PARTS MANUAL (ANSI/CSA, CE, AS & KC) DC ELECTRIC SCISSORS MODELS SJIII 4740

Transcription

1 PARTS MANUAL (ANSI/CSA, CE, AS & KC) DC ELECTRIC SCISSORS MODELS AA June 206

2 This manual is based on Serial Numbers: & Above Please refer to the website - for older Serial Numbers. Service Center 35 Swenson Ave. St. Charles, Illinois, 607 USA Phone: Toll Free: Fax: service@skyjack.com Parts (North America) Toll Free: Toll Free Fax: parts@skyjack.com Australia Pty Ltd. Coates Place Wetherill Park New South Wales 26 Australia Tel: +6 (0) Fax: +6(0) Parts & Service (Europe) Unit Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY0 8NN UK Phone: Fax: info@skyjackeurope.co.uk Brasil Alameda Júpiter, 70 Loteamento American Park Empresarial Indaiatuba, SP, Brasil Tel:

3 DC Electric Scissor Lifts Parts Manual General The information contained in this section is designed to aid the user in locating and identifying replacement parts. Component parts of various assemblies and sub-assemblies comprising the work platform are illustrated and accompanied by a descriptive parts list. Exploded drawings are used to show relative location of component parts in disassembly order. If a part cannot be found in this section, order by work platform model number and serial number, giving a complete description of the part. Parts Ordering Information When ordering replacement parts, the complete part number and description should be used to ensure proper identification and delivery of the desired item. This complete identification should also be used when requesting equipment information. Method of Listing Parts are listed in order according to the reference number shown in the illustration, followed by a full description based upon the NOUN FIRST method. That is, the noun name of the part is listed first, then the modifying description information which serves to specifically identify the item. For example: PIN, Clevis. Assemblies or groups are shown at the beginning of a parts list and are identified with the letter references A, B, C, etc. Individual parts in these lists have corresponding letters after their description to identify which assembly or group it is used in. Individual parts without identifying letters are used in all the assemblies or group shown at the beginning of the parts list. s preceded with an ( ) indicates a serviceable component or attaching hardware for the higher level assembly. If an index number initially starts with the letter K, for example K, means it s a kit. Any item(s) included in a kit will not have an index number. Quantities (Units Per Assy.) The quantities of each part that are required to complete the assembly. If quantity is (AR), it is understood that the quantity may vary when aerial platform is equipped with certain options. Order quantity as needed. Hardware Standard screws, washers, nuts, etc. are not identified by a reference number. These parts are known as COMMON HARDWARE items and appear indented under the major items with which they are used. They should be ordered separately as listed, since they are not component parts of the pieces they attach to. How to Order Repair Parts. Address all orders to your local SKYJACK dealer. 2. Specify model and serial number of the work platform (found on the serial number plate). 3. List the quantity needed.. List the length needed (if bulk item). 5. List the part number and description as shown in this manual for each item. 6. Show billing and shipping address and name of individual if possible. 7. Suggest best routing. CUSTOMER DEALER MODEL NUMBER SERIAL NUMBER DATE PURCHASED Use Only Authorized Replacement Parts! Page 3

4 Table of Contents.0 Platform Related Parts. Platform Group Main Platform and Extension Assembly Main Platform Assembly Extension Platform Assembly....5 Main Railings Assembly Extension Railing Assembly Full Gate Entrance Assembly Half Gate Entrance Assembly (ANSI/CSA, CE & KC) Quick Release Pin Assembly Gate Latch Assembly Extension Handrail Assembly Platform Control Box Assembly Control Console Assembly Enable Controller Assembly Platform A/C Outlet Assembly Scissor Related Parts 2. Scissor Group Scissor Mounting Hardware Assembly Scissor Connecting Hardware Assembly Lift Cylinder Assembly and Mounting Hardware Holding Valve Manifold Assembly Hydraulic Hose Connections - Scissors Scissors Limit Switch Assembly Horn Assembly Load Sensing and Transducer Module Assembly (CE & AS) Pressure Switch Assembly (KC Only) Flashing Light Assembly Base Related Parts 3. Base Assembly Base Assembly (Continued) Front Hub Assembly Steer Cylinder Assembly Rear Brake Assembly Drive Manifold Assembly Brake Release Manifold Assembly Hydraulic Hose Connections - Base Pothole Protection Assembly Wheel Assembly Tilt Switch and Bracket Assembly (ANSI/CSA & KC) Base Control Assembly Counter Reset (CE)... 7 Page

5 Table of Contents.0 Hydraulic Tray Related Parts. Hydraulic Tray Group Hydraulic Tray Group (Continued) Hydraulic Tank Lid Assembly Emergency Lowering Assembly Motor and Pump Assembly Main Manifold Assembly Hydraulic Hose Connections - Hydraulic Tray Battery Tray Related Parts 5. Battery Tray Assembly Battery Assembly Charger Assembly Electrical Related Parts 6. Electrical Panel Assembly Control Cable Assembly Rear Manifold Harness Main Manifold Harness Electrical Harnesses (Continued) Battery Cables Dual Flashing Light Harness (ANSI/CSA only) RST Wire Assembly Optional Equipment 7. Board Carrier Assembly (ANSI/CSA, CE & AS) Inverter Subgroup (ANSI/CSA) Inverter Wiring (ANSI/CSA) Inverter Assembly and Labels (ANSI/CSA) Dual Flashing Light Assembly (ANSI/CSA) Telematics Option - Morey (ANSI/CSA) Telematics Option - ZTR (ANSI/CSA) Telematics Harness (ANSI/CSA) Heavy Duty Pipe Rack Assembly (ANSI/CSA, CE & AS) Residual Current Device Assembly (CE) Aluminum Control Box Guard Assembly (CE) Labels 8. Label Kit Labels - Platform Control Console Labels - Miscellaneous Labels - Left & Right Side Labels - Front, Rear and Top Tables 9. Fluid Table Page 5

6 Notes Page 6

7 .0 PLATFORM RELATED PARTS Gate Latch.0 Half Gate (ANSI/CSA, CE & KC).8 Enable Controller. Full Gate.7 Control Console.3 Main Railing.5 Platform Control Box.2 Extension Handrail Extension Railing..6.9 Quick Release Pin Platform A/C Outlet.5 Extension Platform. Main Platform.3 Page 7

8 . Platform Group 2 3 M69075AE Page 8

9 . Platform Group Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A PLATFORM ASSEMBLY, Full Gate B PLATFORM ASSEMBLY, Half Gate (ANSI/CSA & KC) (Ref.) ASSEMBLY, Main Platform and Extension (For components, refer to Section.2) 2 (Ref.) ASSEMBLY, Railings - Main (For components, refer to Section.5) 3 (Ref.) ASSEMBLY, Railings - Extension (For components, refer to Section.6) (Ref.) ASSEMBLY, Gate Entrance (For components, refer to Section.7), A (For components, refer to Section.8), B Page 9

