JLG 45e Parts Manual

Illustrated Parts Manual

Models

30e 35e/n35e 40e/n40e

45e

P/N

3120862

October 4, 2012

REVISION LOG

October 1997 - Original Issue Of Manual (Was originally part of combine manual 3120834)

November 1998 - Revised

October 18, 2000 - Revised (Manual edited to 0010501 Revision 45 - Model 30electric)

(Manual edited to 0010491 Revision 63 - Model 35electric)

(Manual edited to 0010500 Revision 58 - Model 40electric)

(Manual edited to 0010489 Revision 55 - Model 45electric)

April 16, 2003 - Revised (Manual edited to 0010501 Revision 48 - Model 30electric)

(Manual edited to 0010491 Revision 71 - Model 35electric)

(Manual edited to 0010500 Revision 63 - Model 40electric)

(Manual edited to 0010489 Revision 57 - Model 45electric)

December 31, 2006 - Revised Manual

October 29, 2010 - Revised Manual

October 4, 2012 - Revised Manual

3120862 A

REVISION LOG

B 3120862

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME

1-1 FRAME AND STEERING INSTALLATION - MODEL 30electric . . . . . . . . . . . . . . . . . . . .1-2

1-2 FRAME AND STEERING INSTALLATIONS - MODELS 35electric, 40electric &

45electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-4 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-5 DRIVE HUB ASSEMBLY - MODEL 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

1-6 DRIVE HUB ASSEMBLY - MODELS 35electric, 40electric, 45electric . . . . . . . . . . . . . .1-18

1-7 ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED). . . . . . . . . . . . . . .1-20

1-8 BATTERY CHARGER ASSEMBLY - 220V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

1-9 BATTERY CHARGER ASSEMBLY - 220V/50Hz (Service Replacement - Dutch/

French/German/ Italian/Spanish Specs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

1-10 BATTERY CHARGER ASSEMBLY - 110-220V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

1-11 BATTERY CHARGER ASSEMBLY - 110-240V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34

1-12 HYDRAULIC COMPONENTS & COVERS INSTALLATION (FRAME MOUNTED). . . . . .1-36

SECTION 2 - TURNTABLE

2-1 TURNTABLE MOUNTED COMPONENTS INSTALLATIONS - MODEL 30electric. . . . . .2-2

2-2 TURNTABLE MOUNTED COMPONENTS INSTALLATIONS - MODEL 35electric. . . . . .2-4

2-3 TURNTABLE MOUNTED COMPONENTS INSTALLATIONS - MODEL 40electric

AND 45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4 CONTROL VALVE ASSEMBLY - MODELS 35electric, 40electric, AND 45electric. . . . .2-10

2-5 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS - MODELS 30electric

AND 35electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-6 SWING BEARING ASSEMBLY - MODELS 30electric AND 35electric

(Post Production Service Replacemnt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-7 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS - MODELS 40electric

AND 45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-8 SWING BEARING ASSEMBLY - MODELS 40electric AND 45electric

(Post Production Service Replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-9 SWING MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2-10 GROUND CONTROL COMPONENTS INSTALLATIONS - MODEL 30electric.. . . . . . . .2-26

2-11 GROUND CONTROL COMPONENTS INSTALLATIONS - MODELS 35electric,

40electric, AND 45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-12 TURNTABLE AND HOOD INSTALLATION - MODEL 30electric.. . . . . . . . . . . . . . . . . . .2-34

2-13 TURNTABLE AND HOOD INSTALLATION - MODEL 35electric.. . . . . . . . . . . . . . . . . . .2-38

2-14 TURNTABLE AND HOOD INSTALLATION - MODEL 40electric AND 45electric. . . . . . .2-42

SECTION 3 - BOOM

3-1 BOOMS AND LIMIT SWITCHES INSTALLATION MODEL 30electric . . . . . . . . . . . . . . .3-2

3-2 BOOMS AND LIMIT SWITCHES INSTALLATION MODEL 35electric . . . . . . . . . . . . . . .3-6

3-3 BOOMS INSTALLATION - MODELS 40electric AND 45electric . . . . . . . . . . . . . . . . . . .3-10

3-4 LIMIT SWITCHES, CABLES AND CLAMPS INSTALLATION - MODEL 40electric

AND 45electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 UPPER BOOM COMPONENTS ASSEMBLY - MODELS 35electric, 40electric

AND 45electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3120862 i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO. SECTION 4 - PLATFORMS

4-1 PLATFORM AND COMPONENTS INSTALLATION - MODEL 30electric . . . . . . . . . . . .4-2

4-2 PLATFORM AND COMPONENTS INSTALLATION - MODEL 35electric, 40electric

AND 45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 ROTATOR MOTOR/PUMP/TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-5 CONTROL ASSEMBLY (DRIVE/STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

