JLG Boom Lifts E300AJ E300AJP Global Illustrated Master Parts List Manual ! (S/N 0300138358 To PRESENT,3121254)
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Illustrated Parts Manual
Models
E300AJ
E300AJP
S/N 0300138358
TO PRESENT
3121254
November 4, 2013
3121254 E300AJ E300AJP A
REVISION LOG
October 15, 2009 - Original Issue Of Manual (Edited to B/M 0010720 Revision 4)
October 25, 2010 - Revised Manual (Edited to B/M 0010720 Revision 9)
March 16, 2011 - Revised Manual (Edited to B/M 0010720 Revision 12)
June 10, 2011 - Revised Manual (Edited to B/M 0010720 Revision 12)
September 16, 2011 - Revised Manual (Edited to B/M 0010720 Revision 13)
November 29, 2011 - Revised Manual (Edited to B/M 0010720 Revision 13)
March 20, 2012 - Revised Manual (Edited to B/M 0010720 Revision B)
July 10, 2012 - Revised Manual (Edited to B/M 0010720 Revision C)
October 10, 2012 - Revised Manual (Edited to B/M 0010720 Revision D)
February 12, 2013 - Revised Manual (Edited to B/M 0010720 Revision E)
May 2, 2013 - Revised Manual (Edited to B/M 0010720 Revision H)
August 6, 2013 - Revised Manual (Edited to B/M 0010720 Revision H)
November 4, 2013 - Revised Manual (Edited to B/M 0010720 Revision H)
B E300AJ E300AJP 3121254
REVISION LOG
3121254 E300AJ E300AJP i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 TIRE & WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-4 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-5 ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) . . . . . . . . . . . . . 1-12
1-6 BATTERY BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1-7 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-8 INVERTER INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1 CONTROL VALVES & TANK/MOTOR INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 BOOM FUNCTION VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-4 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-5 TURNTABLE BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-6 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-7 GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-8 ELECTRICAL COMPONENTS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-9 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1 BOOM AND CYLINDERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4 JIB ASSEMBLY & PLATFORM SUPPORT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 3-12
3-5 PLATFORM ROTATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-6 JIB SWING ROTATOR ASSEMBLY (E300AJP ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-7 CABLE, CLAMPS & LIMIT SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-20
SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 PLATFORM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-4 CONTROLLER ASSEMBLY (SWING & LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 LIFT (JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 LIFT (MAIN BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 LIFT (TOWER BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 HYDRAULIC DIAGRAM - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 DRIVE HYDRAULIC DIAGRAM - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-3 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
ii E300AJ E300AJP 3121254
FIGURE NO. TITLE PAGE NO.
TABLE OF CONTENTS
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 DECAL INSTALLATION (COUNTRY SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-3 DECAL INSTALLATION (AUSTRALIAN/CE SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
3121254 E300AJ E300AJP 1-1
SECTION 1
FRAME
1-2 E300AJ E300AJP 3121254
SECTION 1 FRAME
FIGURE 1-1. STEER INSTALLATION
7
12
3
7
12
3
10
4
1
14
16
15
6
9
1
2
6
5
13
101
112
115
108
107
104
105
106
111
110
114
113
109
102
103
102
9
8
3
11
13
17
3121254 E300AJ E300AJP 1-3
SECTION 1 FRAME
FIGURE 1-1. STEER INSTALLATION
ITEM # PART NUMBER QTY. DESCRIPTION REV.
1001108599 Ref STEER INSTALLATION C
1 0100011 AR Compound, Locking
2 0641607 2 Bolt 3/8in-16NC x 7/8in
3 3312005 3 Locknut 5/8in-11NC
4 3422181 1 Pin
5 3422562 2 Pin
6 3841143 3 Keeper, Pin
7 3900118 2 Screw, Shoulder
8 3900255 1 Capscrew, Shoulder 3/4in x 3in
9 1001107712 2 Hub/Spindle Assembly (See Items 101-115 for Breakdown)
10 1001107727 1 Tie-Rod
11 1001108310 1 Steer Cylinder Assembly (See Section 5 for Breakdown)
12 4740086 2 Thrustwasher
13 0440162 4 Thrustwasher
14 0641610 1 Bolt 3/8in-16NC x 1-1/4in
15 3311605 1 Locknut 3/8in-16NC
16 4711600 1 Flatwasher 3/8in Thin
17 1001151428 AR Plate, Shim (SN 0300176716 to Present)
1001107712 Ref HUB/SPINDLE ASSEMBLY A
Ref Note: Qty shown is for 1 Hub Assembly. Machine requires 2
assemblies.
101 7020137 1 Cap, Dust
102 0961951 2 Bushing, Garmax
103 0962140 1 Bearing, Garmax
104 70002434 1 Hub
105 7020036 1 Cup, Bearing (Inner) (Part of Item 104)
106 7020037 1 Cone, Bearing (Inner)
107 7020038 1 Cup, Bearing (Outer) (Part of Item 104)
108 7020039 1 Cone, Bearing (Outer)
109 70002435 1 Spindle
110 7020140 1 Pin, Cotter
111 7020040 1 Seal
112 7020054 1 Nut, Castle 1-1/4in-12
113 7020041 9 Stud 5/8in-18NF
114 7020042 9 Lugnut 5/8in-18NF
115 7020055 1 Washer, Tanged 1-1/4in
1-4 E300AJ E300AJP 3121254
SECTION 1 FRAME
FIGURE 1-2. TIRE & WHEEL DRIVE INSTALLATION
101
102
14
15
29
1
8
9A
9
9B
1
7
17
2
23
1
5
16
20
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The JLG Boom Lifts E300AJ E300AJP Global Illustrated Master Parts List Manual is an indispensable guide for maintaining and repairing these specific boom lift models. This professional-grade service manual provides comprehensive, step-by-step instructions and detailed diagrams, making it an invaluable resource for both professional mechanics and DIY enthusiasts aiming for precise and efficient maintenance.
This manual covers essential components such as the Frame, Turntable, Boom, Platforms, Cylinder, Hydraulics, Electrical systems, Decals, Recommended Service Parts Stock, Special Options, and Parts Number Index. It is a trusted reference that ensures your equipment is maintained to OEM standards, enhancing performance and reliability.
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