10 .2 Main Platform and Extension Assembly 2 3 M79AD Page 0

11 .2 Main Platform and Extension Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Main Platform and Extension (Ref.) ASSEMBLY, Platform (For components, refer to Section.3) 2 (Ref.) ASSEMBLY, Extension Deck (For components, refer to Section.) BUMPER, Scissor 0606 NUT, Hex Nylon Lock (3/8-6, Gr. 5) Page

12 .3 Main Platform Assembly M69086AE Page 2

13 .3 Main Platform Assembly Part ASSEMBLY, Platform NOTE: Part Numbers followed by a DG indicate dark grey painted parts WELDMENT, Platform ASSEMBLY, Pin - Rollout ROLLER, Wide 2533 SLIDER, Bushing PIN, Cotter (/ x -/2 ) SLIDER, Roll out SCREW, Rambo - ST3.5 X 3 Page 3

14 . Extension Platform Assembly M69087AD Page

15 . Extension Platform Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Extension Deck WELDMENT, Extension Platform PIN, Roll Out ROLLER, Narrow SLIDER, Bushing STOP, Extension Deck NUT, Hex Nylon Lock (5/6-8, Gr B) BOLT, Button head (5/6-8 x 3/ ) Page 5

16 .5 Main Railings Assembly Places 7 Places Page 6 Places M69097AE

17 .5 Main Railings Assembly Part ASSEMBLY, Railings - Main NOTE: Part Numbers followed by a DG indicate dark grey painted parts RAILING, Main Side Lower LH RAILING, Main Side Lower RH RAILING, Main Side Upper LH RAILING, Main Side Upper RH PLATE, Kick GUARD, Cable PLUG, Plastic - Tube (-/ x -/ ) SPACER, Railing Retainer 9 (Ref.) 7 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) PLATE, Cable Guard Cover - Right Hand 2595 PLATE, Cable Guard Cover - Left Hand RIVET, Pop (/ Diameter x 5/8 ) CLAMP, Single Clip (G8) BOLT, Self Tapping (/ - x 3/ ) NUT, Hex Nylon Lock (5/6-8, Gr B) BOLT, Carriage (5/6-8 x 2 ) WASHER, Flat (/ ) (If equipped) RIVET, Pop (3/6 Diameter x 9/6 ) 9 (Ref.) 2 ASSEMBLY, Pin - Quick Release Small Loop (For components, refer to Section.9) Page 7

18 .6 Extension Railing Assembly Places M9773AC Page 8

19 .6 Extension Railing Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Railings - Extension WELDMENT, Railing - Extension Deck Lower WELDMENT, Railing - Extension Deck Upper 3 (Ref.) 2 ASSEMBLY, Hand Rail - Extension Deck (For components, refer to Section.) TUBE, Round - Extensiond Deck Midrail BOX, Manual NUT, K-Lock (#0-32) WASHER, Flat (#0) SCREW, Round head machine (#0-32 x /2 ) PLATE, Mount - Info/Warning/Manual box 0 (Ref.) 2 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) PLATE, Retainer - Extension Deck Railing PLUG, Plastic tube (-/ x -/ ) BOLT, Hex head (5/6-8 x -3/ ) BOLT, Self tapping (/ - x 3/ ) NUT, Hex Nylon Lock (5/6-8, Gr B) BOLT, Hex Head (3/8-6 x 5/8 ) NUT, Hex Head Jam (3/8-6) Page 9

20 .7 Full Gate Entrance Assembly Places M999AD Page 20

21 .7 Full Gate Entrance Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 9767 ASSEMBLY, Railing - Entrance Left Hand B 9768 ASSEMBLY, Railing - Entrance Right Hand C ASSEMBLY, Full Gate - Hinged WELDMENT, Railing - End Ent. Lower Left Hand, A WELDMENT, Railing - End Ent. Lower Right Hand, B WELDMENT, Railing - End Ent. Upper Left Hand, A 288 WELDMENT, Railing - End Ent. Upper Right Hand, B PLATE, Kick - End Entrance, A, B 6 (Ref.) ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) BOLT, Carriage (5/6-8 x 2 ), A, B NUT, Hex Nylon Lock (5/6-8, Gr B), A, B PLUG, Plastic Tube (-/ x -/ ) BOLT, Self Tapping (/ - x /2 ), A, B WELDMENT, Gate - Lower, C WELDMENT, Gate - Upper, C 3 (Ref.) ASSEMBLY, Door Spring Latch, C (For components, refer to Section.0) 3676 HINGE, Steel (3.5"), C BUMPER, Door, C PLATE, Latch - Gate Stop, C SCREW, Self tapping (/ - x 3/ ), C CLAMP, Aluminum - Door Sweep, C STRIP, Rubber - Door Sweep, C RIVET, Wide Hd (/8" x 0.390"), C HINGE, Spring, C Page 2

22 .8 Half Gate Entrance Assembly (ANSI/CSA, CE & KC) M7989AC Page 22

23 .8 Half Gate Entrance Assembly (ANSI/CSA, CE & KC) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Entrance - Half Gate (ANSI/CSA, CE & KC) ASSEMBLY, Railing - End Entrance WELDMENT, Railing - Upper WELDMENT, Railing - Left Hand WELDMENT, Railing - Right Hand 083 PAD, Entry Railing PLATE, Kick - End Entrance BOLT, Self tapping (/ - x ) 7 (Ref.) 2 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) BOLT, Carriage (5/6-8 x 2 ) NUT, Hex Nylon Lock (5/6-8, Gr B) ASSEMBLY, Half Gate - Hinged WELDMENT, Gate - Half (Ref.) ASSEMBLY, Gate Latch (For components, refer to Section.0) HINGE, Spring PLUG, Tube 990 STRIP, Rubber - Door Sweep CLAMP, Aluminum - Door Sweep BUMPER, Door SCREW, Self tapping (/ - x 3/ ) PLATE, Latch - Gate Stop RIVET, Wide Head Page 23

24 .9 Quick Release Pin Assembly M068AA_2 Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Quick Release Pin - Large Loop PIN, Quick release (3/8 diameter x 2 ) LANYARD, Plastic coated (6 ) BOLT, Hex head (3/8-6 x 2-/2, Gr 5) WASHER, Flat (3/8 ) 0606 NUT, Hex Nylon Lock (3/8-6, Gr. 5) ASSEMBLY, Quick Release Pin - Small Loop PIN, Quick release (3/8 diameter x 2 ) LANYARD, Plastic coated (6 ) BOLT, Self tapping (#8-8 x /2 ) Page 2

25 .0 Gate Latch Assembly M060AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Latch - Gate PIN, Latch GUIDE, Nylon spring PLATE, Gate latch release PIN, Roll (/8 x ) SPRING, Compression Page 25

26 . Extension Handrail Assembly M62535AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Handrail - Extension Deck (Hinged) 9775 HANDRAIL, Extension - Deck PLUG, Slider BOLT, Hex head (5/6-8 x 2 ) 0398 NUT, Hex Nylon Lock (5/6-8, Gr B) 5 (Ref.) 3 ASSEMBLY, Pin - Quick Release Small Loop (For components, refer to Section.9) BOLT, Self tapping (/ - x 3/ ) Page 26

