JLG E300 Parts Manual

Illustrated Parts Manual

Models

E300A

E300AJ

E300AJP

PRIOR TO

S/N 0300138358

P/N

3120773

November 4, 2013

REVISION LOG

May 10, 1999 - Original Issue Of Manual (Edited to 0010559 Revision 3)

June 1, 1999 - Revised Manual (Edited to 0010559 Revision 5)

August 1, 1999 - Removed Platform Rotator Cylinder Components from Manual. All Production Machines use Hydraulic Platform Rotator. Added E300AJP Components. (Edited to 0010559 Revision 6)

September 15, 1999 - Revised Manual (Edited to 0010559 Revision 7)

November 1, 1999 - Updated Page 2-23

March 15, 2000 - Revised Manual (Edited to 0010559 Revision 9)

March 1, 2001 - Revised Manual (Edited to 0010599 Revision 20)

August 31, 2001 - Revised Manual (Edited to 0010559 Revision 22)

June 30, 2002 - Revised Manual (Edited to 0010559 Revision 26)

June 15, 2003 - Revised Manual (Edited to 0010559 Revision 37)

September 23, 2003 - Revised Manual (Edited to 0010559 Revision 39)

September 23, 2004 - Revised Manual (Edited to 0010559 Revision 41)

June 8, 2006 - Revised Manual (Edited to 0010559 Revision 44)

August 31, 2006 - Revised Manual (Edited to 0010559 Revision 46)

January 24, 2007 - Revised Manual (Edited to 0010559 Revision 48)

August 14, 2007 - Revised Manual (Edited to 0010559 Revision 54)

February 10, 2008 - Revised Manual (Edited to 0010559 Revision 55)

August 31, 2008 - Revised Manual (Edited to 0010559 Revision 56)

March 31, 2009 - Revised Manual (Edited to 0010559 Revision 56)

October 15, 2009 - Revised Manual (Edited to 0010559 Revision 57)

October 25, 2010 - Revised Manual

March 16, 2011 - Revised Manual

June 10, 2011 - Revised Manual

November 29, 2011 - Revised Manual

March 20, 2012 - Revised Manual

July 10, 2012 - Revised Manual

October 10, 2012 - Revised Manual

February 12, 2013 - Revised Manual

May 2, 2013 - Revised Manual

August 6, 2013 - Revised Manual

November 4, 2013 - Revised Manual

3120773 E300A E300AJ E300AJP A

REVISION LOG

B E300A E300AJ E300AJP 3120773

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-3 DRIVE HUB ASSEMBLY (PRIOR TO SN 0300116217) . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4 DRIVE HUB ASSEMBLY (SN 0300116217 TO SN 0300138358) . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-7 ELECTRICAL COMPONENTS INSTALLATION (U/L MACHINES ONLY)

(SN 0300035281 TO SN 0300138358). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-8 BATTERY BOX INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-9 FRAME COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-10 INVERTER INSTALLATION (OPTIONAL ON E300AJ & E300AJP) . . . . . . . . . . . . . . . . 1-26

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 VALVES AND HORN INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 STEER/BRAKE VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-4 TURNTABLE AND SWING DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 SWING BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 SWING MOTOR ASSEMBLY (WHITE ROLLER STATOR) . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7 SWING MOTOR ASSEMBLY (PARKER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-8 PUMP, MOTOR AND TANK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-9 ELECTRICAL COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-10 GROUND CONTROL BOX ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-11 BATTERY CHARGER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-12 HOODS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 BOOM INSTALLATION - E300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 BOOM INSTALLATION - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3 BOOM INSTALLATION - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4 TOWER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-5 MAIN BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-6 JIB ASSEMBLIES (E300AJ & E300AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-7 PLATFORM ROTATOR ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-8 JIB SWING ROTATOR ASSEMBLY (E300AJP ONLY) (PRIOR TO SN 0300064982) . . 3-26 3-9 JIB SWING ROTATOR ASSEMBLY (E300AJP ONLY) (SN 0300064982 TO

SN 0300138358). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-10 CABLES, CLAMPS AND LIMIT SWITCHES INSTALLATION. . . . . . . . . . . . . . . . . . . . . 3-30

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) . . . . . . . . . . . . . . . . . . . . 4-6

4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 CONTROLLER ASSEMBLY (SWING & LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 CONTROLLER ASSEMBLY (DRIVE AND STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-6 PLATFORM PADDING INSTALLATION (FRONT ENTRY PLATFORM). . . . . . . . . . . . . 4-22

