JLG E300 Parts Manual

5 (2)

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

FIGURE 1-1. STEER INSTALLATION

1

12

3

 

11

5

8

 

4

9

14

 

 

2

103

102

5

109

 

 

111

 

13

 

106

 

 

 

105

 

17

 

104

 

 

102

 

107

 

16

108

 

15

103

115

 

 

 

 

 

112

 

 

17

101

 

 

 

113

10

7

 

6

114

110

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

FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION

8

3 1

 

10

1 2

 

4

1

6

9

11

 

5

 

 

6

 

 

5A

 

7 12

102

101

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

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

101

102

103

104

105

106

107

60

20

55

44

88

99

1

11 15

17

2

34

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

56

62

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

53

59

 

 

 

 

 

 

 

 

51

66

 

 

 

 

 

 

 

 

54

 

 

 

 

 

 

 

 

 

52

82

 

 

 

 

 

 

 

 

43

81

 

 

 

 

 

 

 

 

 

98

 

 

 

 

 

 

 

 

49

83

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

82

 

 

 

 

 

 

 

 

22

 

 

 

 

 

 

 

 

 

21

 

 

 

 

 

 

 

 

 

8

12

23

19

6

4

29

30

3

7

33

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

 

9

Not 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

JLG E300 Parts Manual

SECTION 1 FRAME

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

 

 

 

 

 

 

 

 

 

 

 

 

101

 

 

 

 

 

 

 

 

 

 

 

 

 

 

102

 

 

 

 

 

 

 

 

 

 

 

 

 

 

103

 

 

 

 

 

2H

25

 

 

2F

2C 2A 2E

2D

2G

 

1

 

 

 

13

18

 

 

 

 

1C 1A

1D

1F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

17

 

 

 

 

 

 

 

 

 

 

 

 

 

6

26

 

 

 

 

 

 

 

 

 

 

 

 

 

4

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

35

 

 

 

 

 

 

 

 

 

 

 

 

 

 

33

 

 

 

 

 

 

 

 

 

 

 

 

 

 

34

 

 

 

 

 

 

 

 

 

 

 

 

 

 

32

 

 

 

 

 

 

 

 

 

 

 

 

 

 

31

5

 

 

 

 

 

 

 

 

 

 

 

 

 

28

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

36

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1B

15

 

 

 

 

 

 

 

 

 

 

 

 

 

19

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

12

11

 

10

27

9

 

29

8

 

2

24

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2B

 

 

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)

 

 

 

 

 

 

1-14

E300A E300AJ E300AJP

3120773

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

13

12

11

10

9

8

76 5

4

3

2

1

1-16

E300A E300AJ E300AJP

3120773

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

 

 

 

 

 

 

3120773

E300A E300AJ E300AJP

1-17

SECTION 1 FRAME

FIGURE 1-6. ELECTRICAL COMPONENTS INSTALLATION

106

104

 

 

102

 

103

101

 

12

27

22

105

24

21

28

23

26

25

 

1 13

30

1-18

E300A E300AJ E300AJP

3120773

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

 

 

 

 

 

 

3120773

E300A E300AJ E300AJP

1-19

SECTION 1 FRAME

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

 

 

SN 0300138358)

 

 

 

 

42

18

 

 

 

17

 

 

 

 

 

 

 

34

32

 

1

 

 

 

 

3

 

 

 

18

43

 

102

37

33

 

 

36

 

 

 

 

 

103

 

 

104

 

 

 

 

 

 

101

 

 

 

 

30

38 2

29

44

35

41

40

1

4

39

1-20

E300A E300AJ E300AJP

3120773

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

15in/30cm

Shield, Flex Trim

 

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

 

 

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

 

 

 

 

 

 

3120773

E300A E300AJ E300AJP

1-21

SECTION 1 FRAME

FIGURE 1-8. BATTERY BOX INSTALLATIONS

26

27

26

39

26

28

28

28

28

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-22

 

E300A E300AJ E300AJP

3120773

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

 

5

Not 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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E300A E300AJ E300AJP

1-23

SECTION 1 FRAME

FIGURE 1-9. FRAME COVERS INSTALLATION

16

19

14

20

14

14

21

14

14

14

1-24

E300A E300AJ E300AJP

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