27 Notes Page 27

28 .2 Platform Control Box Assembly 7.25" " 2 Places M6387AD5 Page 28

29 .2 Platform Control Box Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A ASSEMBLY, Control Box (ANSI/CSA, CE, & KC) B ASSEMBLY, Control Box (AS) C ASSEMBLY, Control Box (Long Cable Option) (Ref.) - ASSEMBLY, Control Console (For components, refer to Section.3) PLATE, Outside - Control Box, A, C PLATE, Outside - Control Box, B TUBE, Control Box, A, C PLATE, Guard - Control Box, B RIVET, Pop (3/6 x.0 ), A, C RIVET, Pop (3/6 x /2-3/8 ), B SCREW, Hex Hd (#8-8 x /2 ) WASHER, Lock (5/6 ), A, C WASHER, Lock (8-32 ), B NUT, Hex head (#8-32) SCREW, Round Hd (#8-32 x /2-3/8 ) PLUG (7/8" hole) 0 (Ref.) - CONTROL CABLE, 6 Pin - Platform Control Box (For components, refer to Section 6.2) STRAIN RELIEF HOUSING, Male connector (9 pin) (to controller harness) EDGE MOLDING, Control Box, B CLAMP, Control Cable Railing, C 5 (Ref.) ASSEMBLY, Pin - Quick Release Large Loop, C (For components, refer to Section.9) BOLT, Hex Hd (3/8-6 x 2 ), C NUT, Hex Nylon Lock (3/8-6, Gr. 5), C WASHER, Flat (3/8 ), C Page 29

30 .3 Control Console Assembly L M6368AA Page 30

31 .3 Control Console Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Control Console PLATE, Control Console 2 (Ref.) - ASSEMBLY, Enable Controller (For components, refer to Section.) SWITCH ASSEMBLY, Emergency Stop 705 HEAD, Emergency stop switch 7056 LATCH BLOCK, N.C. contact 706 LED BLOCK, 2V (red) 68 SWITCH ASSEMBLY, Horn 7058 HEAD, Pushbutton 7056 LATCH 705 BLOCK, N.O. contact SWITCH, Toggle - (Lift/Off/Drive) SWITCH, Torque GUARD, Toggle switch SEAL, Panel bushing INDICATOR, Battery charge L (Ref) - LABELS (For components, refer to Section 8.) Page 3

32 . Enable Controller Assembly M520AD Page 32

33 . Enable Controller Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Enable Controller ASSEMBLY, Handle HANDLE, Front Half SCREW, Controller Handle SCREW, Plastite (#-20 x 5/6 ) HOLDER, Micro Switch ASSEMBLY, Rocker Micro - Left/Right Steer 7 3 AXLE, Rocker ROCKER BOOT, Rocker WASHER BOOT, Plunger Switch SPRING SWITCH, Plunger SWITCH, Micro Lever - Enable SCREW, Plastite (#2-28 x /2 ) INSULATOR, Micro COUPLING (8mm) SCREW, Set SCREW (#6-32 x 5/8 ) HANDLE, Back Half NUT, Controller Lever LEVER, Trigger BOOT & GASKET WASHER E-CLIP SCREW WASHER SCREW MICROINSULATOR SWITCH, Micro - Neutral Page 33

34 .5 Platform A/C Outlet Assembly 3 L M9538AB Page 3

35 .5 Platform A/C Outlet Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A ASSEMBLY, Platform A/C Outlet (ANSI) B ASSEMBLY, Platform A/C Outlet (Cable Only) (CE, AS & KC) CABTIRE, /3, A CABTIRE, /3, B ASSEMBLY, Wire - Ground INLET, Connector - 0V 3227 SEAL, Tite Cover - 0V PLATE, Receptacle BOX, Outlet - 0V GFCI, Receptacle BOLT, Hex Hd (/ -20 x ) WASHER, Flat (/ ) WASHER, Lock (/ ) NUT, Hex Hd (/ -20) RIVET, Pop (5/32 x ) RIVET, Pop (/ x 0.70 ) 5663 PLATE, Cover - Ontario Hydro 0 (Without Gate) PLATE, Cover - Ontario Hydro 0 (With Gate) L (Ref) - LABELS (For components, refer to Section 8.) Page 35

36 Notes Page 36

37 2.0 SCISSOR RELATED PARTS 2.2 Scissors - Mounting Hardware 2.3 Scissors - Connecting Hardware 2 2. Scissors 2.7 Limit Switch Lift Cylinders 2. Pressure Switch (KC) Holding Valve Manifold Flashing Light Assembly 2.8 Horn 2.6 Hydraulic Hose Connections - Scissors 2.9 Load Sensing and Transducer Module (CE & AS) Page 37

38 2. Scissor Group Page M705AB

39 2. Scissor Group Part ASSEMBLY, Scissors NOTE: Part Numbers followed by a DG indicate dark grey painted parts WELDMENT, Scissor - Inside (Level ) WELDMENT, Scissor - Inside (Level 2) WELDMENT, Scissor - Inside (Level 3) 208 WELDMENT, Scissor - Inside (Level ) WELDMENT, Scissor - Inside (Level 5) WELDMENT, Scissor - Inside (Level 6) WELDMENT, Scissor - Outside (Level ) WELDMENT, Scissor - Outside (Level 2) WELDMENT, Scissor - Outside (Level 3) WELDMENT, Scissor - Outside (Level,5 & 6) 3080 BUMPER, Scissor - Bottom BOLT, Hex Head (M2-.25 x 6mm) WASHER, Flat (M2) BUMPER, Scissor - Upper SCREW, Machine (3/8-6 x 5/8 ) CLAMP, Single (G0) CLAMP, Double (G0) BOLT, Hex Hd (3/8-6 x 7/8 ) WASHER, Flat (3/8 ) WASHER, Flat (7/8 ) ASSEMBLY, Stand - Upper Maintenance Support WELDMENT, Stand - Upper Maintenance Bar BOLT, Hex Hd (5/6-8 x 2-3/ ) NUT, Hex Nylon Lock (5/6-8, Gr B) ASSEMBLY, Stand - Lower Maintenance Support WELDMENT, Stand - Lower Maintenance Bar BOLT, Hex Hd (5/6-8 x 2-3/ ) NUT, Hex Nylon Lock (5/6-8, Gr B) 23 (Ref) - ASSEMBLY, Scissor Mounting Hardware (For components, refer to Section 2.2) 2 (Ref) - ASSEMBLY, Scissor Connecting and Limit Switch Pins Hardware (For components, refer to Section 2.3) 25 (Ref) 2 ASSEMBLY, Lift Cylinder and Mounting Hardware (For components, refer to Section 2.) 26 (Ref) 2 ASSEMBLY, Manifold - Holding Valve (For components, refer to Section 2.5) 27 (Ref) HOSE CONNECTIONS, Scissors (For components, refer to Section 2.6) Page 39

40 2.2 Scissor Mounting Hardware Assembly Platform Slider Assembly 2 Places Platform Mounting Bracket Assembly 2 Places Base Slider Assembly 2 Places Base Mounting Assembly 2 Places M705AB_MountHardware Page 0

