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

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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

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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

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

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FIGURE NO.

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SECTION 1 FRAME

TABLE OF CONTENTS

FIGURE	DESCRIPTION	PAGE
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 And Covers Installation (Frame Mounted) . . . . . . . . . . . . . .	. 1-36. .

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S	FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30electric
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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	2
		2780186)
		Note: Original Equipment Hub p/n 2780186 uses	Ref.
		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	1
		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	2
		S/N 0300053809)
21	4740453	Flatwasher 3/8” (S/N 0300052767 to	2
		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	2
		S/N 0300053809)
25	0100019	Loctite (Not Shown) (S/N 0300052767 to	A/R
		S/N 0300053809)
26	4711600	Flatwasher 3/8” (Narrow) (S/N 0300052767 to	2
		S/N 0300053809)

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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	Ref.
		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	10
		Original Equipment Hub p/n 2780186)
	7016360	Stud, Wheel (5 Per Hub) (Used on Service	10
		Replacement Hub p/n 1001139010) (Not Shown)
	3300255	Lugnut (5 Per Hub) (Used with Service Replacement	10
		Hub p/n 1001139010 - Must be purchased
		separately) (Not Shown)
		— — — — — — — — — —
	2900804	Bearing and Seal Kit (Includes Qty 1 of Items 101-	2
		105)
	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

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		SECTION 1 FRAME
FIGURE 1-1. FRAME AND STEERING INSTALLATION - MODEL 30ELECTRIC (CONTINUED)						S
						E
FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.
						C
						T
						I
						O
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						1
						F
						R
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FIGURE 1-2. FRAME AND STEERING INSTALLATIONS - MODELS 35electric, 40electric & 45electric

1-6

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

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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 C T I O N

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3120862

1-9

	SECTION 1 FRAME
S	FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION
E
C
T
I
O
N
1
F
R
A
M
E

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	2
		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
		TIRE AND WHEEL INSTALLATION OPTIONS -	Ref.
		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	4
		an Assembly Only)
	4520139	Tire, Replacement	4

S E C T I O N

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1-11

S E C T I O N

1

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SECTION 1 FRAME

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

FIG & ITEM #	PART NUMBER	DESCRIPTION	QTY.	REV.
	4520151	Tire and Wheel Assembly (26x7x20 Non-Marking)	4
		(Sold as an Assembly Only) (S/N 43598 to Pres-
		ent)
		Note: Assemblies may require ballast/foam fill-
		ing to manufacturer’s specifications prior to
		installing on a machine. Refer to Operation &
		Safety or Service & Maintenance Manuals. Pur-
		chase individual tire and/or rim only if able to
		foam fill tire & wheel assembly, otherwise, pur-
		chase complete assembly.
		TIRE AND WHEEL INSTALLATION OPTIONS -	Ref.
		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”	Ref.
		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.
151	0256836	Tire & Wheel Assy (G78-15 Foam-Filled/6” Rim)	4
		(Models 35electric and 40electric)
	4520184	Tire, Replacement	4
	0254865	Tire & Wheel Assy (LT215/85R16 Foam-Filled/8”	2
		Rim) (Models 35electric and 40electric)
	Use 4520265	Tire, Replacement (p/n was 4520156)	4
	0253784	Tire & Wheel Assy (ST225/75R15 Foam-Filled/8”	4
		Rim) (Models 35electric, 40electric and 45electric)
	4520148	Tire, Replacement	4
	4520198	Tire & Wheel Assy (7.50x15x20 Static Conductive/	4
		8” Rim) (Model 45electric)
	4520154	Tire & Wheel Assy (22x6x16 Solid) (Models	4
		35electric and 40electric)
	4520155	Tire & Wheel Assy (22x6x16 Solid Non-Marking)	4
		(Models 35electric and 40electric)
	4520159	Tire & Wheel Assy (6.50x16 Solid Non-Marking)	4
		(Models 35electric, 40electric and 45electric)
		Note: Assemblies may require ballast/foam fill-
		ing to manufacturer’s specifications prior to
		installing on a machine. Refer to Operation &
		Safety or Service & Maintenance Manuals. Pur-
		chase individual tire and/or rim only if able to
		foam fill tire & wheel assembly, otherwise, pur-
		chase complete assembly.

