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Illustrated Parts Manual
Models E300AJ E300AJP
S/N 0300138358
TO PRESENT
3121254
November 4, 2013
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)
3121254 |
E300AJ E300AJP |
A |
REVISION LOG
B |
E300AJ E300AJP |
3121254 |
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 |
3121254 |
E300AJ E300AJP |
i |
TABLE OF CONTENTS
FIGURE NO. |
TITLE |
PAGE NO. |
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
ii |
E300AJ E300AJP |
3121254 |
SECTION 1
FRAME
3121254 |
E300AJ E300AJP |
1-1 |
SECTION 1 FRAME
FIGURE 1-1. STEER INSTALLATION
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103 |
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9 |
111 |
102 |
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105 |
106 |
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8 |
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104 |
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107 |
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102 |
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108 |
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115 |
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112 |
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101 |
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113 |
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114 |
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110 |
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1-2 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-1. STEER INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
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1001108599 |
Ref |
STEER INSTALLATION |
C |
1 |
0100011 |
AR |
Compound, Locking |
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2 |
0641607 |
2 |
Bolt 3/8in-16NC x 7/8in |
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3 |
3312005 |
3 |
Locknut 5/8in-11NC |
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4 |
3422181 |
1 |
Pin |
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5 |
3422562 |
2 |
Pin |
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6 |
3841143 |
3 |
Keeper, Pin |
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7 |
3900118 |
2 |
Screw, Shoulder |
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8 |
3900255 |
1 |
Capscrew, Shoulder 3/4in x 3in |
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9 |
1001107712 |
2 |
Hub/Spindle Assembly (See Items 101-115 for Breakdown) |
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10 |
1001107727 |
1 |
Tie-Rod |
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11 |
1001108310 |
1 |
Steer Cylinder Assembly (See Section 5 for Breakdown) |
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12 |
4740086 |
2 |
Thrustwasher |
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13 |
0440162 |
4 |
Thrustwasher |
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14 |
0641610 |
1 |
Bolt 3/8in-16NC x 1-1/4in |
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15 |
3311605 |
1 |
Locknut 3/8in-16NC |
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16 |
4711600 |
1 |
Flatwasher 3/8in Thin |
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17 |
1001151428 |
AR |
Plate, Shim (SN 0300176716 to Present) |
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1001107712 |
Ref |
HUB/SPINDLE ASSEMBLY |
A |
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Ref |
Note: Qty shown is for 1 Hub Assembly. Machine requires 2 |
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assemblies. |
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101 |
7020137 |
1 |
Cap, Dust |
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102 |
0961951 |
2 |
Bushing, Garmax |