41 2.2 Scissor Mounting Hardware Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts PIN, Inside Scissors (3/ dia. x ) PIN, Cotter (/ x -/2 ) BEARING, Plain (3/ I.D. x 7/8" O.D. x -/2 ) 2570 CASTING, Bracket - Platform Mount SHIM, Platform Mount (0.035 ) PIN, Roller - Bottom ROLLER, Scissor SPACER, Pin - Bottom Roller PIN, Upper Slider CASTING, Slider - Platform PAD, Slider SPACER, Slider BOLT, Hex Hd (/ -20 x 5/8 ) WASHER, Flat (/ ) WASHER, Lock (/ ) Page

42 2.3 Scissor Connecting Hardware Assembly End Pin Assembly - Small Pin Places End Pin Assembly - Big Pin 0 Places Center Pin Assembly 2 Places Limit Switch Pin Assemby Place M705AB_ConnectHardware Page 2

43 2.3 Scissor Connecting Hardware Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts PIN, Inside Scissors (3/ DIA x ) PIN, Inside Scissors (" DIA x -9/6") BEARING, Plain (3/ I.D. x.5 ) PIN, Cotter (/ x -/2 ) 233 BEARING, Plain (-/ I.D. x.0" O.D. x -3/6 ) PIN, Center Scissor PIN, Cotter (5/6 DIA x 2 ) WASHER, Thrust (/6 ) WASHER, Flat (/8 ) WASHER, Flat - Nylon (/8 ) BOLT, Hex Hd (3/8-6 x 7/8 ) 0372 WASHER, Flat (3/8 ) PIN, Limit Switch - Scissors BEARING, Plain ( I.D. x -/8" O.D. x -/2") Page 3

44 2. Lift Cylinder Assembly and Mounting Hardware M9758AA_ Page

45 2. Lift Cylinder Assembly and Mounting Hardware Part A 9758 ASSEMBLY, Cylinder - Upper B 9756 ASSEMBLY, Cylinder - Lower NOTE: Part Numbers followed by a DG indicate dark grey painted parts Cylinder, Lift -.0 x GLAND WELDMENT, Rod WELDMENT, Tube SPACER ROD EYE BOLT, Hex (3/"-6 x 3") PISTON 9 (Ref.) - ASSEMBLY, Manifold - Holding Valve (For components, refer to Section 2.5) WELDMENT, Pin 0550 ORIFICE, One Way (3/32 dia) SEAL, O-Ring FITTING, 90D Elbow (06 JICM - 0 ORBM), A FITTING, Tee (06 JICM - 06 JICM - 06 ORBM), B BOLT, Hex head (5/6-8 x 2 ) BOLT, Hex Hd (3/8-6 x ) WASHER, Flat (5/6 ) WASHER, Lock (5/6 ) WASHER, Flat (3/8 ) 9 83 BUSHING, Fiberglide (-/2 dia x -/ ) K 9920 KIT, Seal (Not Shown) Page 5

46 2.5 Holding Valve Manifold Assembly Lower Cylinder Manifold 3 2 M95256AC Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Manifold - Holding 30 ASSEMBLY, Manifold - Transducer Auxilary Lowering 3037 MANIFOLD, Transducer Auxilary Lowering PLUG, Expander VALVE, Relief VALVE, Poppet - Solenoid Cartridge 2250 FITTING, Plug (0 ORB Hex) (ANSI/CSA & KC only) COIL (20 VDC) 6 33 ASSEMBLY, Pressure Transducer (CE & AS only) TRANSDUCER, Pressure PSI SET SCREW, Cup (#8-32 x /8") LABEL, Mylar Cable Page 6

47 2.6 Hydraulic Hose Connections - Scissors 2 M78AB Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts HOSE CONNECTIONS, Scissors H HOSE, Hydraulic (Main Manifold to Lower Cylinder Tee) 2 H HOSE, Hydraulic (Lower Cylinder Tee to Upper Cylinder) Page 7

48 2.7 Scissors Limit Switch Assembly M95393AB, M30559AD Page 8

49 2.7 Scissors Limit Switch Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Limit Switch - Scissors SUB-ASSEMBLY, Limit Switch - Scissors LIMIT SWITCH, Scissors LIMIT SWITCH, Sealed CONNECTOR, Receptacle - 8 Pin CONNECTOR, Receptacle - 8 Pin Wedge CONNECTOR, Contact Pin LABEL, LSA LABEL, LSB LABEL, LS BRACKET, Limit Switch GUARD, Limit Switch WASHER, Lock (/ ) BOLT, Hex Hd (/ -20 x -3/ ) NUT, Hex Hd (/ -20, Gr 8) WASHER, Flat (/ ) BOLT, Hex Hd (/ -20 x -/ ) BUSHING, Snap-In (3/ I.D) CLAMP, Gear #0 (2-/2 ) CAM, Limit Switch WASHER, Flat (#0) NUT, Lock (#0-32) SCREW, Round Hd (0-32 x 5/8 ) CLAMP, Single Page 9

50 2.8 Horn Assembly 2 3 M668AA_2 Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Horn 569 NUT, Hex (/ -20) BOLT, Hex Hd (/ -20 x ) WASHER, Flat (/ ) 669 HORN, 2V - Low Tone Page 50

51 2.9 Load Sensing and Transducer Module Assembly (CE & AS) M972AB Part NOTE : Part Numbers followed by a DG indicate dark grey painted parts. A 9958 ASSEMBLY, Load Sensing (CE) B 972 ASSEMBLY, Load Sensing (AS) 300 TRANSDUCER, Angle BEEPER, SP MODULE, Overload Sensing Controller, A MODULE, Overload Sensing Controller, B 3068 BRACKET, Control Module SCREW, Round Hd (#0-32 x -/") SCREW, Round Hd (#0-32 x ") SCREW, Round Hd (#6-32 x 5/8") WASHER, Flat (#0) WASHER, Flat (#6) WASHER, Flat (/") WASHER, Lock (#0) WASHER, Lock (#6) WASHER, Lock (/") NUT, Hex (#0-32) NUT, Hex (#6-32) BOLT, Hex Hd (/"-20 x 5/8") Page 5

52 2.0 Pressure Switch Assembly (KC Only) 2 M97698AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Pressure Switch (KC only) SWITCH, Pressure (0ORSM) FITTING, Straight (0ORBM-0ORSF) Page 52

53 2. Flashing Light Assembly M738AA_ Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 738 ASSEMBLY, Flashing Light (ANSI/CSA & KC) B 322 ASSEMBLY, Flashing Light (CE & AS) 26 LIGHT, Beacon - With Terminals, A 277 LIGHT, Beacon - 2V, B 653 BULB, Dual Contact - 2V WASHER, Lock (/2") NUT, Hex Hd (/2"-20) 0373 FLASHER, 2-2 Volt, A CLAMP, Plastic (-/ ), A BOLT, Machined (#0-32 x /2 ), A NUT, Machined (#0-32), A INSTRUCTIONS, Flashing Light Page 53