SECTION 5 - CYLINDER

5-1 LIFT CYLINDER ASSEMBLY - MODEL 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 UPPER CYLINDER ASSEMBLIES - MODELS 35electric, 40electric AND 45electric . . . 5-6

5-3 MID LIFT CYLINDER ASSEMBLIES - MODELS 40electric AND 45electric . . . . . . . . . . 5-10

5-4 LOWER LIFT CYLINDER ASSEMBLIES - MODELS 35electric, 40electric AND

45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-5 MASTER CYLINDER ASSEMBLY - MODELS 35electric, 40electric AND 45electric . . . 5-18 5-6 PLATFORM ROTATOR CYLINDER ASSEMBLY - MODELS 35electric, 40electric AND

45electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-7 SLAVE CYLINDER ASSEMBLY - MODELS 35electric, 40electric AND 45electric . . . . . 5-22

5-8 STEER CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

5-9 TELESCOPE CYLINDER ASSEMBLIES - MODELS 35electric, 40electric AND

45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

5-10 CYLINDER BELLOWS INSTALLATION - MODEL 30electric . . . . . . . . . . . . . . . . . . . . .5-30

5-11 OPTIONAL CYLINDER BELLOWS INSTALLATION - MODELS 35electric, 40electric

AND 45electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

SECTION 6 - HYDRAULICS

6-1 HYDRAULICS DISGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 HYDRAULIC DIAGRAM - 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-3 HYDRAULIC DIAGRAM - 35electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-4 HYDRAULIC DIAGRAM - 40electric AND 45electric . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

SECTION 7 - ELECTRICAL

7-1 ELECTRICAL COMPONENTS AMD DIAGRAM - 30electric . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 ELECTRICAL COMPONENTS AMD DIAGRAM - 35electric, 40electric AND 45electric . 7-4 7-3 ELECTRICAL SCHEMATIC - 30electric WITH COLORED WIRE (PRIOR TO

S/N 36544) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-4 ELECTRICAL SCHEMATIC - 30electric WITH NUMBERED COLORED WIRE

(S/N 36544 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-5 ELECTRICAL SCHEMATIC - 35electric/40electric/45electric WITH COLORED WIRE

(PRIOR TO S/N36648). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-6 ELECTRICAL SCHEMATIC - 35electric/40electric/45electric WITH NUMBERED

COLORED WIRE (S/N36648 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7-7 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

SECTION 8 - DECALS

8-1 DECALS INSTALLATION - 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-2 DECALS INSTALLATION - 35electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-3 DECALS INSTALLATION - 40electric AND 45electric . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK

ii 3120862

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO. SECTION 10 - SPECIAL OPTIONS

3120862 iii

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

iv 3120862

SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE DESCRIPTION PAGE

1-1 Frame And Steering Installation - Model 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2

1-3 Tire And Wheel Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4

1-5

1-6 Drive Hub Assembly - Models 35electric, 40electric, 45electric . . . . . . . . . . . . . . . . . . . 1-18

1-7

1-8 1-9 Battery Charger Assembly - 220V/50Hz (Service Replacement - Dutch/French/

German/Italian/Spanish Specs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

1-10 Battery Charger Assembly - 110-220V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-11 Battery Charger Assembly - 110-240V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1-12

Frame And Steering Installations - Models 35electric, 40electric, 45electric. . . . . . . . . 1-6

Drive Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Drive Hub Assembly - Model 30electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Electrical Components Installation - (Frame Mounted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Battery Charger Assembly - 220V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Hydraulic Components And Covers Installation (Frame Mounted) . . . . . . . . . . . . . . . . . 1-36

E C T

I O N

3120862 1-1

SECTION 1 FRAME

S E C T

I O N

FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30electric

1-2 3120862

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30ELECTRIC

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME WELDMENT OPTIONS: 1

2360378 Frame Weldment

STEERING AND SPINDLES INSTALLATION Ref. 0252243 PRIOR TO S/N 0300052767 Ref. 8 0270291 S/N 0300052767 TO PRESENT Ref. 2

1 Use 1001139010 Hub Assembly (Includes Items 101-107) (was p/n

2780186)

Note: Original Equipment Hub p/n 2780186 uses Wheel Bolts. Service Replacement Hub p/n 1001139010 uses pressed in studs - Lugnuts p/n 3300255 must be ordered separately.