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103 |
0962140 |
1 |
Bearing, Garmax |
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104 |
70002434 |
1 |
Hub |
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105 |
7020036 |
1 |
Cup, Bearing (Inner) (Part of Item 104) |
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106 |
7020037 |
1 |
Cone, Bearing (Inner) |
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107 |
7020038 |
1 |
Cup, Bearing (Outer) (Part of Item 104) |
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108 |
7020039 |
1 |
Cone, Bearing (Outer) |
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109 |
70002435 |
1 |
Spindle |
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110 |
7020140 |
1 |
Pin, Cotter |
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111 |
7020040 |
1 |
Seal |
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112 |
7020054 |
1 |
Nut, Castle 1-1/4in-12 |
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113 |
7020041 |
9 |
Stud 5/8in-18NF |
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114 |
7020042 |
9 |
Lugnut 5/8in-18NF |
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115 |
7020055 |
1 |
Washer, Tanged 1-1/4in |
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3121254 |
E300AJ E300AJP |
1-3 |
SECTION 1 FRAME
FIGURE 1-2. TIRE & WHEEL DRIVE INSTALLATION
2
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9B |
1 |
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7 |
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1
8 9
29
1
5
14 |
23 |
15 |
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20
16
9A
102
101
1-4 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-2. TIRE & WHEEL DRIVE INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
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Ref |
WHEEL DRIVE INSTALLATION OPTIONS: |
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1001109430 |
Ref |
Standard Spec |
F |
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1001109431 |
Ref |
UL Spec |
H |
1 |
0100019 |
AR |
Compound, Locking |
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2 |
0340047 |
2 |
Band, Motor (UL Spec Only) |
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3 to 4 |
Not Used |
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5 |
0641609 |
8 |
Bolt 3/8in-16NC x 1-1/8in |
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6 |
Not Used |
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7 |
0641826 |
4 |
Bolt 1/2in-13NC x 3-1/2in |
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8 |
0682012 |
12 |
Bolt 5/8in-11NC x 1-1/2in(SN 0300113683 to SN 0300138358) |
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9 |
0920113 |
2 |
Drive Brake Assembly |
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Use 0920113 |
2 |
Ring, Sensor (1 Per Assembly) (was p/n 7027275 which is no |
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longer available. Replace Complete Brake.) |
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7007977 |
2 |
Ring, Bearing Retaining (Large) (1 per Assembly) |
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7011716 |
2 |
Ring, Bearing Retaining (Small) (1 per Assembly) |
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7007913 |
4 |
Bolt |
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7011757 |
2 |
Complete Repair Kit (Includes Case & Oil Seals, O-Rings, |
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Back-Up Rings, Stator & Rotor Discs, Return Plate, Springs, |
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Bearing & Brake to Hub Gasket) (1 per Assembly) |
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2900768 |
2 |
Bearing Kit (1 per Assembly) |
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7007900 |
