Service and Maintenance Manual

1 Service and Maintenance Manual Model E300A. E300AJ. E300 AJP. P/N - 3120772. January 23, 2009. INTRODUCTION. SECTION A. INTRODUCTION - Maintenance SAFETY PRECAUTIONS. A GENERAL C Maintenance . This section contains the general safety precautions which must be observed during Maintenance of the aerial platform. It is of utmost importance that Maintenance per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN. sonnel pay strict attention to these warnings and precau- THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL.

2 Tions to avoid possible injury to themselves or others, or INJURY OR DEATH AND IS A SAFETY VIOLATION. damage to the equipment. A Maintenance program must be followed to ensure that the machine is safe to operate. ENSURE REPLACEMENT PARTS OR COMPONENTS. ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS. OR COMPONENTS. MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A. NO SMOKING IS MANDATORY. NEVER REFUEL DUR- RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS. ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP.

3 SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION. IS CLOSED AND SECURE AT ALL OTHER TIMES. The specific precautions to be observed during mainte- REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN. nance are inserted at the appropriate point in the Manual . PERFORMING ANY Maintenance . These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component DO NOT WEAR LONG HAIR UNRESTRAINED, OR. parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH. ARE APT TO BECOME CAUGHT ON OR ENTANGLED.

4 Your safety, and that of others, is the first consideration IN EQUIPMENT. when engaging in the Maintenance of equipment. Always be conscious of weight. Never attempt to move heavy OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS. parts without the aid of a mechanical device. Do not allow ON MACHINE AND IN SERVICEMANUAL. heavy objects to rest in an unstable position. When raising KEEP OIL, GREASE, WATER, ETC. WIPED FROM. a portion of the equipment, ensure that adequate support STANDING SURFACES AND HAND HOLDS.

5 Is provided. USE CAUTION WHEN CHECKING A HOT, PRESSUR- IZED COOLANT SYSTEM. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- NEVER WORK UNDER AN ELEVATED BOOM UNTIL. TROL OVER THE FIELD INSPECTION AND Maintenance , SAFETY BOOM HAS BEEN SAFELY RESTRAINED FROM ANY. IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR. MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR. BOOM SAFETY PROP HAS BEEN ENGAGED. B HYDRAULIC SYSTEM SAFETY BEFORE MAKING ADJUSTMENTS, LUBRICATING OR. It should be noted that the machines hydraulic systems PERFORMING ANY OTHER Maintenance , SHUT.

6 Operate at extremely high potentially dangerous pres- OFF ALL POWER CONTROLS. sures. Every effort should be made to relieve any system BATTERY SHOULD ALWAYS BE DISCONNECTEDDUR- pressure prior to disconnecting or removing any portion of ING REPLACEMENT OF ELECTRICAL COMPONENTS. the system. KEEP ALL SUPPORT EQUIPMENT AND ATTACH- Relieve system pressure by cycling the applicable control MENTS STOWED IN THEIR PROPER PLACE. several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir.

7 Pressure USE ONLY APPROVED, NONFLAMMABLE CLEANING. feed lines to system components can then be discon- SOLVENTS. nected with minimal fluid loss. 3120772 JLG Lift A-1. INTRODUCTION. REVISON LOG. Original Issue November 15, 2000. Revised October 1, 2001. Revised April 10, 2002. Revised June 4, 2002. Revised November 3, 2006. Revised January 14, 2008. Revised January 23, 2009. A-2 JLG Lift 3120772. TABLE OF CONTENTS. SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - Maintenance SAFETY PRECAUTIONS. A General.

8 A-1. B Hydraulic System Safety ..A-1. C Maintenance ..A-1. SECTION 1 - SPECIFICATIONS. Capacities ..1-1. Operating specifications ..1-1. Battery Charger ..1-2. Drive System ..1-2. Tires ..1-2. Hydraulic Filter..1-2. Hydraulic Pump/Electric Motor Assembly ..1-2. Dimensional Data ..1-2. Function Speeds ..1-3. Torque Specifications ..1-3. Pressure Settings ..1-3. Cylinder Specifications ..1-4. Major Component Weights ..1-4. Critical Stability Weights .. 1-5. Serial Number Locations..1-5. Hydraulic Oil.

9 1-5. Lubrication..1-7. SECTION 2 - GENERAL. Machine Preparation, Inspection, and Maintenance ..2-1. General.. 2-1. Preparation, Inspection, and Maintenance .. 2-1. Pre-Start Inspection .. 2-1. Pre-Delivery Inspection and Frequent Inspection .. 2-1. Annual Machine Inspection .. 2-1. Preventative Maintenance .. 2-1. Service and Guidelines ..2-2. General.. 2-2. Safety and Workmanship .. 2-2. Cleanliness.. 2-2. Components Removal and Installation .. 2-2. Component Disassembly and Reassembly .. 2-3. Pressure-Fit Parts.

10 2-3. Bearings .. 2-3. Gaskets .. 2-3. Bolt Usage and Torque Application .. 2-3. Hydraulic Lines and Electrical Wiring .. 2-3. Hydraulic System.. 2-3. Lubrication .. 2-3. Battery .. 2-3. Lubrication and Servicing .. 2-3. Lubrication and Information ..2-4. Hydraulic System.. 2-4. Hydraulic Oil .. 2-4. Changing Hydraulic Oil .. 2-4. Lubrication Specifications .. 2-4. Cylinder Drift Test ..2-5. Platform Drift .. 2-5. Cylinder Drift .. 2-5. Pins and Composite Bearing Repair Guidelines ..2-5. Welding on JLG Equipment.