2 4130286 Spindle Weldment (Includes Items 201-205) 2 3 3421988 Kingpin 2 4 3450810 Pin, Cotter 1/4" x 2 1/2" 2 5 3313003 Nut, Slotted 1 1/4" - 7NC 2 6 0440162 Washer, Thrust 2 7 0642016 Bolt 5/8"-16NC x 2" 2 8 3312005 Locknut 5/8"-16NC 2

9 3841146 Rod-End 2 10 3322002 Nut, Jam 5/8"-16NC 2 11 Steer Cylinder Assembly (See Section 5 for

Breakdown) 1682527 Prior to S/N 37950 1683695 S/N 37950 to Present

12 3340644 Pad, Wear 1 13 0641510 Bolt 5/16"-18NC x 1 1/4" 2 14 3311505 Locknut 5/16"-18NC 2 15 4751500 Flatwasher 5/16" 4 16 3020022 Grease A/R 17 4070809 Shim A/R 18 3780182 O-Ring 4 19 See Note Bolt, Wheel (Note: Refer to Item 107) 10 20 0641608 Bolt 3/8”-16NC x 1” (S/N 0300052767 to

S/N 0300053809)

21 4740453 Flatwasher 3/8” (S/N 0300052767 to

S/N 0300053809)

22 0182002 Angle (S/N 0300052767 to S/N 0300053809) 1 23 0182000 Angle (S/N 0300052767 to S/N 0300053809) 1 24 0641514 Bolt 5/16”-18NC x 1 3/4” (S/N 0300052767 to

S/N 0300053809)

25 0100019 Loctite (Not Shown) (S/N 0300052767 to

S/N 0300053809)

26 4711600 Flatwasher 3/8” (Narrow) (S/N 0300052767 to

S/N 0300053809)

Ref.

A/R

S E

I O N

F R A

3120862 1-3

SECTION 1 FRAME

S E

I O N

FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30ELECTRIC (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780186 HUB ASSEMBLY (ORIGINAL EQUIPMENT) Ref. C

1001139010 HUB ASSEMBLY (SERVICE REPLACEMENT) Ref. A

Note: Original Equipment Hub p/n 2780186 uses Wheel Bolts. Service Replacement Hub p/n 1001139010 uses pressed in studs - Lugnuts p/n 3300255 must be ordered separately.

101 7012519 Cup, Bearing - Inner (1 Per Hub) 2 102 7012520 Cone, Bearing - Inner (1 Per Hub) 2 103 7012521 Cup, Bearing - Outer (1 Per Hub) 2 104 7012522 Cone, Bearing - Outer (1 Per Hub) 2 105 7012523 Seal (1 Per Hub) 2 106 Use 1001102354 Cap, Dust (1 Per Hub) (was p/n 7012524) 2 107 Use 0630016 Bolt, Wheel (5 Per Hub) (was p/n 7012525) (Used on

Original Equipment Hub p/n 2780186)

7016360 Stud, Wheel (5 Per Hub) (Used on Service

Replacement Hub p/n 1001139010) (Not Shown)

3300255 Lugnut (5 Per Hub) (Used with Service Replacement

Hub p/n 1001139010 - Must be purchased separately) (Not Shown)

— — — — — — — — — —

2900804 Bearing and Seal Kit (Includes Qty 1 of Items 101-

105)

Ref.

4130286 SPINDLE WELDMENT Ref.

201 0961621 Bushing, Bronze (2 Per Spindle) 4 202 Not Used 203 7012542 Washer (1 Per Spindle) 2 204 7012541 Nut, Slotted (1 Per Spindle) 2 205 7012543 Pin, Cotter (1 Per Spindle) 2

1-4 3120862

SECTION 1 FRAME

FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30ELECTRIC (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

F R A

3120862 1-5

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. FRAME AND STEERING INSTALLATIONS - MODELS 35electric, 40electric & 45electric

1-6 3120862

SECTION 1 FRAME

FIGURE 1-2. FRAME AND STEERING INSTALLATIONS - MODELS 35ELECTRIC, 40ELECTRIC & 45ELECTRIC

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FRAME WELDMENT OPTIONS: 1

2360371 Model 35electric (Prior to S/N 24526) 2360405 Model 35electric (S/N 24526 to Present) 2360375 Model n35electric (Prior to S/N23550) 2360404 Model n35electric (S/N23550 to Present) 2360372 Model 40electric (Prior to S/N24233) 2360406 Model 40electric (S/N24233 to Present) 2360373 Model n40electric (Prior to S/N25492) 2360407 Model n40electric (S/N25492 to Present) 2360379 Model 45electric (Prior to S/N24324) 2360408 Model 45electric (S/N24324 to Present) 9983829 Lifting Lug Repair Plate (Right) (45electric) 2 9983833 Lifting Lug Repair Plate (Left) (45electric) 2