54 Notes Page 5

55 3.0 BASE RELATED PARTS Drive Manifold 3.5 Brake Release Manifold 3.6 Counter Reset (CE) Tilt Switch and Bracket (ANSI/CSA & KC) Base Control Base Group 3. 3 Wheels Rear Brakes Pothole Protection Device 3.2 Front Hub 3.3 Steer Cylinder 3.7 Hydraulic Hose Connections - Base Page 55

56 3. Base Assembly M7053AD Page 56

57 3. Base Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts GROUP, Base ASSEMBLY, Base 6926 WELDMENT, Base SWITCH, Main Power Disconnect TRIM, Protective / - / BOLT, Carriage (/2-3 x -/2 ) NUT, Hex Hd Jam (/2-3) COVER, Spacer WASHER, Lock (/ ) BOLT, Hex Hd (/ -20 x 5/8 ) ASSEMBLY, Base Cover WELDMENT, Cover PLATE, Base Cover - Rear 30 8 RIVET, Pop (/ x 0.70 ) ASSEMBLY, Static Trap STRAP, Ground BOLT, Hex Hd (3/8-6 x 3/ ) WASHER, Lock (3/8 ) NUT, Hex Hd (3/8-6) 3 (Ref.) 2 ASSEMBLY, Front Hub (For components, refer to Section 3.2) (Ref.) ASSEMBLY, Cylinder - Steer (For components, refer to Section 3.3) 5 (Ref.) 2 ASSEMBLY, Rear Brake (For components, refer to Section 3.) 6 (Ref.) ASSEMBLY, Manifold - Drive (For components, refer to Section 3.5) 7 (Ref.) ASSEMBLY, Manifold - Brake Release (For components, refer to Section 3.6) 8 (Ref.) HOSE CONNECTIONS, Base (For components, refer to Section 3.7) 9 (Ref.) ASSEMBLY, Pothole Protection - Battery and Hydraulic Tray (For components, refer to Section 3.8) 20 (Ref.) ASSEMBLY, Wheels (For components, refer to Section 3.9) 2 (Ref.) ASSEMBLY, A/C Outlet (For components, refer to Section.5) 22 (Ref.) ASSEMBLY, Tilt Switch and Bracket (ANSI/CSA and KC) (For components, refer to Section 3.0) 22 (Ref.) ASSEMBLY, Counter Reset (CE) (For components, refer to Section 3.2) 23 (Ref.) ASSEMBLY, Base Control (For components, refer to Section 3.) 2 (Ref.) ASSEMBLY, Battery Tray (For components, refer to Section 5.) 25 (Ref.) ASSEMBLY, Hydraulic Tray (For components, refer to Section.) Parts list continued on the following page. Page 57

58 3. Base Assembly (Continued) M7053AD Page 58

59 3. Base Assembly (Continued) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. Parts list continued from the previous page ASSEMBLY, Ladder WELDMENT, Ladder BOLT, Hex Hd (3/8-6 x ) WASHER, Lock (3/8 ) WASHER, Flat (3/8 ) COUNTERWEIGHT (ANSI) COUNTERWEIGHT (CE/AS/KC) BOLT, Hex Hd (/2-3 x 2-/ ) WASHER, Flat (/2 ) NUT, Lock (/2-3) Page 59

60 3.2 Front Hub Assembly K M9898AD_2 Page 60

61 3.2 Front Hub Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 9898 ASSEMBLY, Front Hub - Hydraulic Side B 9899 ASSEMBLY, Front Hub - Battery Side 987 WELDMENT, Housing - Wheel Motor, A 9875 WELDMENT, Housing - Wheel Motor, B MOTOR, Wheel cu.in BEARING, Front Roller 9762 NUT (-/8"-8) SHAFT KEY, Rounded (-/2") BUSHING, Center Boss BUSHING, Center Boss WASHER, Kingpin ASSEMBLY, Pin - Steering Long ASSEMBLY, Pin - Steering Short ASSEMBLY, Arm - Steering 9752 ARM, Steering FITTING, Straight - Grease (/ -28) PIN, Cylinder End 7362 HUB, -/ WASHER, Lock - Internal Tooth (-/8 ) FITTING, 90D (08JICM - 0ORBM) WASHER, Flat - Hard (/2 ) WASHER, Lock (/2 ) WASHER, Lock (5/6 ) BOLT, Hex Hd (/2-3 x 3 ) BOLT, Hex Hd (5/6-8 x 5/8 ) RETAINER, Drive Link SCREW, FHCS (/ -20 x ) PIN, Cotter (/8 dia x -/2 ) K SEAL KIT (Not Shown) Page 6

62 3.3 Steer Cylinder Assembly K K 3 K K M9823AB Part ASSEMBLY, Cylinder - Steer NOTE: Part Numbers followed by a DG indicate dark grey painted parts CYLINDER, Steer 9982 TUBE WELDMENT, ROD AND PISTON ROD COVER SPACER END, Rod - Steel Ball Joint w/ Grease Fitting FITTING, Straight (06JICM - 06ORBM) ORIFICE, Steer (0.035") NUT, Hex Hd (3/ -6) WASHER, Lock - Internal Tooth ( ) NUT, Hex Hd ( -) K 9987 SEAL KIT Page 62

63 3. Rear Brake Assembly M7057AD Part ASSEMBLY, Rear Brake NOTE: Part Numbers followed by a DG indicate dark grey painted parts BRAKE, Rear NUT (-/8"-8) SHAFT KEY, Rounded (-/2") 9270 BOLT, Hex Hd (/2-3 x ) WASHER, Flat (/2 ) NUT, Lock (/2-3) FITTING, Straight (0JICM - 0ORBM) FITTING, Plug (07 ORBM) WASHER, Lock - Internal Tooth (-/8 ) HUB, -/2 (Ref.) - BRAKE OIL, SAE 20W (For components, refer to Section 9.0) Page 63

64 3.5 Drive Manifold Assembly M732AC Page 6

65 3.5 Drive Manifold Assembly Part ASSEMBLY, Manifold - Drive NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 785 MANIFOLD, Drive ORIFICE, Plug - Crossover (0.020 ) ORIFICE, Disc - Differential (0.00") VALVE, Solenoid - 3-Way Spool VALVE, Solenoid - 2-Way Spool VALVE, Flow Divider VALVE, Needle - Positive Shut-Off COIL, 20 VDC COIL, 20 VDC FITTING, 90D (06JICM - 08ORBM) FITTING, 90D (0JICM - 0ORBM) FITTING, Straight (08JICM - 08ORBM) PLUG, Port (#) FITTING, Straight (6 SAE - JIC) WASHER, Flat (3/8 ) WASHER, Lock (3/8 ) BOLT, Hex Hd (3/8-6 x ) Page 65

