JLG E300AJ E300AJP Electric Boom Lift Service and Maintenance Manual Rev C 2021

Description

JLG E300AJ E300AJP Service and Maintenance Manual – Rev C, February 2021

This is the complete JLG E300AJ E300AJP Service and Maintenance Manual (document number 31217115, Revision C, dated February 16, 2021), covering both the E300AJ and E300AJP electric boom lift models. The manual is designed for service technicians, maintenance personnel, and owners responsible for keeping these machines in safe operating condition. It spans every major system on the machine — from chassis and turntable assemblies through the boom, platform, hydraulic circuits, and the JLG Control System — with step-by-step disassembly, inspection, assembly, and calibration procedures. Specification tables, torque values, wear limits, and troubleshooting guides appear throughout.

File Details

• Manual Type: Service and Maintenance Manual
• Brand: JLG
• Models Covered: E300AJ, E300AJP
• Document Number: 31217115
• Revision: Rev C
• Date: February 16, 2021
• Language: English
• Page Count: 444 pages
• File Format: PDF

Chapters Covered

• Section 1 – Specifications: Operating Specifications, Capacities, Tires, Dimensional Data, Lubrication Specifications, Hydraulic Oil, Critical Stability Weights, Major Component Weights, Operator Maintenance, Thread Locking Compound, Torque Charts (SAE and Metric Fastener Torque Charts)
• Section 2 – General: Machine Preparation, Inspection, and Maintenance; Service and Guidelines; 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; Battery; Cylinder Drift; Pins and Composite Bearing Repair Guidelines; Welding on JLG Equipment; Inspection and Preventive Maintenance Schedule
• Section 3 – Chassis & Turntable: Tires & Wheels (Wheel Installation, Tire Damage, Tire Replacement, Wheel and Tire Replacement); Spindle (Setting Wheel Bearing End Play, Specifications, Checking, Greasing Requirements); Tilt Sensor; Speed Sensor; Drive Hub (Roll and Leak Testing, Main Disassembly, Output Carrier Disassembly, Hub Spindle Disassembly, Cover Disassembly, Assembly); Drive Motor (Removal, Disassembly, Inspection, Assembly, Installation); Swing Drive (Disassembly, Assembly); Swing Motor (Preparation Before Disassembly, Assembly, Final Checks, Installation Torque); Swing Bearing (Turntable Bearing Mounting Bolt Condition Check, Wear Tolerance, Replacement of Swing Bearing, Swing Bearing Torque Value); Battery Maintenance and Charging; Battery Charger (Operating Instructions, Maintenance Instructions, Delta-Q Battery Charger, Diagnostic Trouble Codes); Chassis Tilt Indicator System; Drive Orientation System; Hoods
• Section 4 – Boom & Platform: 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 and Installation; Boom Maintenance (Removal of the Main Boom, Disassembly of the Main Boom, Inspection, Assembly of the Main Boom, Installation of the Main Boom); Wear Pads; Tilt Sensor Check; Boom Limit Switches; Boom Cleanliness Guidelines; Foot Switch Adjustment; Articulating Jib Boom (Removal, Disassembly, Inspection, Assembly, Installation); Boom Synchronizing Procedure; Rotary Actuator (Theory of Operation, Tools Required, Disassembly, Inspection, Assembly, Installing Counterbalance Valve, Greasing Thrust Washers, Testing the Actuator, Installation and Bleeding, Troubleshooting); Powertrack Maintenance (Removing a Link, Installing a New Link, Replacing Fixed End Brackets, Replacing Moving End Brackets); SkyGuard (Operation, Function Test, Diagnostics & Troubleshooting)
• Section 5 – Basic Hydraulic Information & Schematics: Lubricating O-Rings in the Hydraulic System (Cup and Brush, Dip Method, Spray Method, Brush-on Method); Hydraulic Connection Assembly and Torque Specification (Definitions, Assembly Instructions for NPTF, BSPT, JIC 37°, SAE 45°, ORFS, DIN 24° Cone, Bulkhead, ORB, MFF, MPP, BSPP, Flange Connections, Double Wrench Method, FFWR and TFFT Methods, Adjustable Stud End Assembly, O-ring Installation); Hydraulic Cylinders (Platform Level Cylinder, Jib Lift Cylinder, Main Boom Lift Cylinder, Master Cylinder, Tower Boom Lift Cylinder, Steer Cylinder, Telescope Cylinder); Cylinder Removal and Installation (Main Boom Lift Cylinder, Main Boom Telescope Cylinder, Phase Check Cartridge); Pressure Setting Procedure (Adjustments at Main Valve Bank and Boom Function Valve Bank); Initial Hydraulic Pump Start-up Procedure; Hydraulic Schematics (E300AJP and E300AJ, 4 sheets each)
• Section 6 – JLG Control System: JLG Control System Analyzer Kit Instructions; Using the Analyzer; Changing Access Level; Adjusting Parameters; Machine Setup; Level Vehicle Description; Machine Configuration Programming Information – Version P1.12; Machine Personality Settings; Machine Orientation When Performing Test; Test Notes; Help Descriptions and Fault Flash Codes; Analyzer Diagnostics Menu Structure; System Self Test; Calibrating Steer; LSS System (Diagnostic Menu, Calibration Procedure, Testing & Evaluation, Troubleshooting); Calibrating Tilt Sensor; Drive Cutout Override Service Mode; Calibrating Load Sensing
• Section 7 – Basic Electrical Information & Schematics: Multimeter Basics (Grounding, Backprobing, Min/Max, Polarity, Scale, Voltage, Resistance, Continuity, Current Measurement); Checking Switches (Basic Check, Limit Switches, Automatic Switches, Switch Wiring); 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, Exceptions); AMP Connector (Assembly, Disassembly, Wedge Lock, Service – Voltage Reading); DEUTSCH Connectors (DT/DTP Series Assembly and Disassembly, HD30/HDP20 Series Assembly and Disassembly); Wiring Harness Connector Labels; Electrical Harness; Electrical Schematics (14 sheets)