STEERING AND SPINDLES INSTALLATIONS

0253594 Standard 35/40/45electric Prior to June 1994 Ref. 8/G 0255011 Standard 35/40/45electric June 1994 to Present Ref. 4/C 0253735 Standard n35/n40electric Prior to June 1994 Ref. 7/F 0255012 Standard n35/n40electric June 1994 to Present Ref. 4/C

S E

I O N

F R A

1 2780201 Hub Assembly (See Items 101-107 for Breakdown) 2 2 Spindle Weldment Options (See Items 201-202 for

Breakdown): 4130302 Standard Machines Prior to June 1994 4130319 Standard Machines June 1994 to Present

3 3421988 Kingpin 2 4 3450810 Pin, Cotter 1/4" x 2 1/4" 2 5 3313003 Nut, Slotted 1 1/4 -7NC 2 6 0440162 Washer, Thrust 2 7 0642016 Bolt 5/8"-11NC x 2" 2 8 3312005 Locknut 5/8"-11NC 2

9 3841146 End, Rod 2 10 3322002 Nut, Jam 5/8"-18NF 2 11 Steer Cylinder Assembly (See Section 5 for Break-

down): 1682527 35/40/45electric Prior to S/N37950 1683695 35/40/45electric S/N37950to Present 1682893 n35/n40electric Prior to S/N37950 1683696 n35/n40electric S/N37950to Present

12 3340644 Pad, Wear 1 13 3020022 Grease A/R 14 4070809 Shim A/R 15 4712400 Flatwasher 7/8" 2 16 Not Used 17 3450506 Pin, Cotter 2 18 3780182 O-Ring 4

3120862 1-7

SECTION 1 FRAME

S E

I O N

FIGURE 1-2. FRAME AND STEERING INSTALLATIONS - MODELS 35ELECTRIC, 40ELECTRIC & 45ELECTRIC (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

19 0641510 Bolt 5/16"-18NC x 1 1/4" 1 20 4751500 Flatwasher 5/16" 1 21 3311505 Locknut 5/16"-18NC 1 22 0630016 Bolt, Wheel 1/2"-20NF x 1" 12 23 4060808 Trim 2 Ft/.61m 24 1120457 Cap, Dust 2

2780201 HUB ASSEMBLY Ref. D

101 Kit Cup, Bearing - Inner (1 Per Hub) 2 102 Kit Cone, Bearing - Inner (1 Per Hub) 2 103 Kit Cup, Bearing - Outer (1 Per Hub) 2 104 Kit Cone, Bearing - Outer (1 Per Hub) 2 105 Kit Seal (1 Per Hub) 2

— — — — — — — — — —

2900842 Bearing Kit (Includes Qty. 1 of Item 101-105) 2

SPINDLE ASSEMBLY Ref.

201 0961621 Bushing (2 Per Spindle) 4 202 3322403 Nut, Slotted 7/8"-14NF (1 Per Spindle) 2

AXLE INSTALLATIONS Ref. 0253613 35/40/45electric Ref. D 0253734 n35/n40electric Ref. C

301 Axle Weldment Options: 1

4844324 35/40/45electric 4844369 n35/n40electric

301A 0961621 Bushing 2

302 0940048 Bumper 2 303 4070832 Shim 1/2"-13mm A/R 304 4070833 Shim 1/16"-1.6mm A/R 305 0641814 Bolt 1/2"-13NC x 1 3/4" 4 306 3311805 Locknut 1/2"-13NC 4 307 0641608 Bolt 3/8"-16NC x 1" 1 308 3841143 Pin, Keeper 1 309 3422170 Pin, Axle 1 310 4740247 Washer, Thrust 2 311 3451210 Pin, Cotter 3/8" x 2 1/2" 1 312 3340450 Pad, Wear 2 313 4070834 Shim 1/4"-6.4mm A/R 314 4070835 Shim 1/16"-1.6mm A/R 315 0641610 Bolt 3/8"-16NC x 1 1/4"" 4 316 4751600 Flatwasher 3/8" 4 317 4070853 Shim 1/32"-.8mm A/R

— — — — — — — — — — —

0100011 Loctite #242 (Not Shown) A/R

1-8 3120862

SECTION 1 FRAME

FIGURE 1-2. FRAME AND STEERING INSTALLATIONS - MODELS 35ELECTRIC, 40ELECTRIC & 45ELECTRIC (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