66 3.6 Brake Release Manifold Assembly M3653AE Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Manifold - Brake Release MANIFOLD, Brake Release 6563 BLOCK, Manifold - Brake Release ASSEMBLY, Valve HANDLE, Valve ASSEMBLY, Pump HANDLE, Pump FITTING, Straight ( JIC) BOLT, Hex head (3/8-6 x 7/8, Grade 8) WASHER, Flat (3/8 ) WASHER, Lock (3/8 ) K 656 SEAL KIT (Not Shown) Page 66

67 3.7 Hydraulic Hose Connections - Base M7323AB Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts HOSE CONNECTIONS, Base HOSE, Hydraulic (Drive Manifold BRP. to Brake Manifold) HOSE, Hydraulic (Drive Manifold M to Right Motor A) HOSE, Hydraulic (Drive Manifold M2 to Left Motor B) 968 HOSE, Hydraulic (Drive Manifold M3 to Right Motor B) HOSE, Hydraulic (Drive Manifold M to Left Motor A) HOSE, Hydraulic (Hose Main Manifold H-2 to Steer - LH Turn) HOSE, Hydraulic (Hose Main Manifold H-23 to Steer - RH Turn) 8 H HOSE, Hydraulic (Left Brake to Brake Manifold) 9 H HOSE, Hydraulic (Right Brake to Brake Manifold) SLEEVE, Nylon - Hose Protection (HG-28) 09 0 SLEEVE, Nylon - Hose Protection (HG-28) Page 67

68 3.8 Pothole Protection Assembly M70235AB Page 68

69 3.8 Pothole Protection Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 6935 ASSEMBLY, Pothole Bar - Hydraulic Side B 693 ASSEMBLY, Pothole Bar - Battery Side LOCK, Tray cam PIN, Pothole Hinge PIN, Spring (0.09 x ) PIN, Spring (0.09 x ) PIN, Lock - Stainless BUSHING, Fiberglide (3/8 dia x 5/8 ) BUSHING, Fiberglide (7/6 dia x 3/8 ) WELDMENT, Angle - Pothole Bar Hydraulic Side, A WELDMENT, Angle - Pothole Bar Battery Side, B ASSEMBLY, Pothole Protection BAR, Pothole Lever BUSHING, Fiberglide (7/6 dia x /2 ) PIN, Cotter (3/32" x PIN, Clevis (7/6 dia x -/ ) ASSEMBLY, CAM LOCK PIN, Guide - Pothole Spring (3/ dia x 8 ) 878 LOCK, Driver - Pothole 5 93 SPRING, Pothole LOCATOR, Pothole Pin BUSHING, Self Lubricating (3/ dia x ) LOCK, Cam - Pothole WASHER, Flat (-/6 ) PIN, Spring (3/32 dia x -3/8 ) ASSEMBLY, Compression Rod - Pothole ROD ASSY, Pothole Compression BOLT, Carriage (3/ -0 x 2, Gr 5) NUT, Hex Hd (3/ -0, Gr B) BAR, Kicker - Pothole PIN, Clevis (7/6 x 53/6 ) SPRING, Compression - Pothole GUARD, Pothole - Battery Side GUARD, Pothole - Hydraulic Side PIN, Clevis (7/6 x -3/ ) SCREW, Socket Hd (#8-32 x -/ ) NUT, Lock - Nylon (#8-32) WASHER, Flat (7/6 ) SET SCREW, Square Hd (3/8-6 x 3/, Gr 5 ZN) BUSHING, Handrail Slide BOLT, Hex Hd (/"-20 x /2", Gr 5) WASHER, Lock (/ ) WASHER, Flat (/ ) LIMIT SWITCH, Pothole - Hydraulic Tray, A (ANSI/CSA & KC) LIMIT SWITCH, Pothole - Hydraulic Tray, A (CE & AS) LIMIT SWITCH, Pothole - Battery Tray, B (ANSI/CSA & KC) LIMIT SWITCH, Pothole - Battery Tray, B (CE & AS) Page 69

70 3.9 Wheel Assembly 2 M689AB Part ASSEMBLY, Wheel NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 689 TIRE, Grey - Non-Marking (6x5x2) BOLT, Wheel Page 70

71 3.0 Tilt Switch and Bracket Assembly (ANSI/CSA & KC) M7376AC Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Tilt Switch and Bracket (ANSI/CSA & KC) 7560 ASSEMBLY, Tilt Switch (.5 x 3.5) WASHER, Lock (/ ) NUT, Hex Hd (/ -20, Gr 8) BOLT, Hex Hd (/ -20 x, Gr 5) PLATE, Mount - Tilt Switch NUT, Machine (#0-32) SCREW, Round Hd (#0-32 x 5/8 ) WASHER, Lock (#0) Page 7

72 3. Base Control Assembly L A B C D E F 2 8 M7693AC Page 72

73 3. Base Control Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 7693 ASSEMBLY, Base Control (ANSI/CSA & KC) B 777 ASSEMBLY, Base Control (CE) C ASSEMBLY, Base Control (AS) ASSEMBLY, Cover - Base Control COVER, Base Control ASSEMBLY, Key Switch - 3 Way (Off/Platform/Base), A, C ASSEMBLY, Key Switch - 3 Way (Off/Platform/Base), B HEAD, Key Switch - 3 Position, A, C HEAD, Key Switch - 3 Way, B 2 37 HOUSING, Connector - 6 Way NUT, Key Switch KEY, # BOOT, Key Switch ASSEMBLY, Switch - Emergency Stop SWITCH HEAD, Emergency Stop BLOCK, Contact (N.C.) BLOCK, Led - 2V (Red) LATCH 977 ASSEMBLY, Key Switch - 2 Way (Lower/Neutral/Raise) 7069 SWITCH HEAD, Selector BLOCK, Contact (N.O.) 7056 LATCH CONNECTOR, Receptacle CONNECTOR, Wedge CONNECTOR, Contact Pin CONTROL CABLE, 6/ PLATE, Mount - Base Control L (Ref.) - LABELS (For components, refer to Section 8.) WASHER, Lock (/ ) BOLT, Hex Hd (/ -20 x 3-/ ) Page 73

74 3.2 Counter Reset (CE) M9903AA Part NOTE : Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Counter Reset (CE only) BRACKET, 0V Outlet BOX, 0V Outlet - Assembled COVER, Black - 0V Outlet (Ref.) HARNESS, Reset Fuse (For components, refer to Section 6.5) BOLT, Hex Hd (/ -20 x, Gr 5) BOLT, Hex Hd (/"-20 x 3/", Gr 5) WASHER, Flat (/") WASHER, Lock (/") NUT, Hex Hd (/ -20, Gr 8) Page 7

75 .0 HYDRAULIC TRAY RELATED PARTS.6 Hydraulic Hose Connections - Hydraulic Tray. Hydraulic Tray. Pump and Motor Emergency Lowering.3 Hydraulic Tank Lid.2 Main Manifold.5 Page 75

76 . Hydraulic Tray Group Detail A Detail A TO MAIN DISCONNECT + TO BATTERY TRAY M9532AB_ Page 76