4-7 PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM). . . . . . . . . . . . . . . 4-24

3120773 E300A E300AJ E300AJP i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 JIB CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 JIB CYLINDER ASSEMBLY (SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) . . . . . 5-6

5-4 LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (SERVICE REPLACEMENT) . . . 5-8

5-5 LIFT CYLINDER ASSEMBLY - MAIN BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 LIFT CYLINDER ASSEMBLY - TOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT). . . . . . . . . . . . . . . . . . . . . 5-14

5-8 MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT). . . . . . . . . . . . . . . . . . . 5-16

5-9 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-10 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-11 CYLINDER BELLOWS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 STANDARD HYDRAULIC DIAGRAM (E300A & E300AJ). . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 STANDARD HYDRAULIC DIAGRAM (E300AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

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 SPEC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii E300A E300AJ E300AJP 3120773

SECTION 1

FRAME

3120773 E300A E300AJ E300AJP 1-1

SECTION 1 FRAME

102

110

114

113

101

104

105

106

111

109

103

112

115

108

107

103

1021317

FIGURE 1-1. STEER INSTALLATION

1-2 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-1. STEER INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0258985 Ref STEER INSTALLATION F

1 0100011 AR Compound, Locking 2 0440162 2 Bearing, Thrust 3 0641608 1 Bolt 3/8in-16NC x 1in 4 1683732 1 Steer Cylinder Assembly (See Section 5 for Breakdown) 5 2780234 2 Hub/Spindle Assembly (See Items 101-115 for Breakdown) 6 3312005 3 Locknut 5/8in-11NC 7 3313003 2 Nut, Castle 1-1/4in-11NF 8 3422327 1 Pin

9 3422774 2 Kingpin 10 3450812 2 Pin, Cotter 11 3841143 1 Keeper 12 3900109 1 Bolt, Shoulder 13 3900118 2 Bolt, Shoulder 14 4712600 1 Flatwasher 1in Thin (Prior to SN 0300045452 Only) 15 4713000 2 Flatwasher 1-1/4in Thin 16 4845897 1 Tie-Rod 17 4740156 4 Thrustwasher (SN 0300080297 to SN 0300138358)

2780234 Ref HUB/SPINDLE ASSEMBLIES D

101 7020033 2 Cap, Dust (1 per Assembly) 102 0961951 4 Bushing, Garmax (2 per Assembly) 103 0962140 4 Bearing, Garmax (2 per Assembly) 104 7020035 2 Hub (1 per Assembly) 105 7020036 2 Cup, Bearing (Inner) (1 per Assembly) 106 7020037 2 Cone, Bearing (Inner) (1 per Assembly) 107 7020038 2 Cup, Bearing (Outer) (1 per Assembly) 108 7020039 2 Cone, Bearing (Outer) (1 per Assembly) 109 7020148 2 Spindle (1 per Assembly) 110 7020140 2 Pin, Cotter (1 per Assembly) 111 7020040 2 Seal (1 per Assembly) 112 7020054 2 Nut, Castle 1-1/4in-12 (1 per Assembly) 113 7020041 18 Stud 5/8in-18NF (9 per Assembly) 114 7020042 18 Lugnut 5/8in-18NF (9 per Assembly) 115 7020055 2 Washer, Tanged 1-1/4in (1 per Assembly)

3120773 E300A E300AJ E300AJP 1-3

SECTION 1 FRAME

101

102

311

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

1-4 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref WHEEL DRIVE INSTALLATION OPTIONS: 0258984 Ref Standard Spec (2WD) (Prior to SN 0300116217) K 0274282 Ref Standard Spec (2WD) (SN 0300116217 to SN 0300138358) C 0258984 Ref UL Spec (Prior to SN 0300035281) K 0259396 Ref UL Spec (SN 0300035281 to SN 0300116217) C 0274283 Ref UL Spec (SN 0300116217 to SN 0300138358) C

1 0100019 AR Compound, Locking 2 0641609 8 Bolt 3/8in-16NC x 1-1/8in 3 0641826 4 Bolt 1/2in-13NC x 3-1/2in 4 12 Bolt Options:

0682010 Bolt 5/8in-11NC x 1-1/4in (Prior to SN 0300116217) 0682012 Bolt 5/8in-11NC x 1-1/2in (SN 0300116217 to

SN 0300138358)