2 |
Seal, Oil - Front (1 per Assembly) |
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9A |
7007933 |
2 |
Gasket (1 Per Assembly) |
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9B |
70002408 |
2 |
Gasket, Brake to Motor (1 Per Assembly) (Not Included in |
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Repair Kit) |
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10 to 13 |
Not Used |
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14 |
2780282 |
2 |
Drive Hub Assembly (See Drive Hub Assembly for Breakdown) |
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15 |
3020008 |
AR |
Lubricant, Mobilube HD 80W-90 |
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16 |
3020037 |
AR |
Lube, Coupling Grease |
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17 |
3160237 |
2 |
Drive Motor Assembly (See Drive Motor Assembly for |
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Breakdown) |
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18 to 19 |
Not Used |
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20 |
3990105 |
2 |
Speed Sensor Assembly |
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21 to 22 |
Not Used |
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23 |
4711600 |
8 |
Flatwasher 3/8in Thin |
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24 to 28 |
Not Used |
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29 |
4892000 |
12 |
Flatwasher 5/8in Hardened |
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0258986 |
Ref |
TIRE AND WHEEL INSTALLATION |
C |
101 |
3300106 |
18 |
Lugnut |
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102 |
1001110772 |
4 |
Tire & Wheel Assembly |
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3121254 |
E300AJ E300AJP |
1-5 |
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY
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101 |
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103 |
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2H |
25 |
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2F |
2C 2A 2E |
2D |
2G |
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1 |
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13 |
18 |
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1C 1A |
1D |
1F |
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1E |
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17 |
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26 |
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31 |
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1B |
15 |
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19 |
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7 |
12 |
11 |
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27 |
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24 |
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2B |
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1-6 |
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E300AJ E300AJP |
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3121254 |
|||
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
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2780282 |
Ref |
DRIVE HUB ASSEMBLY |
A |
1 |
70001366 |
1 |
Carrier, Sub Assembly (Purchase p/n 70001366 for items 1A-1F) |
|
1A |
Use 70001366 |
3 |
Shaft, Planet |
|
1B |
Use 70001366 |
1 |
Carrier |
|
1C |
Use 70001366 |
3 |
Gear, Planet |
|
1D |
Use 70001366 |
42 |
Bearing, Needle |
|
1E |
Use 70001366 |
3 |
Pin, Roll |
|
1F |
Use 70001366 |
6 |
Thrustwasher |
|
2 |
70001367 |
1 |
Carrier, Input (Purchase p/n 70001367 for items 2A-2H) |
|
2A |
Use 70001367 |
3 |
Shaft, Planet |
|
2B |
Use 70001367 |
1 |
Carrier |
|
2C |
Use 70001367 |
3 |
Gear, Planet |
|