77 . Hydraulic Tray Group Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A ASSEMBLY, Hydraulic Tray (ANSI) B ASSEMBLY, Hydraulic Tray (CE/AS/KC) ASSEMBLY, Tray - Hydraulic WELDMENT, Tray - Hydraulic 2 (Ref.) ASSEMBLY, Pothole Protection (For components, refer to Section 3.8) ASSEMBLY, Latch - Hydraulic Tray Rotary 2307 LATCH, Rotary NUT, Hex Hd (/ -20, Gr 8) BOLT, Hex Hd (5/6-8 x ) BOLT, Hex Hd (/ -20 x, Gr 5) WASHER, Lock (/ ) 9 53 KNOB, Latch INSTALLATION, Tray to Base PIN, Eccentric - Upper Tray ( dia x 2-/6 ) 8983 PIN, Bottom Tray (0.750 dia x -7/8 ) TRIM, Protective - Standard Double Lip BUSHING, Bronze ASSEMBLY, Plug - Tank (3/ -6 Magnetic Thread) 9606 PLUG, Drain - Magnetic Thread Gasket WASHER, Drain Sealing Plug 6 80 BOLT, Carriage (3/8-6 x ) BOLT, Carriage (/2-3 x -/2 ) NUT, Hex jam (/2-3) NUT, Hex jam (3/8-6) 20 (Ref.) ASSEMBLY, Lid - Hydraulic Tank (For components, refer to Section.2) ASSEMBLY, Cylinder - Cushion CYLINDER, Cushion BRACKET, Conduit WASHER, Flat (/ ) WASHER, Lock (/ ) BOLT, Hex Hd (/"-20 x /2", Gr 5) WELDMENT, Counterweight - Hydraulic Tray 27 (Ref.) ASSEMBLY, Motor/Pump -.8CC (For components, refer to Section.) BOLT, Hex head (/2-3 x 3-3/ ) WASHER, Flat (/2 ) WASHER, Lock (/2 Gr 5) ASSEMBLY, Level Indicator INDICATOR, 3 Level BOLT, Hex head (/ -20 x /2 ) Parts list continued on the following page. Page 77

78 . Hydraulic Tray Group (Continued) Detail A Detail A TO MAIN DISCONNECT + TO BATTERY TRAY M9532AB_ Page 78

79 . Hydraulic Tray Group (Continued) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. Parts list continued from the previous page SUBGROUP, Motor Controller ASSEMBLY, Motor Controller CONTROLLER, Pump/Motor (2VDC, 360 Amp) BOLT, Hex Hd (/"-20 x 3/", Gr 5) BOLT, Hex Hd (/ -20 x, Gr 5) WASHER, Lock (/ ) WASHER, Flat (/ ) CLIP, Double (G0) NUT, Hex Hd (/ -20, Gr 8) ASSEMBLY, Contactor KIT, Contactor - Motor Controller BOLT, Hex Hd (/"-20 x /2", Gr 5) WASHER, Flat (/ ) WASHER, Lock (/ ) KIT, Power Cable 9550 CABLE, Welding - Main Contactor Positive to Main Disconnect Positive CABLE, Welding - Main Contactor Negative to Battery Negative CABLE, Welding - Battery Tray Negative to Battery Negative CABLE, Welding - Pump/Motor Positive to Motor Positive CABLE, Welding - Pump/Motor Negative to Battery Negative INSULATOR, Boot (Red) 50 (Ref.) - ASSEMBLY, Manifold - Main (For components, refer to Section.5) BOLT, Hex head (3/8-6 x 2-/2, Gr 5) WASHER, Flat (3/8 ) WASHER, Lock (3/8 ) 5 (Ref.) - ASSEMBLY, Emergency Lowering (For components, refer to Section.3) ASSEMBLY, Hose - Suction HOSE, Tank Truck (3/ x.00 ) CLAMP, Worm (#2) 57 (Ref.) - HOSE CONNECTIONS, Hydraulic Tray (Not Shown) (For components, refer to Section.6) 58 (Ref.) - OIL, Hydraulic (Not Shown) (For components, refer to Section 9.0) Page 79

80 .2 Hydraulic Tank Lid Assembly M29602AD Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Lid - Hydraulic Tank 09267DG WELDMENT, Hydraulic Tank Lid ASSEMBLY, Manifold - Manual Lowering w/ Fittings SUB-ASSEMBLY, Manifold - Manual Lowering 2 32 MANIFOLD, VC PLUG, Expander 0727 VALVE, Directional - Manual FITTING, Straight - Connector (06 JICM - 06 ORBM) FILTER, Hydraulic Inlet FITTING, Straight - Connector (#2 ORB - #6) HOSE, Filter to Tank Clamp, Gear - # ASSEMBLY, Filler/Cap SCREW, Machine (#0-32 x /2 ) GASKET, Hydraulic tank BOLT, Hex head (5/6-8 x ) NUT, Hex Nylon Lock (5/6-8, Gr B) Page 80

81 .3 Emergency Lowering Assembly M95582AC Part NOTE : Part Numbers followed by a DG indicate dark grey painted parts ASSEMBLY, Emergency Lowering ASSEMBLY, Toggle Switch - E-Lower 9900 SWITCH, Toggle - SPST BRACKET, Switch - E-Lower BREAKER, 0 Amp 692 SCREW, Round Hd (#8-32 x 5/8 ) NUT, Lock (#8-32) COVER, Breaker - Red COVER, Breaker - Black (Switch) CAP, Toggle Switch - Red 9 (Ref.) HARNESS, Emergency Lowering Switch (For components, refer to Section 6.5) 0 (Ref.) HARNESS, Breaker Assembly (For components, refer to Section 6.5) Page 8

82 . Motor and Pump Assembly Page 82 M9532AB

83 . Motor and Pump Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts GROUP, Motor/Pump -.8cc ASSEMBLY, Motor/Pump -.8cc MOTOR, 2VDC PUMP, Hydraulic FITTING, 90 (2 BEAD - 0 ORBM) 9999 BOLT, Socket Hd (M8 x 95, CL2.9 ZN) (Not Shown) KIT, Brush Repair (Not Shown) DG PLATE, Mount - Motor Universal BOLT, Hex Hd (5/6-8 x 3/ ) WASHER, Flat (5/6 ) WASHER, Lock (5/6 ) FITTING, Elbow 90 (06 JICM - 08 ORBM) K KIT, Seal (Not Shown) Page 83

84 .5 Main Manifold Assembly M96592AC_ Page 8

85 .5 Main Manifold Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 2002 ASSEMBLY, Manifold - Main (ANSI) B 2003 ASSEMBLY, Manifold - Main (CE/AS/KC) 0735 MANIFOLD, Main 9 BLOCK, Manifold PLUG, Expander FITTING, Plug (#8) COIL, 2 Volt VALVE, 3-Way VALVE, System Relief COIL, 2 Volt VALVE, Solenoid PLUG (#3) FITTING, Plug (06 ORBM) VALVE, Counterbalance 09 PLUG (/6 NPT) FITTING, Straight (06 JICM - 06 ORBM), A FITTING, Straight (06 JICM - 06 ORBM), B 3 58 FITTING, Tee (06 JICM - 06 ORBM - 06 JICM) 580 FITTING, Elbow 5 (06 JICM - 06 ORBM) FITTING, Elbow 90 (06 JICM - 0 ORBM) NUT, Cap (06 JICF), A ASSEMBLY, Quick Disconnect, B COUPLER, B 6 52 COVER, Dust, B FITTING, Straight (06 ORBM - 06 ORBM), B VALVE, Solenoid VALVE ASSY, Directional COIL, 2 Volt VALVE ASSY, Directional - Open Center BOLT, SHC (#0-2 x 2 ) BOLT, SHC (#0-2 x -3/ ) HOSE, Hydraulic Line (Main Manifold to Cushion Cylinder) ORIFICE, Pressure Plug (0.3 ) BUMPER, Rubber Male SCREW, Hex Hd Machine (/ -20 x ) Page 85