5 0920113 2 Drive Brake Assembly

Use 0920113 2 Ring, Sensor (1 Per Assembly) (was p/n 7027275 which is no

longer available. Replace Complete Brake.) 7007977 2 Ring, Bearing Retaining (Large) (1 per Assembly) 7011716 2 Ring, Bearing Retaining (Small) (1 per Assembly) 7007913 4 Bolt 7011757 2 Complete Repair Kit (Includes Case & Oil Seals, O-Rings,

Back-Up Rings, Stator & Rotor Discs, Return Plate, Springs,

Bearing & Brake to Hub Gasket) (1 per Assembly) 2900768 2 Bearing Kit (1 per Assembly) 7007900 2 Seal, Oil - Front (1 per Assembly)

5A 7007933 2 Gasket (1 Per Assembly) 5B 70002408 2 Gasket, Brake to Motor (1 Per Assembly) (Not Included in

Repair Kit)

6 3020037 AR Lube, Coupling Grease 7 2 Drive Hub Assembly Options:

2780236 Prior to SN 0300116217 (See Drive Hub Assembly for

Breakdown) 2780282 SN 0300116217 to SN 0300138358 (See Drive Hub

Assembly for Breakdown)

8 3160237 2 Drive Motor Assembly (See Drive Motor Assembly for

Breakdown)

7020149 2 Brush

9 3990105 2 Speed Sensor Assembly 10 4711600 8 Flatwasher 3/8in Thin 11 4892000 12 Flatwasher5/8in Hardened 12 3020008 AR Lubricant, Mobilube HD 80W-90

3120773 E300A E300AJ E300AJP 1-5

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TIRE AND WHEEL INSTALLATIONS

Ref Prior to SN 0300100669 0258986 Ref Standard B 0273587 Ref CSA Spec E 0273587 Ref SN 0300100669 to SN 0300138358 E

101 3300106 18 Lugnut 102 4 Tire & Wheel Assembly

Prior to SN 0300100669 Use 1001110772 Standard (was p/n 4520208) (See Notes Below) Use 1001110776 CSA Spec (was p/n 4520276 & p/n 4520675) (See Notes

Below)

Use 1001110776 SN 0300100669 to SN 0300138358 (was p/n 4520675) (See

Notes Below)

Ref Note: Wheel is now gray, Orange Wheel is no longer

available.

Ref Note: When replacing tires & wheels with either p/n

1001110772 or 1001110776, assemblies must be replaced in complete sets only.)

1-6 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120773 E300A E300AJ E300AJP 1-7

SECTION 1 FRAME

107

101

102

103

104

105

106

11 15

30294

17 2

FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300116217)

1-8 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300116217)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

2780236 Ref DRIVE HUB ASSEMBLY D

1 7021323 4 Gear, Planet 2 7021324 3 Gear, Planet 3 7021325 1 Gear, Sun 4 7023803 1 Nut, Shaft

Ref NOTE: Unless there is capability to torque shaft nut (item 4)

to 625 ft/lbs. (850Nm) Repair beyond this level is NOT

advised.

5 7021326 3 Bolt, Planet 6 7021327 1 Ring, Support 7 7021328 1 Carrier, Planet 8 70003711 1 Cover

9Not Used 10 70003712 3 Bearing, Roller 11 70003713 4 Bearing, Roller 12 70003714 2 Bearing, Roller 13 Not Used 14 70003715 3 Ring, Retaining 15 70003716 4 Ring, Retaining 16 7021341 1 Ring, Retaining 17 70003717 3 Disk, Support 18 Not Used 19 See Note 1 O-Ring (Note: Use Item 103 or 107) 20 See Note 1 Seal, Ring (Note: Use Item 103 or 107) 21 See Note 3 Plug (Note: Use Item 104 or 107) 22 See Note 3 Seal, Ring (Note: Use Item 104 or 107) 23 7021342 3 Bolt

24 to 28 Not Used

29 7024049 1 Washer, Housing 30 7021335 1 Gear, Ring

31 to 32 Not Used

33 See Note 1 O-Ring (Note: Use Item 103, 104 or 107) 34 70003718 1 Ring, Retaining

35 to 42 Not Used

43 7021336 1 Shaft, Sun Gear 44 7021337 1 Shaft, Input

45 to 48 Not Used

49 7024051 1 Thrustwasher 50 Not Used 51 70003719 1 Cover 52 70003720 1 Disk 53 70003721 2 Bolt 54 See Note 1 O-Ring (Note: Use Item 104, 105, 106 or 107) 55 7024053 1 Spring, Pressure 56 70003722 1 Rod, Shaft