S E

I O N

F R A

3120862 1-9

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

1-10 3120862

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

WHEEL DRIVE INSTALLATIONS

0254710 30electric U/L Models Ref. 8 0257551 30electric Non-U/L Models Ref. 1 0254485 35/40electric U/L Models Ref. 8 0257549 35/40electric Non-U/L Models Ref. 1 0254485 n35/n40electric U/L Models Prior to October 1994 Ref. 8 0255111 n35/n40electric U/L Models Oct 1994 to Present Ref. 3 0257548 n35/n40electric Non-U/L Models Ref. 1 0254599 45electric U/L Models Ref. 7 0257550 45electric Non-U/L Models Ref. 1

1 Drive Hub Assembly Options: 1

2780185 30electric (See Figure 1-5 for Breakdown) 2780198 35/40/45electric (See Figure 1-6 for Breakdown) 2780198 n35/n40electric Non-U/L Models (See Figure 1-6

for Breakdown)

2780198 n35/n40electric U/L Models Prior to October 1994

(See Figure 1-6 for Breakdown)

2780206 n35/n40electric U/L Models October 1994 to Pres-

ent (See Figure 1-6 for Breakdown) 2 0920090 Drive Brake Assy (See Figure 1-4 for Breakdown) 2 3 3160186 Drive Motor Assembly 2

2900811 Repair Kit (Includes All Bearings, Brushes, Springs

and Wavy Washer (1 Per Motor)

7012546 Field Coil Kit (1 Per Motor) 2

4 3321801 Nut 1/2"-20NF 18

0100011 Loctite #242 A/R 5 4711800 Flatwasher 1/2" Narrow 22 6 0641811 Bolt 1/2"-13NC 4 7 0641608 Bolt 3/8"-16NC x 1" 8 8 4711600 Flatwasher 3/16" Narrow 8 9 4761600 Lockwasher 3/16" 8

10 0630016 Bolt, Wheel Options: A/R

30electric 10 35/40/45electric 12

11 3990053 Sensor, Tach Drive 1

7012609 Boot, Rubber 1

12 4761800 Lockwasher 1/2" 4 13 3790240 O-Ring 2 14 2220273 Fitting, Reducer (S/N 32280 to Present) 2 15 2180819 Vent, Breather (S/N 32280 to Present) 2

S E

I O N

F R A

TIRE AND WHEEL INSTALLATION OPTIONS MODEL 30electric

0252430 Tire and Wheel Assembly (Foam-Filled) Ref. 0252349 Tire and Wheel Assembly (26x7x20 Non-Marking) Ref. A

101 0252431 Tire and Wheel Assembly (Foam-Filled) (Sold as

an Assembly Only)

4520139 Tire, Replacement 4

3120862 1-11

Ref.

SECTION 1 FRAME

S E

I O N

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

151

4520151 Tire and Wheel Assembly (26x7x20 Non-Marking)

(Sold as an Assembly Only) (S/N 43598 to Present)

Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

TIRE AND WHEEL INSTALLATION OPTIONS MODEL 35electric, 40electric AND 45electric

0256837 Tire & Wheel Assy (G78-15 Foam-Filled/6” Rim) Ref. 0254866 Tire & Wheel Assy (LT215/85R16 Foam-Filled/8”

Rim)

0254120 Tire & Wheel Assy (22x6x16 Solid) Ref. 0254874 Tire & Wheel Assy (6.50x16 Solid Non-Marking) Ref. 0254121 Tire & Wheel Assy (22x6x16 Solid Non-Marking) Ref.

0256836

4520184 Tire, Replacement 4

0254865

Use 4520265 Tire, Replacement (p/n was 4520156) 4

0253784

4520148 Tire, Replacement 4

4520198

4520154

4520155

4520159

Tire & Wheel Assy (G78-15 Foam-Filled/6” Rim) (Models 35electric and 40electric)

Tire & Wheel Assy (LT215/85R16 Foam-Filled/8” Rim) (Models 35electric and 40electric)

Tire & Wheel Assy (ST225/75R15 Foam-Filled/8” Rim) (Models 35electric, 40electric and 45electric)

Tire & Wheel Assy (7.50x15x20 Static Conductive/ 8” Rim) (Model 45electric)

Tire & Wheel Assy (22x6x16 Solid) (Models 35electric and 40electric)

Tire & Wheel Assy (22x6x16 Solid Non-Marking) (Models 35electric and 40electric)

Tire & Wheel Assy (6.50x16 Solid Non-Marking) (Models 35electric, 40electric and 45electric)

Ref.

1-12 3120862

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

HUBCAP INSTALLATION (OPTIONAL) Ref. 0252754 Use on Model 30electric Ref. B 0253864 Use on Model 35electric/40electric with 8" Rim/

Pneumatic and 8" Rim/ Foam-Filled Tires. Use on Model 45electric with 8" Rim /Foam-Filled Tires.