2D |
Use 70001367 |
84 |
Bearing, Needle |
|
2E |
Use 70001367 |
3 |
Spacer, Thrust |
|
2F |
Use 70001367 |
3 |
Pin, Roll |
|
2G |
Use 70001367 |
12 |
Thrustwasher |
|
2H |
Use 70001367 |
1 |
Thrustwasher |
|
3 |
70001368 |
1 |
Cover |
|
4 |
70001369 |
1 |
Shaft, Input |
|
5 |
70001370 |
1 |
Coupling |
|
6 |
70001371 |
1 |
Shaft, Sun Gear |
|
7 |
70001372 |
1 |
Spindle |
|
8 |
70001373 |
1 |
Gear, Ring |
|
9 |
Use 2780282 |
1 |
Housing |
|
10 |
Use 7017007 |
1 |
Bearing, Tapered-Cone |
|
11 |
Use 7017007 |
2 |
Bearing, Tapered-Cup |
|
12 |
Use 7017007 |
1 |
Bearing, Tapered-Cone |
|
13 |
7017009 |
1 |
Thrustwasher |
|
14 |
Not Used |
|
|
|
15 |
Use 70001380 |
1 |
Seal, Lip |
|
16 |
70001374 |
1 |
Spring |
|
17 |
70001375 |
1 |
Ring, Retaining (Internal) |
|
18 |
Use 70001380 |
1 |
Ring, Retaining (External) |
|
19 |
7024738 |
1 |
Ring, Retaining (Internal) |
|
20 |
70001376 |
1 |
Ring, Retaining (External) |
|
21 |
70001377 |
1 |
Ring, Retaining (External) |
|
22 |
7000281 |
4 |
Screw (Not Shown - ID plate screws) |
|
23 |
7017022 |
3 |
Bolt, Flathead (Not Shown - Located on front of hub) |
|
24 |
Use 70001380 |
1 |
O-Ring |
|
25 |
Use 70001380 |
1 |
O-Ring |
|
26 |
70001378 |
1 |
Spacer, Thrust |
|
27 |
70001379 |
1 |
Thrustwasher |
|
28 |
7024741 |
1 |
Spacer, Thrust |
|
29 |
7007640 |
9 |
Stud, Wheel |
|
30 |
Use 70001368 |
1 |
Flange, Plate |
|
31 |
Use 70001368 |
1 |
Cap, Disengage |
|
32 |
Use 70001368 |
1 |
Pin, Dowel |
|
33 |
Use 70001368 |
2 |
Bolt |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-7 |
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
34 |
Use 70001368 |
1 |
O-Ring |
|
35 |
Use 70001368 |
1 |
O-Ring |
|
36 |
Use 70001368 |
1 |
Plug |
|
|
|
Ref |
KIT OPTIONS |
|
101 |
7017007 |
1 |
Planet Gear Bearing Kit (Includes Items 10-12) |
|
102 |
70001380 |
1 |
Planet Gear Seal Kit (Includes Items 15, 18, 24 & 25) |
|
103 |
70001368 |
1 |
Cap/Disengage Kit (Includes Items 30-36) |
|
|
|
|
|
|
1-8 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-9 |
SECTION 1 FRAME
FIGURE 1-4. DRIVE MOTOR ASSEMBLY
13
12
11
10
9
8
76 5 
4
3
2
1
1-10 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-4. DRIVE MOTOR ASSEMBLY
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
3160237 |
Ref |
DRIVE MOTOR ASSEMBLY |
E |
1 |
7020184 |
1 |
Plate, Drive End |
|
2 |
7012545 |
1 |
Bearing |
|
3 |
7020185 |
1 |
Ring, Retaining |
|
4 |
Use 3160237 |
1 |
Armature |
|
5 |
Use 3160237 |
1 |
Frame & Field Assembly |
|
6 |
7012548 |
4 |
Spring, Brush |
|
7 |
7020149 |
4 |
Brush |
|
8 |
7020150 |
1 |
Holder, Brush |
|
9 |
7020151 |
2 |
Brush Lead Assembly Kit |
|
10 |
7012545 |
1 |
Bearing |
|
11 |
7012549 |
1 |
Washer, Wavy |
|
12 |
7020189 |
1 |
End, Commutator |
|
13 |
7019609 |
1 |
Headband Assembly |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-11 |
SECTION 1 FRAME
FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)
1 |
|
11 |
4 |
|
|
24 |
|
102 |
106 |
104 |
103 |
101 |
|
|
105 1
43
52
10
19
47
42
27 18
46
44
49
50
12
1
48
28
13
44
1
3
28
UL MACHINES ONLY
53
22
21
1-12 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref |
ELECTRICAL COMPONENTS INSTALLATION |
|
|
1001109430 |
Ref |
Standard Spec |
F |
|
1001109431 |
Ref |
UL Spec |
H |
1 |
0100019 |
AR |
Compound, Locking |
|
2 |
Not Used |
|
|
|
3 |
0721003 |
2 |
Screw #10-24NC x 3/8in (UL Spec Only) |
|
4 |
0641504 |
4 |
Bolt 5/16in-18NC x 3/4in |
|
5 |
Not Used |
|
|
|
6 |
0641610 |
1 |
Bolt 3/8in-16NC x 1-1/4in |
|
7 to 9 |
Not Used |
|
|
|
10 |
1600293 |
1 |
Module (Note: Calibration is required when replaced) |
|
11 |
|
1 |
Contactor Plate Assembly Options (See Items 101 to 106 for |
|
|
|
|
Breakdown): |
|
|
1600294 |
|
Standard Spec |
|
|
1600300 |
|
UL Spec |
|
12 |
2400062 |
1 |
Fuse, 300 Amp (UL Spec Only) |
|
13 |
2400044 |
