

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-13Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121253Input Carrier Assembly(Refer to Figure 3-8., Input Carrier)1. Apply a liberal coat of grea

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-15Output Carrier Assembly(Refer to Figure 3-6., Output Carrier)1. Place Thrust Washer (4H) i

3121253 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121253Figure 3-11. Hub Assembly - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-171A Spindle1B Lip Seal1C Tapered Bearing Cone1D Tapered Bearing Cup1E T

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121253Cover Subassembly(Refer to Figure 3-10., Cover Assembly)1. Grease O-Ring (6E) and insert i

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-19Figure 3-13. Cup Pressing ToolFigure 3-14. Cup Pressing Tool

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 31212533.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving t

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-212322192118171615201211109876542331131421. Capscrew2. Washer3. Pressure Plate4. Case Seal5.

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121253Table 3-2. Drive Brake DiagnosisProblem Cause ExplanationCorrectiveActionBrake slips Exces

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-233.5 SPEED SENSOR ADJUSTMENTFOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2)MUST BE PROPER

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121253Verification w/ Analyzer ProcedureThe motor controller averages the readings from the righ

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-2518. While watching the analyzer display select drive for-ward. Be ready to remove your foo

ii – JLG Lift – 3121253TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121253BLACKWIREBLACKWIREBLACKWIREBLACKWIREWHITEWIREWHITEWIREWHITEWIREWHITEWIREGREENWIREGREENWIRE

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-27MAIN CONTACTORPOSI-TRAC CONTACTORPOSI-TRAC/TILTMODULEFWD/REVCONTACTORPOWERDIODEDRIVEMOTOR

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121253NOTE: CONNECTS TOPUMP MOTOR NEGATIVE.(-) ON POWER MODULE.NOTE: DRIVEFORWARD/REVERSECONTACT

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-293.7 SWING MOTORIF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [INEXCESS OF 200°F (93.3°C

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121253Table 3-3. Swing Motor TroubleshootingTrouble Cause RemedyOil Leakage 1. Hose fittings loo

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-31123444888E8A8C8B48D9445761012131414151625171819201. Bolt2. End Cover3. Seal Ring4. Seal Ri

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3121253Preparation Before Disassembly• Before you disassemble the motor unit or any of itscompone

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-333. Remove the special ring head bolts (1) using anappropriate 1/2 or 9/16 inch size socket

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3121253these conditions exist, replace commutator andcommutator ring as a matched set.8. Remove m

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-35NOTE: A polished pattern on the wear plate from rotor rota-tion is normal.10. Place rotor

3121253 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121253keyway. Replace coupling shaft if any of these con-ditions exist.NOTE: Minor shaft wear in

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-37rosion. Remove burrs that can be removed withoutchanging dimensional characteristics. Insp

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 312125321. If the bearings, bushing or thrust washers must bereplaced use a suitable size bearing

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-39RECT RELATIONSHIP TO ADJACENT COMPONENTS WHENASSEMBLED. BECAUSE THE BEARING/BUSHINGS (13)

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 31212536. Assemble thrust washer (14) then thrust bearing (15)that was removed from the motor. NO

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-419. Apply a small amount of clean grease to a new sealring (4) and insert it into the housi

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121253NOTE: It may be necessary to turn one alignment stud outof the housing (18) temporarily to

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-43of drive link (10) onto manifold (7) with seal ring sideup. 19. Assemble a new seal ring (

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121253cover and other components into place with a finaltorque of 25-30 ft. lbs. (34-41 N m).One

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-454. Assemble six vanes, or as many vanes that will read-ily assemble into the stator vane p

iv – JLG Lift – 3121253TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 31212538. Assemble six vanes, or as many vanes that will read-ily assemble into the stator vane p

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-471. Bearing2. Oil Seal3. Capscrew4. Bolt5. Bolt6. Plug7. Pressure Vent8. Seal9. Grease Fitt

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 31212535. Using a press, disassemble the pinion and gearassembly. Support the worm gear (30) on t

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-4911. Install the worm cap (21) using proper shims (28) toachieve 0.000 to 0.001" (0.00

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121253c. Lower the main boom to horizontal and fullyextend the boom.d. At the position indicated

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-51JIB ELEVATED90 DEGREESMAIN BOOM FULLY ELEVATEDAND FULLY RETRACTEDMEASURING POINTNOTE:LOWER

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3121253MAIN BOOMFULLY EXTENDEDMAIN BOOMHORIZONTALLOWER BOOMFULLY ELEVATEDMEASURING POINTNOTE:Figu

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-53Replacement of Swing Bearing1. Removal.a. Attach an adequate support sling to the boomand

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121253f. Following the torque sequence diagram shownin Figure 3-26., Swing Bearing TorqueSequenc

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-553.10 BATTERY MAINTENANCE AND CHARGINGTO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE ORALL

3121253 – JLG Lift – v LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31212533.11 BATTERY CHARGERLEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGENGAS DURING NORMAL O

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-5710911876543**21*1001108560-BFigure 3-27. Battery Boxes1. Battery Terminal Grease2. Left B

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121253NO LIGHTS AT ALLNo Lights at all indicate that AC power to the charger isnot connected or

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-59[5 Flashes] - Over TemperatureThis fault indicates the charger has become too hot duringop

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121253Checking/Changing the Battery Charger AlgorithmThe charger is pre-loaded with programming

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-613.13 DRIVE ORIENTATION SYSTEMThe Drive Orientation System (DOS) is intended to indi-cate t

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121253UNLESS OTHERWISE SPECIFIED, ALLDIMENSIONS ARE IN INCHES.DRIVE TARGET CAMPROXIMITY SWITCHSW

SECTION 3 - CHASSIS & TURNTABLE3121253 – JLG Lift – 3-63TURNTABLERETAINING BOLT, NOTE A,NOTE BCOUNTER-WEIGHT*RETAININGHOOKFigure 3-30. Counterwei

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121253NOTES:

SECTION 4 - BOOM & PLATFORM3121253 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval of the Main BoomHYDRAULIC LINES AND