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/	Ref.	B
		Pneumatic and 8" Rim/ Foam-Filled Tires. Use on
		Model 45electric with 8" Rim /Foam-Filled Tires.
	0256832	Use on Model 35electric/40electric/45electric	Ref.	—
		with. 6” Rim.
	0254155	Use on Model 35electric and 40electric with Solid	Ref.	B
		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	Bolt 5/16"-18NC x 2 1/4" - Model 35electric and
		40electric with Solid Tires
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-
		matic and 8” Rim/Foam-Filled Tires. use on
		Model 45electric with 8” Rim/Foam-Filled Tires.
	3300356	Model 35electric/40electric/45electric with 6”
		Rims
	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-
		matic and 8” Rim/Foam-Filled Tires. use on
		Model 45electric with 8” Rim/Foam-Filled Tires.
	3311501	Model 35electric/40electric/45electric with 6”
		Rims
	Not Required	Model 35electric and 40electric with Solid Tires

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1-13

	SECTION 1 FRAME
S	FIGURE 1-4. DRIVE BRAKE ASSEMBLY
E
C
T
I
O
N
1
F
R
A
M
E

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
6	Not 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 C T I O N

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3120862

1-15

	SECTION 1 FRAME
S	FIGURE 1-5. DRIVE HUB ASSEMBLY - MODEL 30electric
E
C
T
I
O
N
1
F
R
A
M
E

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 C T I O N

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3120862

1-17

	SECTION 1 FRAME
S	FIGURE 1-6. DRIVE HUB ASSEMBLY - MODELS 35electric, 40electric, 45electric
E
C
T
I
O
N
1
F
R
A
M
E

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,	Ref.	B
		40ELECTRIC AND 45ELECTRIC
	2780198	DRIVE HUB ASSEMBLY - MODEL N35ELECTRIC AND	Ref.	B
		N40ELECTRIC BUILT PRIOR TO OCTOBER 1994
	2780206	DRIVE HUB ASSEMBLY - MODEL N35ELECTRIC AND	Ref.	—
		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

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1-19

	SECTION 1 FRAME
S	FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)
E
C
T
I
O
N
1
F
R
A
M
E

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	1
		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	2
		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 C T I O N

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1-21

S E C T I O N

1

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R A M E

SECTION 1 FRAME

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	35electric U/L Prior to S/N 0300024526 with Wet	Ref.	6
		Batteries
	0256121	35electric U/L S/N 0300024526 to Present with Wet	Ref.	9
		Batteries
	0257557	35electric Non U/L with Wet Batteries	Ref.	3
	0256125	35electric U/L Prior to S/N 0300024526 with Dry	Ref.	2
		Batteries
	0254483	n35electric U/L Prior to S/N 0300023550 with Wet	Ref.	6
		Batteries
	0256121	n35electric U/L S/N 0300023550 to Present with Wet	Ref.	9
		Batteries
	0257557	n35electric Non U/L with Wet Batteries	Ref.	2
	0256125	n35electric U/L with Dry Batteries	Ref.	2
	0254276	40electric U/L Prior to S/N 0300024233 with Wet	Ref.	H
		Batteries
	0256530	40electric U/L S/N 0300024233 to Present with Wet	Ref.	6
		Batteries
	0257558	40electric Non U/L with Wet Batteries	Ref.	2
	0256124	40electric U/L with Dry Batteries (Prior to	Ref.	2
		S/N 0300050377)
	0270258	40electric U/L with Dry Batteries (S/N 0300050377 to	Ref.	1
		Present)
	0254276	n40electric U/L Prior to S/N 0300025492 with Wet	Ref.	H
		Batteries
	0257558	n40electric Non U/L with Wet Batteries	Ref.	1
	0256530	n40electric U/L S/N 0300025492 to Present with Wet	Ref.	6
		Batteries
	0256124	n40electric U/L with Dry Batteries (Prior to	Ref.	A
		S/N 0300050377)
	0270258	n40electric U/L with Dry Batteries (S/N 0300050377	Ref.	1
		to Present)
	0254276	45electric U/L Prior to S/N 0300024324 with Wet	Ref.	H
		Batteries
	0256530	45electri c U/L S/N 0300024324 to Present with Wet	Ref.	6
		Batteries
	0257558	45electric Non U/L with Wet Batteries	Ref.	1
	0256124	45electric U/L with Dry Batteries (Prior to	Ref.	A
		S/N 0300050377)
	0270258	45electric U/L with Dry Batteries (S/N 0300050377 to	Ref.	1
		Present)
101		Battery Box Weldment Options:	1
	4844689	30electric

1-22

3120862