57 to 58 Not Used

59 70003723 1 Disk, Rotor 60 7021339 1 Spindle

3120773 E300A E300AJ E300AJP 1-9

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300116217) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

61 Not Used 62 7021340 1 Coupler

63 to 65 Not Used

66 70003724 1 Ring, Retaining

67 to 80 Not Used

81 7024983 1 Bearing, Ball 82 7021341 2 Ring, Retaining 83 7024931 1 Ring, Retaining

84 to 87 Not Used

88 Use 7021344 9 Stud, Wheel (was p/n 7024984)

89 to 97 Not Used

98 7024985 1 Plug 99 AR Component Options:

See Note 2 Ball Prior to SN 0300089391 (Note: Not Available - Use

Slotted Pin in Item 103 Kit)

See Note 2 Expander Prior to SN 0300089391 (Note: Not Available - Use

Slotted Pin in Item 103 Kit)

See Note 2 Plug Prior to SN 0300089391(Note: Not Available - Use

Slotted Pin in Item 103 Kit)

70003725 2 Pin, Slotted SN 0300089391 to SN 0300115723

Ref KIT OPTIONS

101 7024981 1 Planet Gear Kit 1 (Includes Items 1, 11 & 15) 102 7024986 1 Planet Gear Kit 2 (Includes Items 2, 10,14 & 17) 103 7024047 1 Bearing Kit (Includes Items 4, 12, 19, 20, 23, 33 & 99)

Ref NOTE: Unless there is capability to torque shaft nut (item 4)

to 625 ft/lbs. (850Nm) Repair beyond this level is NOT advised.

104 7021329 1 Cover Kit (Includes Items 8, 21, 22, 33, 34 & 51-54) 105 7021338 1 Mechanical Disconnect Kit (Includes Items 54-56, 59 & 66) 106 7024054 1 Mechanical Disconnect Kit (Includes Items 51, 53, 54 & 56) 107 7021333 1 Seal Kit (Includes Items 19-22, 33 & 54)

1-10 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-3. DRIVE HUB ASSEMBLY (PRIOR TO SN 0300116217) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120773 E300A E300AJ E300AJP 1-11

SECTION 1 FRAME

1E6343533343231

361B192422B8

29910

2A 2E 2D 2G

101 102 103

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300116217 TO SN 0300138358)

1-12 E300A E300AJ E300AJP 3120773

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300116217 TO SN 0300138358)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

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

3120773 E300A E300AJ E300AJP 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300116217 TO SN 0300138358) (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)

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SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (SN 0300116217 TO SN 0300138358) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3120773 E300A E300AJ E300AJP 1-15

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

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SECTION 1 FRAME

FIGURE 1-5. 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

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SECTION 1 FRAME

2123282425

101

106

104

103

102

105

FIGURE 1-6. ELECTRICAL COMPONENTS INSTALLATION

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SECTION 1 FRAME

FIGURE 1-6. ELECTRICAL COMPONENTS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref ELECTRICAL COMPONENTS INSTALLATION 0258984 Ref Standard Spec (2WD) (Prior to SN 0300116217) K 0274282 Ref Standard Spec (2WD) (SN 0300116217 to SN 0300138358) C 0258984 Ref UL Spec (Prior to SN 0300035281) K

1 0100019 AR Compound, Locking

2 to 11 Not Used

12 0641404 4 Bolt 1/4in-20NC x 1/2in 13 0641506 1 Bolt 5/16in-18NC x 3/4in

14 to 20 Not Used

21 1600293 1 Module (Note: Calibration is required when replaced) 22 1600294 1 Contactor Plate Assembly (See Items 101 to 106 for

Breakdown) 23 3310601 4 Nut #6-32NC 24 3910636 4 Bolt #6-32NC 25 4240084 1 Strap 26 4711500 1 Flatwasher 5/16in Thin 27 4751400 4 Flatwasher 1/4in Regular 28 4760600 4 Lockwasher #6 29 Not Used 30 4060807

15in/30cm

Shield, Flex Trim

1600294 Ref CONTACTOR PLATE ASSEMBLY E

7022003 1 Harness, Contactor (Not Shown) (See Section 7 for Breakdown) 7022004 1 Harness, Posi-Track Contactor (Not Shown) (See Section 7 for

Break-down)

7022005 1 Harness, Shunt (Not Shown) (See Section 7 for Breakdown) 101 7022002 1 Contactor, FWD / REV 102 7022001 1 Contactor, Main 103 7022000 1 Contactor, Posi-Track 104 7022012 1 Cable, Power 105 7022011 1 Diode, Power 106 70001052 1 Shunt/Bus Bar With Harness Assembly