This JLG E300AJ E300AJP service and maintenance manual gives you the complete factory service information for both models in a single document. It covers the full range of maintenance and repair tasks — from routine lubrication and inspection intervals to complete teardown and rebuild of the drive hubs, swing drive, swing motor, hydraulic cylinders, and rotary actuator. The hydraulic section alone includes detailed assembly instructions for every fitting type used on the machine, with torque tables for steel, aluminum, and brass configurations, making it practical for real-world service work where fitting material matters. The electrical schematics (14 sheets) and hydraulic schematics (8 sheets) are broken down by circuit and component, with connector pin assignments and wire labels that let you trace faults methodically rather than guessing. The JLG Control System section covers the handheld analyzer, machine configuration programming, personality settings, calibration procedures for steer, tilt, and load sensing, plus a full Diagnostic Trouble Code table and system self-test messages. Everything is written around the specific E300AJ and E300AJP, so the torque values, pressure settings, wear limits, and component weights are the correct ones for these machines — not generic values borrowed from a different model.

Specifications Snapshot

• Maximum Work Load (ANSI): 500 lb (227 kg) unrestricted
• Maximum Work Load (CE & Australia): 500 lb (230 kg) unrestricted
• Maximum Travel Grade (Gradeability): 25%
• Maximum Travel Grade (Side Slope): 3 degrees
• Ground Bearing Pressure (Maximum): 170 psi (11.95 kg/cm²)
• Maximum System Voltage: 48 VDC
• Gross Machine Weight (E300AJ): 15,060 lb (6,831 kg) approximate
• Gross Machine Weight (E300AJP): 15,040 lb (6,985 kg) approximate
• Maximum Main Relief Hydraulic Pressure: 3,000 psi (207 bar)
• Hydraulic Oil Tank: 2.9 Gal (11 L), 2.1 Gal (8 L) to full mark
• Tire Size: 25 x 7 x 12, solid non-marking
• Battery Recharge Time: 14 hours from full discharge

When you are working on an E300AJ or E300AJP, the difference between a correct repair and a costly comeback often comes down to having the right torque value, the right pressure setting, or the right calibration procedure in front of you. This manual provides all of that in one place — the cylinder drift limits, the wheel torque sequence, the swing bearing installation torque, the relief valve pressure settings for main, swing, steer, jib lift, and platform level circuits, the rotary actuator assembly timing marks, and the JLG Control System analyzer flow charts. It also covers the maintenance schedule at pre-delivery, quarterly, and annual intervals so you can keep the machine compliant and serviceable. Delivered as an instant PDF download, the manual is printable, works on any device, and can be kept in the workshop or on a laptop for quick reference during a job. Whether you are performing a routine 150-hour inspection, diagnosing a fault code, resealing a hydraulic cylinder, or rebuilding a swing drive, this JLG E300AJ E300AJP service manual is the reference you want within reach.