0256832 Use on Model 35electric/40electric/45electric

with. 6” Rim.

0254155 Use on Model 35electric and 40electric with Solid

Tires.

201 Hubcap Options: 4

1670633 Model 30electric 1670633 Model 35electric/40electric with 8" Rim/ Pneu-

matic and 8" Rim/ Foam-Filled Tires. Use on Model 45electric with 8" Rim /Foam-Filled Tires.

1670808 Model 35electric/40electric/45electric with. 6”

Rim

1670692 Model 35electric and 40electric with Solid Tires.

202 Bolt Options: 8

0630455 J-Bolt 5/16"-18NC - Model 30electric 0630465 J-Bolt 5/16"-18NC - Model 35electric/40electric

with 8" Rim/ Pneumatic and 8” Rim/Foam-Filled Tires. use on Model 45electric with 8” Rim/ Foam-Filled Tires.

0630513 J-Bolt 5/16"-18NC - Model 35electric/40electric/

45electric with 6” Rims

0641518

203 4761500 Lockwasher 5/16" 8 204 Nut, Acorn 5/16"-18NC Options: 8

3300356 Model 30electric 3300356 Model 35electric/40electric with 8" Rim/ Pneu-

3300356 Model 35electric/40electric/45electric with 6”

Not Required Model 35electric and 40electric with Solid Tires

205 Nut 5/16"-18NC Options: 8

3311501 Model 30electric 3311501 Model 35electric/40electric with 8" Rim/ Pneu-

3311501 Model 35electric/40electric/45electric with 6”

Not Required Model 35electric and 40electric with Solid Tires

Bolt 5/16"-18NC x 2 1/4" - Model 35electric and 40electric with Solid Tires

matic and 8” Rim/Foam-Filled Tires. use on Model 45electric with 8” Rim/Foam-Filled Tires.

Rims

matic and 8” Rim/Foam-Filled Tires. use on Model 45electric with 8” Rim/Foam-Filled Tires.

Rims

Ref. B

Ref. —

Ref. B

S E

I O N

F R A

3120862 1-13

SECTION 1 FRAME

S E

I O N

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

1-14 3120862

SECTION 1 FRAME

FIGURE 1-4. DRIVE BRAKE ASSEMBLY

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

0920090 DRIVE BRAKE ASSEMBLY Ref. B

1 7012552 Magnet and Coil Assembly 1 2 7012582 Armature 1 3 7012554 Shaft 1 4 Not Available Plate, Mounting 1 5 Kit Plate, Friction (Solid) 3 6Not Used 7 Kit Plate, Outer 2 8 7012692 Spacer 3

9 7014116 Bolt, Metric Socket Head 3 10 Kit Spring, Compression 8 11 7026609 Bearing, Ball 1 12 7014129 Ring, Retainer (External) 1 13 7014130 Ring, Retainer (Internal) 1 14 7012689 Manual Release Assembly 3

15 to 18 Not Used

19 3790240 O-Ring 1 20 7012691 Shim A/R 21 7012580 Connector, Electrical 1

7014127 Plug, Base 1 22 3790225 O-Ring (January 1995 to Present) 1 23 7014128 Seal (S/N 50521 to Present) 1

— — — — — — — — — —

7012583 Repair Kit (Includes Items 5,7,10,11 & 22) 1

S E

I O N

F R A

3120862 1-15

SECTION 1 FRAME

S E

I O N

FIGURE 1-5. DRIVE HUB ASSEMBLY - MODEL 30electric

1-16 3120862

SECTION 1 FRAME

FIGURE 1-5. DRIVE HUB ASSEMBLY - MODEL 30ELECTRIC

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780185 DRIVE HUB ASSEMBLY - MODEL 30ELECTRIC Ref. B

Hub-Shaft Assembly 1 1 7010463 Spindle 1 2 7000228 Seal, Lip (Part of Seal Kit) 1 3 7000255 Cup, Bearing (Outer) 1 4 7000256 Cone, Bearing (Outer) 1 5 7000257 Cup, Bearing (Inner) 1 6 7000258 Cone, Bearing (Inner) 1 7 7000259 Housing 1 8 7000232 Thrustwasher (Part of Seal Kit) 1 9 7000229 Ring, Retaining (Part of Seal Kit) 1

10 7000242 Plug, Pipe - 1/4" NPTF 2 11 7000241 Stud, Wheel 1/2"-20NF 9 12 7001952 Plug, Pipe 3/4" NPTF 1 13 7000246 Gear, Internal 1