1 |
Holder, Fuse (UL Spec Only) |
|
14 to 17 |
Not Used |
|
|
|
18 |
3310601 |
4 |
Nut #6-32NC |
|
19 |
3910628 |
4 |
Screw #6-32NC x 1-3/4in |
|
20 |
Not Used |
|
|
|
21 |
4060807 |
14in/36cm |
Shield, Flex Trim |
|
22 |
4240084 |
1 |
Strap, Anti-Static |
|
23 |
Not Used |
|
|
|
24 |
4751500 |
4 |
Flatwasher 5/16in Regular |
|
25 |
4751600 |
1 |
Flatwasher 3/8in Regular |
|
26 |
4752200 |
1 |
Flatwasher 3/4in Regular |
|
27 |
4760600 |
4 |
Lockwasher #6 |
|
28 |
4751000 |
2 |
Flatwasher #10 Regular |
|
29 to 40 |
Not Used |
|
|
|
41 |
|
1 |
Drive Cable System Cables Options (Not Shown - See Section |
|
|
|
|
7 for Breakdown): |
|
|
2901818 |
|
Standard Spec |
|
|
2901864 |
|
UL Spec |
|
42 |
4750600 |
4 |
Flatwasher #6 Regular |
|
43 |
0642208 |
1 |
Bolt 3/4in-10NC x 1in |
|
44 |
0861375 |
1 |
Box |
|
45 |
Not Used |
|
|
|
46 |
1704712 |
1 |
Decal - 300 Amp Fuse |
|
47 |
2540037 |
2 |
Grommet |
|
48 |
3311001 |
2 |
Nut #10-24NC |
|
49 |
3311501 |
2 |
Nut 5/16in-18NC |
|
50 |
4711500 |
4 |
Flatwasher 5/16in Thin |
|
51 |
Not Used |
|
|
|
52 |
4712200 |
1 |
Flatwasher 3/4in Thin |
|
53 |
1001116273 |
1 |
Bracket |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-13 |
SECTION 1 FRAME
FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref |
CONTACTOR PLATE ASSEMBLY |
|
|
1600294 |
|
Standard Spec |
|
|
1600300 |
|
UL Spec |
|
|
|
1 |
Harness, Contactor Options (Not Shown) (See Section 7 for |
|
|
|
|
Breakdown): |
|
|
7022003 |
|
Standard Spec |
|
|
7022008 |
|
UL Spec |
|
|
7022004 |
1 |
Harness, Posi-Track Contactor (Not Shown) (See Section 7 for |
|
|
|
|
Breakdown) |
|
|
7022005 |
1 |
Harness, Shunt (Not Shown) (See Section 7 for Breakdown) |
|
101 |
|
1 |
Contactor, FWD / REV Options: |
|
|
7022002 |
|
Standard Spec |
|
|
7022007 |
|
UL Spec |
|
102 |
|
1 |
Contactor, Main Options: |
|
|
7022001 |
|
Standard Spec |
|
|
7022009 |
|
UL Spec |
|
103 |
|
AR |
Contactor, Posi-Track Options: |
|
|
7022000 |
1 |
Standard Spec |
|
|
7022010 |
2 |
UL Spec |
|
104 |
7022012 |
1 |
Cable, Power |
|
105 |
7022011 |
1 |
Diode, Power |
|
106 |
70001052 |
1 |
Shunt/Bus Bar with Harness Assembly |
|
|
|
|
|
|
1-14 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-5. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-15 |
SECTION 1 FRAME
FIGURE 1-6. BATTERY BOX INSTALLATION
13
31
|
|
16 |
|
|
|
|
14 |
|
|
20 |
1 29 33 |
|
|
|
29 |
5 |
|
|
|
6 |
29 |
|
|
|
|
|
15 |
||
|
|
|
||
|
|
|
|
|
|
|
25 |
|
|
30A |
|
3 |
|
|
23 |
|
32 |
|
|
27 |
|
|
19 |
|
|
|
|
|
|
27 |
|
2 |
|
|
21 |
|
|
|
|
|
|
|
|
28 |
|
|
|
|
1 |
|
|
|
|
24 |
|
|
15 |
|
|
|
|
17 |
28 1 |
1 |
|
|
7 |
||
|
30 |
|
4 |
26 |
|
|
|
|
39 |
|
|
|
|
22 |
|
|
18 |
|
|
1-16 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-6. BATTERY BOX INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
Ref |
BATTERIES INSTALLATION |
|
|
1001108560 |
Ref |
Machines with 305AH Batteries |
B |
|
1001115997 |
Ref |
Machines with 305AH AGM Batteries |
A |
|
0259042 |
Ref |
Machines with 375AH Batteries |
J |
1 |
0100011 |
AR |
Compound, Locking |
|
2 |
0100048 |
AR |
Grease, Dialectric |
|
3 |
0100051 |
AR |
Grease, Battery Terminal |
|
4 |
0641403 |
4 |
Bolt 1/4in-20NC x 3/8in |
|
5 |
0641505 |
4 |
Bolt 5/16in-18NC x 5/8in (Machines with AGM Batteries Only) |
|
6 |
|
4 |
Bolt 5/16in-18NC Options: |
|
|
0641512 |
|
Bolt 5/16in-18NC x 1-1/2in |
|
|
0641514 |
|
Bolt 5/16in-18NC x 1-3/4in |
|
7 |
0641606 |
4 |
Bolt 3/8in-16NC x 3/4in |
|
8 to 12 |
Not Used |
|
|
|
13 |
1670878 |
1 |
Cover, (Right) |
|
14 |
1670890 |
1 |
Cover, (Left) |
|
15 |
2540020 |
4 |
Grommet |
|
16 |
2940073 |
2 |
Latch |
|
17 |
2940114 |
2 |
Latch |
|
18 |
3000003 |
2 |
Liner |
|
19 |
3311401 |
4 |
Nut 1/4in-20NC |
|
20 |
3311505 |
4 |
Locknut 5/16in-18NC (Machines with 305AH Batteries Only) |