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SECTION 1 FRAME

101

104

102

103

1 3

382944

1 4

FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (U/L MACHINES ONLY) (SN 0300035281 TO

SN 0300138358)

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SECTION 1 FRAME

FIGURE 1-7. ELECTRICAL COMPONENTS INSTALLATION (U/L MACHINES ONLY) (SN

0300035281 TO SN 0300138358)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref ELECTRICAL COMPONENTS INSTALLATION 0259396 Ref UL Machines Only (SN 0300035281 to SN 0300116217) C 0274283 Ref UL Machines Only (SN 0300116217 to SN 0300138358) C

1 0100019 AR Compound, Locking 2 0340047 2 Band, Motor 3 0641404 4 Bolt 1/4in-20NC x 1/2in 4 0641506 1 Bolt 5/16in-18NC x 3/4in

5 to16 Not Used

17 0721005 4 Screw, Hex Head 18 0861375 1 Box, Cover

19 to 28 Not Used

29 1600293 1 Module (Note: Calibration is required when replaced) 30 1600300 1 Contactor Plate Assy (See Items 101 to 104 for Breakdown) B 31 1704712 1 Decal, 300 Amp Fuse (Not Shown) 32 2400044 1 Fuse, Mounting Block 33 2400062 1 Fuse, 300 Amp 34 2540037 2 Grommet, Fuse Box 35 3310601 4 Nut #6-32NC 36 3311001 2 Nut, #10-24NC 37 3311501 2 Nut, 5/16-18NC 38 3910636 4 Bolt #6-32NC 39 4060807 40 4240084 1 Strap, Anti-Static 41 4711500 5 Flatwasher 5/16in Thin 42 4751000 6 Flatwasher, #10 Regular 43 4751400 4 Flatwasher 1/4in Regular 44 4760600 4 Lockwasher #6

15in/30cm

Shield, Flex Trim

1600300 Ref CONTACTOR PLATE ASSEMBLY B

7022008 1 Harness, Contactor (Not Shown) (See Section 7 for Breakdown) 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 7022007 1 Contactor, FWD / REV 102 7022009 1 Contactor, Main 103 7022010 2 Contactor, Posi-Track 104 7022012 1 Cable, Power

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SECTION 1 FRAME

FIGURE 1-8. BATTERY BOX INSTALLATIONS

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SECTION 1 FRAME

FIGURE 1-8. BATTERY BOX INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

BATTERIES INSTALLATION

0259042 Ref Standard Machines J 0259417 Ref U/L Machines F

1 8 Battery Options:

0400055 Wet 0400107 Dry

2 0641403 4 Bolt 1/4in-20NC x 3/8in 3 0641512 4 Bolt 5/16in-18NC x 1-1/2in 4 0641606 4 Bolt 3/8in-16NC x 3/4in 5Not Used 6 1670878 1 Cover, (Right) 7 1670890 1 Cover, (Left)

8 to 10 Not Used

11 2940073 2 Latch 12 2940114 2 Latch 13 3000003 2 Liner 14 3312005 4 Locknut 5/8in-11NC 15 3340852 2 Pad 16 3900266 4 Screw, Shoulder 17 4567739 2 Tube 18 4711600 4 Flatwasher 3/8in Thin 19 4751500 8 Flatwasher 5/16in Regular 20 4845923 1 Box, Battery (Left)

20A 0962233 2 Bushing

21 4845924 1 Box, Battery (Right)

21A 0962233 2 Bushing (Not Shown)

22 2820066 4 Insulator - Sides (Prior to SN 0300052764 Only) 23 2820101 4 Insulator - Ends (Prior to SN 0300052764 Only) 24 2820102 2 Insulator - Tops (U/L Machines Only) (Not Shown) 25 2540020 4 Grommet 26 0100011 AR Compound, Locking 27 0100048 AR Grease, Dialectric 28 0100051 AR Grease, Battery Terminal 29 0840031 9 Boot 30 0840032 7 Boot

31 to 33 Not Used

34 3311401 4 Nut 1/4in-20NC 35 3931430 4 Bolt 1/4in-20NC x 1-7/8in 36 4740086 8 Thrustwasher 37 4751400 8 Flatwasher 1/4in Regular 38 4420055 AR Tape (Not Shown) (Prior to SN 0300103058) 39 4070904 2 Shim

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SECTION 1 FRAME

1916201

FIGURE 1-9. FRAME COVERS INSTALLATION

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