— — — — — — — — — —

Carrier Assembly 1

14 7001931 Carrier 1 15 7001985 Thrustwasher, Tanged 6 16 7001909 Bearing, Needle 96 17 7000263 Spacer, Thrust 3 18 7001911 Shaft, Planet 3 19 7001912 Gear, Cluster 3 20 7001913 Rollpin 3 21 7000248 Gear, Ring 1 22 7000230 O-Ring (Part of Seal Kit) 2 23 7000209 Cover, Input 1 24 7010461 Gear, Sun 1 25 7000269 Spacer, Input 1 26 7000270 Thrustwasher 1 27 7000253 Thrustwasher (Part of Seal Kit) 2 28 7000217 Bolt, Hex 8 29 7000214 Bolt, Shoulder 4 30 7000242 Plug, Pipe 1/4" NPTF 1

— — — — — — — — — —

2900034 Seal Kit (Includes Items 2,8,9 and 22) 1 2900661 Seal Kit (Includes Items 2,9 22 and 27) 1

S E

I O N

F R A

3120862 1-17

SECTION 1 FRAME

S E

I O N

FIGURE 1-6. DRIVE HUB ASSEMBLY - MODELS 35electric, 40electric, 45electric

1-18 3120862

SECTION 1 FRAME

FIGURE 1-6. DRIVE HUB ASSEMBLY - MODELS 35ELECTRIC, 40ELECTRIC, 45ELECTRIC

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2780198 DRIVE HUB ASSEMBLY - MODEL 35ELECTRIC,

40ELECTRIC AND 45ELECTRIC

2780198 DRIVE HUB ASSEMBLY - MODEL N35ELECTRIC AND

N40ELECTRIC BUILT PRIOR TO OCTOBER 1994

2780206 DRIVE HUB ASSEMBLY - MODEL N35ELECTRIC AND

N40ELECTRIC BUILT OCTOBER 1994 TO PRESENT

Hub-Shaft Assembly 1 1 7010486 Spindle 1 2 7000228 Seal, Lip (Part of Seal Kit) 1 3 7000255 Cup, Bearing (Outer) 1 4 7000256 Cone, Bearing (Outer) 1 5 7000257 Cup, Bearing (Inner) 1 6 7000258 Cone, Bearing (Inner) 1 7 7000259 Housing 1 8 7000232 Thrustwasher (Part of Seal Kit) 1 9 7000229 Ring, Retaining (Part of Seal Kit) 1

10 7000242 Plug, Pipe - 1/4" NPTF 2 11 7000241 Stud, Wheel 1/2"-20NF 9 12 7001952 Plug, Pipe 3/4" NPTF 1 13 7000246 Gear, Internal (2780198) 1

7010491 Gear, Internal (2780206) 1

— — — — — — — — — —

Carrier Assembly 1

14 7010481 Carrier (2780198) 1

7010489 Carrier (2780206) 1 15 7001985 Washer, Tanged Thrust 6 16 7001909 Bearing, Needle 96 17 7000263 Spacer, Thrust 3 18 7010483 Shaft, Planet 3 19 7010484 Gear, Cluster (2780198 Hub) 3

7010490 Gear, Cluster (2780206 Hub) 3 20 7010474 Rollpin 3 21 7000248 Gear, Ring 1 22 7000230 O-Ring (Part of Seal Kit) 2 23 7000209 Cover, Input 1 24 7010482 Gear, Sun 1 25 7010485 Spacer, Input 1 26 7007642 Thrustwasher 1 27 7000253 Thrustwasher (Part of Seal Kit) 2 28 7001923 Bolt, Hex (2780198) 8

7000217 Bolt, Hex (2780206) 8 29 7000214 Bolt, Shoulder 4 30 7000242 Plug, Pipe 1/4" NPTF 1

— — — — — — — — — — 2900034 Seal Kit (Includes Items 2,8,9 and 22) 1 2900661 Seal Kit (Includes Items 2,9 22 and 27) 1

Ref. B

Ref. —

S E

I O N

F R A

3120862 1-19

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)

1-20 3120862

SECTION 1 FRAME

FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

DRIVE CONTACTOR INSTALLATIONS

0254710 30electric U/L Ref. 8 0257551 30electric Non-U/L Ref. 1 0254485 35/40electric U/L Ref. 8 0257549 35/40electric Non-U/L Ref. 1 0254485 n35/n40electric U/L Prior to October 1994 Ref. 8 0255111 n35/n40electric U/L Oct 1994 to Present Ref. 3 0257548 n35/n40electric Non-U/L Ref. 1 0254599 45electric U/L Ref. 7 0257550 45electric Non-U/L Ref. 1