|
21 |
3312005 |
4 |
Locknut 5/8in-11NC |
|
22 |
3340852 |
2 |
Pad |
|
23 |
3900266 |
4 |
Screw, Shoulder |
|
24 |
3931430 |
4 |
Bolt 1/4in-20NC x 1-7/8in |
|
25 |
4567739 |
2 |
Tube |
|
26 |
4711600 |
4 |
Flatwasher 3/8in Thin |
|
27 |
4740086 |
8 |
Thrustwasher |
|
28 |
4751400 |
8 |
Flatwasher 1/4in Regular |
|
29 |
4751500 |
AR |
Flatwasher 5/16in Regular |
|
30 |
4845923 |
1 |
Box, Battery (Left) |
|
30A |
0962233 |
2 |
Bushing |
|
31 |
4845924 |
1 |
Box, Battery (Right) |
|
31A |
0962233 |
2 |
Bushing (Not Shown) |
|
32 |
|
8 |
Battery Options: |
|
|
1001105091 |
|
Wet Battery (6V-305-S) |
|
|
1001114782 |
|
Wet Battery (6V-305A-A AGM) |
|
|
0400055 |
|
Wet Battery (6V-370-S) |
|
|
See Note |
|
Dry Battery (6V-305-S) (Note: Not Available for Purchase) |
|
|
See Note |
|
Dry Battery (6V-305A-A AGM) (Note: Not Available for |
|
|
|
|
Purchase) |
|
|
0400107 |
|
Dry Battery (6V-370-S) |
|
33 |
1001116006 |
4 |
Bracket (Machines with AGM Batteries Only) |
|
34 to 38 |
Not Used |
|
|
|
39 |
4070904 |
2 |
Shim |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-17 |
SECTION 1 FRAME
FIGURE 1-7. FRAME COVERS INSTALLATION
4
9
10
1
2
8
7
3
5
6
11
1-18 |
E300AJ E300AJP |
3121254 |
SECTION 1 FRAME
FIGURE 1-7. FRAME COVERS INSTALLATION
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
1001109383 |
Ref |
FRAME COVERS INSTALLATION |
C |
1 |
0100011 |
AR |
Compound, Locking |
|
2 |
0641504 |
2 |
Bolt 5/16in-18NC x 1/2in |
|
3 |
1380138 |
3 |
Nut, Clip |
|
4 |
1704246 |
1 |
Decal - Cable Routing |
|
5 |
3760308 |
3 |
Retainer |
|
6 |
1001112496 |
3 |
Thumbscrew |
|
7 |
3960447 |
63in/1.6m |
Seal |
|
8 |
4711500 |
2 |
Flatwasher 5/16in Thin |
|
9 |
1001107751 |
1 |
Cover, Contactor |
|
10 |
1001108251 |
1 |
Cover, Rear Axle |
|
11 |
3960389 |
2ft/.6m |
Seal |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-19 |
SECTION 1 FRAME
FIGURE 1-8. INVERTER INSTALLATION (OPTIONAL)
13
|
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1-20 |
|
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|
E300AJ E300AJP |
3121254 |
|||||||||||||||||||||||||||
SECTION 1 FRAME
FIGURE 1-8. INVERTER INSTALLATION (OPTIONAL)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
1001110271 |
Ref |
INVERTER INSTALLATION |
B |
1 |
0641406 |
8 |
Bolt 1/4in-20NC x 3/4in |
|
2 |
0641618 |
4 |
Bolt 3/8in-16NC x 2-1/4in |
|
3 to 5 |
Not Used |
|
|
|
6 |
1271463 |
1 |
Channel, Mounting |
|
7 |
1670953 |
1 |
Cover |
|
7A |
2600103 |
1 |
Hinge (Welded on Part) |
|
7B |
2940048 |
1 |
Latch |
|
8 |
2460037 |
1 |
Inverter/Generator Assembly |
|
9 |
Not Used |
|
|
|
10 |
3300353 |
4 |
Nut, Tinnerman |
|
11 |
3311405 |
4 |
Locknut 1/4in-20NC |
|
12 |
3311605 |
4 |
Locknut 3/8in-16NC |
|
13 |
4060803 |
8.5in/21cm |
Flex-Trim |
|
14 to 16 |
Not Used |
|
|
|
17 |
4460426 |
1 |
Connector, Strain Relief |
|
18 |
4568165 |
4 |
Spacer, Tube |
|
19 |
4751400 |
4 |
Flatwasher 1/4in Regular |
|
|
|
|
|
|
3121254 |
E300AJ E300AJP |
1-21 |
SECTION 1 FRAME
FIGURE 1-8. INVERTER INSTALLATION (OPTIONAL) (CONTINUED)
ITEM # |
PART NUMBER |
QTY. |
DESCRIPTION |
REV. |
|
|
|
|
|
|
|
|
|
|
1-22 |
E300AJ E300AJP |
3121254 |
SECTION 2 TURNTABLE
3121254 |
E300AJ E300AJP |
2-1 |
SECTION 2 TURNTABLE
1
32
15 
31
15
1
30
33
FIGURE 2-1. CONTROL VALVES & TANK/MOTOR INSTALLATIONS
|
1 |
24 |
|
3 |
29 |
1 |
|
19 |
3 |
29 |
1 |
|
|
6 |
20A
20B
20
2 |
|
|
|
|
18 |
|
|
|
|
1 |
|
|
|
|
3 |
|
|
|
|
15 |
|
|
|
|
1 |
|
|
|
154 |
3 15 |
|
|
|
|
|
|
15 |
21C |
|
|
1 |
|
|
|
19 |
|
21B |
|
|
6 |
|
|
||
9 |
|
|
21 |
|
|
|
|
21A |
18 |
25 |
|
|
22 |
13 |
|
|
|
||
|
|
|
21D |
|
11 |
|
|
|
|
8 17 12
5 17
10 |
|
23 |
1 |
7 |
|
26 |
19 |
|
|
|
|
|
16 |
|
|
19 |
|
|
14 |
15 |
|
|
|
|
|
1 |
|
|
4 |
2-2 |
E300AJ E300AJP |
3121254 |
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