Jlg E300 Service Manual Manuel d'utilisateur

Service and Maintenance ManualModelE300AE300AJE300AJPP/N - 3120772January 23, 2009

vi – JLG Lift – 3120772LIST OF FIGURES FIGURE NO. TITLE

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3120772Cylinders With Dual Counterbalance Valve (Lower Lift, Telescope, and Slave Cylinders)OPERATE ALL FUNCTIO

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-55.4 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31207725. Mark cylinder head and barrel with a center punchfor easy realignment. Using an allen wrench, loosent

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-7Cleaning and Inspection1. Clean all parts thoroughly in an approved cleaningsolvent.2. Inspect the cylin

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 312077212111,3,26618 195192518 1410162022179233*,4*,24212713138877*Prior to S/N 03001065171. Loctite #2422. Not

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-911132312220201215141437891019161764222155181. Loctite #2422. Primer #74713. Bolt4. Tapered Bushing5. Com

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 3120772722412234415161114211817174683519120231012131. Loctite #2422. Bolt3. Tapered Bushing4. Composite Bushin

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-111. O-ring2. O-ring3. Backup Ring4. Seal5. Wiper6. O-ring7. Seal8. Wear Ring9. Wear Ring10. Not Used11.

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31207725126755101221121416191381817141520209312451. Loctite #2422. Locking Primer3. Bolt4. Tapered Bushing5. C

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-1315A7248910131261131451. Locknut2. Piston3. Piston Seal4. O-ring5. Barrel6. Rod7. Guide8. O-ring9. Backu

3120772 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31207721027122829306119831133151415267222119251616181823241720321. Loctite #2422. Not Used3. Locking Primer4.

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-15AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31207728. Using suitable protection, clamp the cylinder rod ina vise or similar holding fixture as close to pi

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-1717. Position the cylinder barrel in a suitable holding fix-ture.EXTREME CARE SHOULD BE TAKEN WHEN INSTA

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31207725.5 CYLINDER REMOVAL AND INSTALLATIONUpper (Main) Boom Lift Cylinder Removal1. Place the machine on a f

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-194. Tag, disconnect and cap the lift cylinder hydrauliclines and ports.5. Remove the hardware securing t

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3120772Upper Boom Telescope Cylinder Installation1. Attach a hydraulic power supply to the telescopecylinder p

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-215.7 PRESSURE SETTINGSCold temperatures have a significant impact on pressurereadings.JLG Industries Inc

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3120772Platform Level Down Relief1. On machines prior to S/N 0300063313, install thepressure gauge at the “G”

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-235.8 BRAKE/STEER VALVE HYDRAULIC FILTER REPLACEMENTThe Brake /Steer Valve is located on the turntable, u

viii – JLG Lift – 3120772LIST OF TABLES TABLE NO. TITLE

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3120772ORMANUAL DESCENTHANDLEMAIN CONTROLVALVEJIB VALVEJIB VALVESTEER/BRAKEVALVEFigure 5-26. Control Valve In

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-25Figure 5-27. Main Valve Components - Prior to S/N 0300063313

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3120772201485679101811121624171913141532211. Proportional Flow Regulator2. Bypass Unloading3. Lower Lift4. Upp

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-27Figure 5-29. HydraForce Cartridge Torque Value Chart

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3120772NOTES:

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3120772Figure 6-2. Power Module

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-3The upper lift, swing, and drive are controlled by individualjoysticks, with steering being cont

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3120772The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-5Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 OPERATING SPECIFICATIONSTable 1-1. CapacitiesHydraulic

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3120772Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-7Machine Configuration Programming InformationTable 6-2. Machine Configuration Programming Inform

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 31207725(JIB)012No JIB installed.JIB installed which has up and down movements only. OptionJIB installe

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-9Machine Personality Settings NOTE: Personality settings can be adjusted within theadjustment ran

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3120772SWING ACCELeration 0.5 to 5.0s 2.0DECELeration 0.0 to 3.0s 1.5MINimum LEFT speed 0 to 10% 6MAXi

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-11JIB ACCELeration 0.5 to 5.0 1.5DECELeration 0.5 to 3.0 0.5MINimum UP speed 0 to 50 9MAXimum U

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3120772Level Vehicle DescriptionDO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.LEVEL VEHICLE Y

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-13Table 6-5. Help Descriptions and Fault Flash CodesFlash Code DescriptionNo flash code is indic

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31207722/2Flash code 2/2 indicates problems with drive & steer selection.DRIVE JOYSTICK FAULTYThe

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-152/5Flash code 2/5 indicates that a function is prevented due to a cutout.BOOM PREVENTED - DRIVE

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31207721.3 BATTERY CHARGER1.4 DRIVE SYSTEM1.5 TIRES1.6 HYDRAULIC FILTER1.7 HYDRAULIC PUMP/ELECTRIC MOTOR AS

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 31207723/5Flash code 3/5 indicates that there is a brake pressure problem.BRAKES DID NOT LOCKBrake pre

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-176/6Flash code 6/6 indicates problems with the CANbus.48V PROTECTION TRIPPED - CHECK INTER-MODUL