1 to 11 Not Used

12 Contactor Plate Assembly Options (See Section 7 for

Breakdown of Additional Components) 0254549 30e/35e/n35e/40e/n40e 0254597 45e

12A 70003552 Cable, Electrical (8.5in/21.5cm) 3 12B 70003553 Cable, Electrical (10in/25.4cm) 1

13 0641408 Bolt 1/4"-20NC x 1" 3 14 4711400 Flatwasher 1/4" 7 15 4761400 Lockwasher 1/4" 3 16 1060404 Cable Assembly 1 17 0641416 Bolt 1/4"-20NC x 2" 4 18 3311405 Locknut 1/4"-20NC 4

19 to 20 Not Used

21 1060464 Cable - 37"/94cm Length 1 22 1060465 Cable - 42"/106.7cm Length 1 23 1060466 Cable - 44"/111.8cm Length 1 24 1060467 Cable - 27"/68.6cm Length 1 25 1060468 Cable - 33"/83.8cm Length 1 26 1060469 Cable - 29"/73.7cm Length 1 27 1060535 Cable - 36"/91.4cm Length 1 28 1060435 Cable - 48"/122cm Length 1 29 1060534 Cable - 12"/30.5cm Length 1 30 0641508 Bolt 5/16"-18NC x 1" 1 31 3311505 Locknut 5/16"-18NC 1 32 4751500 Flatwasher 5/16" 2 33 2540020 Grommet 2 34 2540019 Grommet 2 35 0840027 Cover, Battery Terminal (Not Shown - Located on

Motor)

36 4240084 Strap, Static 1 37 2400045 Fuse 1 38 2400044 Fuseholder 1 39 0741008 Screw #10-24NC x 1" 2 40 4751000 Flatwasher #10 2 41 3311005 Locknut #10-24NC 2 42 Not Used 43 2540023 Grommet (30electric Non U/L Machines Only) 1

S E

I O N

F R A

3120862 1-21

SECTION 1 FRAME

S E

I O N

FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

44 3538157 Plate, Drain 2 45 0791004 Screw, Lock #110-24NC x 1/2" 8 46 1670835 Cover, Drain (U/L Machines) 4

BATTERY BOX INSTALLATIONS

Note: See Section 10 for Gel-Cell Batteries

0254499 30electric U/L with Wet Batteries Ref. 7 0257556 30electric Non U/L with Wet Batteries Ref. 2 0256123 30electric U/L with Dry Batteries Ref. —

0254483

0256121 35electric U/L S/N 0300024526 to Present with Wet

0257557 35electric Non U/L with Wet Batteries Ref. 3

0256125

0254483 n35electric U/L Prior to S/N 0300023550 with Wet

0256121 n35electric U/L S/N 0300023550 to Present with Wet

0257557 n35electric Non U/L with Wet Batteries Ref. 2 0256125 n35electric U/L with Dry Batteries Ref. 2

0254276

0256530 40electric U/L S/N 0300024233 to Present with Wet

0257558 40electric Non U/L with Wet Batteries Ref. 2 0256124 40electric U/L with Dry Batteries (Prior to

0270258 40electric U/L with Dry Batteries (S/N 0300050377 to

0254276 n40electric U/L Prior to S/N 0300025492 with Wet

0257558 n40electric Non U/L with Wet Batteries Ref. 1 0256530 n40electric U/L S/N 0300025492 to Present with Wet

0256124 n40electric U/L with Dry Batteries (Prior to

0270258 n40electric U/L with Dry Batteries (S/N 0300050377

0254276

0256530 45electri c U/L S/N 0300024324 to Present with Wet

0257558 45electric Non U/L with Wet Batteries Ref. 1 0256124 45electric U/L with Dry Batteries (Prior to

0270258

35electric U/L Prior to S/N 0300024526 with Wet Batteries

Batteries

35electric U/L Prior to S/N 0300024526 with Dry Batteries

Batteries

40electric U/L Prior to S/N 0300024233 with Wet Batteries

Batteries

S/N 0300050377)

Present)

Batteries

S/N 0300050377)

to Present) 45electric U/L Prior to S/N 0300024324 with Wet

Batteries

S/N 0300050377) 45electric U/L with Dry Batteries (S/N 0300050377 to

Present)

Ref. 6

Ref. 9

Ref. 2

Ref. 6

Ref. 9

Ref. H

Ref. 6

Ref. 2

Ref. 1

Ref. H

Ref. 6

Ref. A

Ref. 1

Ref. H

Ref. 6

Ref. A

Ref. 1

101 Battery Box Weldment Options: 1

4844689 30electric

1-22 3120862

+ 200 hidden pages