86 .6 Hydraulic Hose Connections - Hydraulic Tray M9532AB_Hoses Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. H HOSE, Hydraulic (Main Manifold to Pump Outlet) HOSE, Hydraulic (Main Manifold to Manual Lowering Valve) HOSE, Hydraulic (Main Manifold to Filter Inlet) 3775 HOSE, Hydraulic (Drive Manifold Brake to Main Manifold Brake) HOSE, Hydraulic (Main Manifold H-6 to Drive Manifold IN) HOSE, Hydraulic (Main Manifold H-5 to Drive Manifold INR) Page 86

87 5.0 BATTERY TRAY RELATED PARTS Battery Tray Assembly 5. Battery Battery Charger 5 Page 87

88 5. Battery Tray Assembly M6933AC Page 88

89 5. Battery Tray Assembly Part ASSEMBLY, Battery Tray NOTE: Part Numbers followed by a DG indicate dark grey painted parts WELDMENT, Battery Tray ASSEMBLY, Latch - Battery Tray Rotary LATCH, Rotary Right Hand BOLT, Hex head (5/6-8 x ) BOLT, Hex Hd (/ -20 x, Gr 5) WASHER, Lock (/ ) NUT, Hex Hd (/ -20, Gr 8) 8 53 KNOB, Latch INSTALLATION, Tray to Base PIN, Eccentric - Upper Tray (.00 dia x 2-/6 ) PIN, Bottom Tray (3/ dia x -7/8 ) BUSHING, Bronze 2 80 BOLT, Carriage (3/8-6 x ) BOLT, Carriage (/2-3 x -/2 ) NUT, Hex jam (3/8-6) NUT, Hex jam (/2-3) 6 (Ref.) - ASSEMBLY, Pothole Protection (For components, refer to Section 3.8) Page 89

90 5.2 Battery Assembly L L M78AD Page 90

91 5.2 Battery Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 78 - ASSEMBLY, Battery - Standard (ANSI/CSA, CE & KC) B ASSEMBLY, Battery - Standard (AS) C ASSEMBLY, Battery - AGM (ANSI/CSA & CE) PLYWOOD (3/8" x " x 33"), A, C NEOPRENE SHEET (/" x " x 28.50"), B SPACER, Plastic (2" x 3" x ") BATTERY, 2V, A, B BATTERY, 2V - AGM, C INSULATOR, Boot - Black INSULATOR, Boot - Red INSULATOR, Boot - Red CABLE, Welding - #Ga (5/6" x 6" x 5/6") CABLE, Welding - #Ga (5/6" x 0" x 5/6") CABLE, Battery - 300A In-line Fuse CABLE, Welding - #Ga (5/6" x 8" x 3/8") (+,+) INSULATOR, Fuse TERMINAL, Boot - Red WASHER, Lock (/") WASHER, Flat (/") BOLT, Hex Hd (/"-20 x /2", Gr 5) L (Ref.) - LABELS (For components, refer to Section 8.) Page 9

92 5.3 Charger Assembly 3 2 M97633AA Page 92

93 5.3 Charger Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A ASSEMBLY, Charger - Signet (ANSI/CSA & AS) B ASSEMBLY, Charger - Signet (CE & KC) C ASSEMBLY, Charger - AGM (ANSI/CSA) D ASSEMBLY, Charger - AGM (CE) 707 CHARGER, 750W Chord - Signet, A 708 CHARGER, 750W Socket - Signet, B 9975 CHARGER, 750W Chord - AGM, C CHARGER, 750W Socket - AGM, D BOLT, Hex Hd (/"-20 x 3/", Gr 5) WASHER, Flat (/") 0000 WASHER, Lock (/") CORD, Charger - 220V, B, D Page 93

94 Notes Page 9

95 6.0 ELECTRICAL RELATED PARTS 6 Electrical Panel Control Cable Assembly Rear Manifold Harness Main Manifold Harness 6.5 Electrical Panel Harnesses 6.6 Battery Cables 6.7 Dual Flashing Light Harness 6.8 RST Wire Assembly Page 95

96 6. Electrical Panel Assembly KC CE/AS 7 ANSI/CSA L M96050AB_ Page 96

97 6. Electrical Panel Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A ASSEMBLY, Electrical Panel (ANSI/CSA) B ASSEMBLY, Electrical Panel (CE) C ASSEMBLY, Electrical Panel (AS) D ASSEMBLY, Electrical Panel (KC) - - ASSEMBLY, Electrical Panel 63057DG WELDMENT, Electrical Panel HOURMETER, Digital, A, C, D HOURMETER, Counter, B BREAKER, Circuit - 5 Amp RELAY, 2 Volt, A RELAY, 2 Volt, B RELAY, 2 Volt, C RELAY, 2 Volt, D CLAMP, Plastic (-/ ) TERMINAL BLOCK, 9P TERMINAL BLOCK, 2P BUMPER, Rubber - Female SCREW, Round Hd (#6-32 x ) SCREW, Round Hd (#0-32 x /2 ), A SCREW, Round Hd (#0-32 x /2 ), B SCREW, Round Hd (#0-32 x /2 ), C SCREW, Round Hd (#0-32 x /2 ), D SCREW, Round Hd (#8-32 x /2 ) NUT, Hex (#6-32) NUT, Hex (#0-32), A NUT, Hex (#0-32), B NUT, Hex (#0-32), C NUT, Hex (#0-32), D NUT, Hex (#8-32) WASHER, Lock (#0), A WASHER, Lock (#0), B WASHER, Lock (#0), C WASHER, Lock (#0), D WASHER, Lock (/ ) WASHER, Flat (/ ) NUT, Hex Hd (/ -20, Gr 8) BOLT, Hex Hd (/ -20 x 5/8 ) BEEPER, Slow Pulsing - -28VDC, A BEEPER, Slow Pulsing - -28VDC, D PLUG (-/8 dia), A PLUG (-/8 dia), B, C RESISTOR ASM,.5 Ohm, A, B, C RESISTOR ASM, 7.5 Ohm - AGM Option A, B BOLT, Hex Hd (/"-20 x /2", Gr 5) WASHER, Lock (/ ) CLAMP, Single, A, C, D CLAMP, Single, B L (Ref.) - LABELS (For components, refer to Section 8.) Page 97