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 31207729/9Flash code 9/9 indicates problems with the controller.POWER MODULE FAILURE: CONTACTOR DRIVE

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-19Figure 6-3. Analyzer Flow Chart - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3120772Figure 6-4. Analyzer Flow Chart - Sheet 2 of 2

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-21Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item i

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3120772System Self TestThe system self test is utilized to locate typical problems.See Table 6-7, Syst

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-23Table 6-7. System Test DescriptionsACTIVATE TESTSYES:ENTER, NO:ESCNot available once tests are

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3120772Table 6-8. System Test MessagesRUNNING Initial display when system test is run; certain “crit

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-25TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-31.9 FUNCTION SPEEDS 1.10 TORQUE SPECIFICATIONS 1.11 PRESSURE SETTINGSTable 1-11. Function SpeedsFun

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3120772CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 6 - JLG CONTROL SYSTEM3120772 – JLG Lift – 6-27TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3120772NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3120772Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31207727.4 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3120772Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31207721.12 CYLINDER SPECIFICATIONSNOTE: All dimensions are given in inches (in.), with the met-ric equival

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31207727.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3120772PLATFORMWORKLIGHTSRECEPTACLEAT PLATFORMFOOTSWITCHMAINVALVESTEER /BRA

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-11BOOMLIMITSWITCHESHORNGROUNDCONTROLBOXBEACONLIGHTPOSI-TRACK/TILT MODU

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3120772Figure 7-20. Electrical Schematic - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-13Figure 7-21. Electrical Schematic - Sheet 2 of 21870225 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3120772Figure 7-22. Hydraulic Schematic - 300A - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-15Figure 7-23. Hydraulic Schematic - 300A - Sheet 2 of 22792521 B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3120772Figure 7-24. Hydraulic Schematic - 300AJ - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-17Figure 7-25. Hydraulic Schematic - 300AJ - Sheet 2 of 22792522 B

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-5Critical Stability WeightsDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMSOF DIFFERENT WEIGHT O

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3120772Figure 7-26. Hydraulic Schematic - 300AJP - Sheet 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120772 – JLG Lift – 7-19Figure 7-27. Hydraulic Schematic - 300AJP - Sheet 2 of 22792523 B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3120772NOTES:

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

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120772NOTE: Machines Manufactured before S/N 03000046376were filled with Mobilfluid 424 hydraulic oil. If

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-71.16 LUBRICATIONNOTE: The following numbers correspond to those in Fig-ure 1-1., Operator Maintenanc

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31207722. Swing Bearing/Worm Gear TeethLube Point(s) - 2 Grease FittingsCapacity - Spray OnLube - Mobiltac3

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-9Figure 1-2. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)VALUES FOR ZINC PLATED / YELLOW CHR

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3120772 Figure 1-3. Torque Chart (Metric Conversion) - (For ASTM Fasteners) VALUES FOR Z

SECTION 1 - SPECIFICATIONS3120772 – JLG Lift – 1-11VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS 8.8 METRIC BOLTS &CLASS 8 METRIC N

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120772NOTES:

SECTION 2 - GENERAL3120772 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31207722.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3120772 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31207722.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3120772 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

INTRODUCTION3120772 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - GENERAL2-6 – JLG Lift – 31207722.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 2 - GENERAL3120772 – JLG Lift – 2-7Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL2-8 – JLG Lift – 3120772Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 2 - GENERAL3120772 – JLG Lift – 2-9Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL2-10 – JLG Lift – 3120772NOTES:

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire Wear and DamageInspect tires pe

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31207723.2 DRIVE HUB PART NO. 2780236The final drive consists of two planetary stages with aninteg

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-3Assembly of end cover unit (8)1. Press sleeve (52) into cover (8).2. Install “o” ring (54)

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3120772Figure 3-1. Drive Hub

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-53.3 DRIVE HUB (S/N 115723 TO PRESENT)Roll and Leak TestingTorque-Hub units should always be

INTRODUCTIONA-2 – JLG Lift – 3120772REVISON LOGOriginal Issue November 15, 2000Revised October 1, 2001Revised April 10, 2002Revised June 4, 2002Revise

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3120772NOTE: On units with a ratio 48:1, the Sun Gear (11) and theInput Shaft (9) will need to be

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-7Figure 3-3. Main Disassembly Drawing 21F. Ring Gear1G. Housing4. Output Carrier Sub

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3120772Output Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-95. Remove 4 Thrust Washers (4B), 28 Needle Rollers(4C) and the Thrust Spacer (4D) from the

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3120772Input Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-11Hub-Spindle Disassembly1. Place unit on bench with Spindle (1 A) end down.2. Remove Retain

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3120772Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-13Input Carrier Assembly(Refer to Figure 3-6., Input Carrier)1. Apply a liberal coat of grea

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3120772Output Carrier Assembly(Refer to Figure 3-4., Output Carrier)1. Place Thrust Washer (4H) i

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-15Cover Subassembly(Refer to Figure 3-8., Cover Assembly)1. Grease O-Ring (6E) and insert in

3120772 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3120772Figure 3-9. Hub Assembly - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-171A Spi ndle1B Lip Seal1C Tapered Bearing Cone1D Tapered Bearing Cup1E

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3120772Figure 3-11. Cup Pressing ToolFigure 3-12. Cup Pressing Tool

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-193.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving t

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 31207722322192118171615201211109876542331131421. Capscrew2. Washer3. Pressure Plate4. Case Seal5.

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-21Table 3-2. Drive Brake DiagnosisProblem Cause ExplanationCorrectiveActionBrake slips Exces

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31207723.5 SPEED SENSOR ADJUSTMENTFOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2)MUST BE PROPER

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-23Figure 3-14. Speed Sensor Orientation. (E300)

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3120772MOTOR A MOTOR B1704246-DJLG P/N1600292Fuse BoxU/L Machines OnlyFigure 3-15. Frame Mounted

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-252812345678910111213141114151617181920212223242526272930Figure 3-16. Steering Components a

ii – JLG Lift – 3120772TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3120772Figure 3-17. Drive Components

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-273.7 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is design

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3120772Wear Tolerance1. With the boom positioned over the side of themachine, the Upper Boom hori

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-29Figure 3-20. Swing Bearing Tolerance Boom Placement.

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3120772Figure 3-21. Swing Bearing Tolerance Boom Placement

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-312. Installation.a. Install bearing to rotation box with two capscrews, so that fill plug o

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3120772Swing Bearing Torque ValueInstall bolts with Loctite - 240 ft. lbs. (326 Nm).Figure 3-22.

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-33Checking Worm Gear End PlayJLG Industries requires that a annual inspection be per-formed

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 31207728. Gently tap the shaft upward through the housingand remove through the rear of the housi

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-353. Lower the drive link into the shaft making sure thatthe timing mark end of the drive li

3120772 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31207721. Dust Seal 2. Retainer Ring3. Backup Shim4. Housing Seal5. Body Seal

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-37105103117102201104431011SWING MOTORSWING BEARINGSWING ROTATION BOXFigure 3-27. Swing Comp

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31207723.9 HELAC ROTARY ACTUATORTheory Of OperationThe rotary actuator is a simple mechanism that

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-391. H ousi ng2. S haft3. Piston Sleeve4. E nd C ap109. Lock Pin113.

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 31207721. H ous ing2. S haf t3. P isto n Sl eev e4. E nd C ap109. Lock Pi

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-41Tools Required for Assembly/DisassemblyUpon assembly and disassembly of the actuator there

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31207724. Install the end cap (4) removal tools provided withthe Helac seal kit.5. Using a metal

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-439. Prior to removing the shaft, (2), use a felt marker toclearly indicate the timing marks

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 312077215. Remove the wear guides (302) from the end cap (4)and shaft (2).16. To remove the main

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-45Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspe

iv – JLG Lift – 3120772TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 31207724. Using a seal tool install the main pressure seal (205)onto shaft (2) and end cap (4). U

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-4710. Looking from the opposite end of the housing (1)you can see if your timing marks are l

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 312077216. Install the O-ring (204) and back-up ring (207) intothe inner seal groove on the end c

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-493.10 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarterly1. Open battery compart

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3120772151111111111131010371111141211529822674*1. Battery2. Cable3. Cover4. Cover5. Hold Down6. I

SECTION 3 - CHASSIS & TURNTABLE3120772 – JLG Lift – 3-51Figure 3-32. Battery Cable Connections

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3120772NOTES:

SECTION 4 - BOOM & PLATFORM3120772 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCEIF PERFORMING MAINTENANCE ON THE BOOM, DO NO

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31207721141212768910351. Master Cylinder2. Boom Lift3. Level Cylinder4. Base Boom5. Fly Boom6. Mid Lin

SECTION 4 - BOOM & PLATFORM3120772 – JLG Lift – 4-3113311533333314141167129814314101311367433331611111. Loctite #2422. Bumper3. Composite Bearing4

3120772 – JLG Lift – v LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31207726. Using a suitable lifting device, remove telescope cyl-inder from boom sections.7. Using a pi

SECTION 4 - BOOM & PLATFORM3120772 – JLG Lift – 4-5Installation of the Boom Assembly1. Using suitable lifting equipment, position boomassembly on

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31207724.3 ARTICULATING JIB (AJ/AJP)Removal1. Place the Jib in a horizontal position and support theco

SECTION 4 - BOOM & PLATFORM3120772 – JLG Lift – 4-7Figure 4-4. Jib - E300AJFigure 4-5. Jib - E300AJP

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3120772A,B,DC,DABCDTorque to 50 ft.lbs. (68 Nm)Loctite #242Torque 250-270 ft. lbs. (339-366 Nm)Check t

SECTION 4 - BOOM & PLATFORM3120772 – JLG Lift – 4-9NOTE: UPPER BOOM ANGLE TO BE 1° BELOWHORIZONTAL TO 3° ABOVE HORIZONTALTO ACTIVATE SWITCH. UPPER

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3120772NOTES:

SECTION 5 - HYDRAULICS3120772 – 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 – 3120772Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3120772 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONSystems Incorporating Double Acting CylindersUpper Boom Lift, Lower B