2017 PARTS MANUAL STOCKCHASER IS-12

Transcription

1 2017 PARTS MANUAL STOCKCHASER IS-12

2 IS Parts Manual Revision #0 Dated 7/1/2016 Preface Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your vehicle has been designed and manufactured to conform to applicable sections of ANSI B56.8. Your safe use and operation of your vehicle is important to us. Any alteration of your Columbia vehicle that results in the vehicle being in noncompliance with applicable ANSI standards is strictly prohibited. Columbia ParCar Corp. is not responsible or liable for any damage that results from any such alteration, and all warranties for any such altered vehicles are null and void. These vehicles are not designed for over-the-road use. They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations, and are not equipped for operation on public streets, roads, or highways. To the best knowledge of Columbia ParCar Corp., the material contained herein is accurate as of the date this publication was approved for printing. Columbia ParCar Corp. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. Columbia ParCar Corp. reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation. This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of this manual may be photocopied, reproduced, or translated to another language without the written consent of Columbia ParCar Corp. Columbia ParCar Corp. products are manufactured under one or more of the following U.S. Patents , , , , , , , , , , , , , Des CHANGE HISTORY DATE DESCRIPTION BY 7/1/2016 Issued CPC 1115 Commercial Avenue Reedsburg, WI Phone: (608) Fax: (608) (800) Web:

3 IS Parts Manual Revision #0 Dated 7/1/2016 INDEX SECTION 1 ACCELERATOR AND BRAKE Accelerator Pedal and Brake Linkage 1-1 Accelerator Linkage 1-4 SECTION 2 Front Fork Systems and Steering Single Front Fork 2-1 Dual Front Fork 2-3 Transport ExpressFront Fork 2-5 Steering Wheel Linkage 2-7 SECTION 3 Rear Axle Components Rear Axle / Wheel / Brake 3-1 Rear Axle Components 3-3 Gear Sets 3-5 Mechanical Brake Assembly 3-6 Motor, SEP-EX 3-7 SECTION 4 Body Components and Console Body Components 4-1 Instrument Console 4-2 Vehicle Labels 4-4 SECTION 5 Electrical System Battery and Charger System 5-1 Delta Q Charger with Remote LED 5-3 Control Panel 5-4 Power System 5-5 Main Wire Harness and Schematic 5-7 SECTION 6 Accessories Battery Watering System 6-1 4/6 Step Ladder 6-2 Transport Express 6-4 Transfer Stand 6-5 Battery Roll-Out Hardware 6-8 Mobile Cart Dock 6-9 Hitches 6-10 Ladder/Pole Strobe Light 6-11 Clipboard Holder 6-12 Folding Side Rails 6-13 Inner Fenders IS Head & Tail Lights V Accessory Harness and Schematics 6-16 Flashing Lights 6-20 Strongbox w/clipboard Lid 6-21 Deadman Foot Presence Switch 6-23

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5 IS12 Parts Manual Section 1 Accelerator Pedal & Brake Linkage

6 IS Parts Manual Section 1 Page 1 ACCELERATOR PEDAL & BRAKE LINKAGE

7 IS Parts Manual Section 1 Page 2 ACCELERATOR PEDAL & BRAKE LINKAGE (Continued)

8 IS Parts Manual Section 1 Page 3 ACCELERATOR PEDAL & BRAKE LINKAGE (Continued) ITEM CPC PN DESCRIPTION QTY REF # A WLDMT, PEDAL MTG BASE - ISRT A WLDM'T, PEDAL - BRAKE/ACCL MAT, PEDAL, BRAKE/ACCEL ARM - SPRINGS BAR, GUIDE - SPRINGS PLATED, BRAKE EQUALIZER ARM, BRAKE - ISRT ROD END, 5/16 (KPF-5-G) SPRING, ACCELERATOR ACTUATOR ROD, 5/16-24 UNF X 11" FULLY THDED BEARING, FLANGED.50 ID X 5/16 LG ROD, 5/16-24 X 3" FULLY THDED SCREW, 1/2 X 1/2 LG SHLDR SOCKET W SCREW, 5/16-18 X 1-1/4, HHCS, G5, YWZC CLEVIS PIN, 5/16 X 1 ZINC/CLEAR W PIN,1/8X1,COTTER,YWZC COTTER RING #RUE B WASHER,5/16,USS/STD,F/W,BLK MAX WASHER FLT STL BLK ZNC 3/8 STD WASHER.515X.812X B WASHER.515X.812X WASHER,5/16,SAE,F/W,BLK MAX CLEVIS #52 5/ LOCKNUT, 5/16-24 HEX NYLOK NUT,5/16-18,L/N,NYLOK,NE,GA,BLKMAX NUT, 5/16-24 GR 2 HEX JAM YWZC PIN,HAIR CLIP,#13,ZC

9 IS Parts Manual Section 1 Page 4 ACCELERATOR LINKAGE

10 IS Parts Manual Section 1 Page 5 ACCELERATOR LINKAGE (Continued)

11 IS Parts Manual Section 1 Page 6 ACCELERATOR LINKAGE (Continued) ITEM CPC PN DESCRIPTION QTY REF # PANEL, IS12 LAD MTG ARM, IS12 LAD PULL, SECONDARY ARM, IS12 LAD PULL, PRIMARY BRKT, IS12 LAD PULL ARM SPEED CONTROL LINKAGE SPRING, PARKING BRAKE RETURN LANYARD, 7 3/4" LG SCREW, 10-24X1/2PHILLIPS,BLK ZNC CABLE TIE, BLACK SCR, #10-24 X 3/4" HEX HD MACH SCREW, X 2 PHILLIPS PHM STANDOFF, WHT DELRIN.203 X.625 X * 516 CLEVIS PIN, 3/8X1-1/8 YELLOW/ZINC W PIN, COTTER 1/8 X 1 YELLOW/ZINC PALNUT, 3/16 STUD PS STYLE PHOS/OIL SPACER BRASS.192 ID.25 OD.25THK WASHER,5/16,USS/STD,F/W,BLK MAX WASHER,#10,SAE,F/W,BLK MAX NUT GR A NM MACH NYLON LOCK W NUT,10-32 GR A NM MACH. NYLON LOCK LIN ACLTR UNIT - SEVCON CLEVIS ENDS - M10 X

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13 IS12 Parts Manual Section 2 Front Fork Systems & Steering

14 IS Parts Manual Section 2 Page 1 SINGLE FRONT FORK SYSTEM

15 IS Parts Manual Section 2 Page 2 SINGLE FRONT FORK SYSTEM (Continued) ITEM CPC PN DESCRIPTION QTY REF # WLDMT, FRONT FORK, STANDARD UNIT SEAL BEARING, TB ROLLER BEARING, L RACE BEARING, L B WASHER, 3/4", STL FLAT, SAE MIL-CARB NUT, 3/4-16 SLOTTED HEX BLK, G5, YWZC PIN, 1/8" X 1-1/2", COTTER, ZNC AXLE, FRONT FORK NUT, BEARING ADJUSTING NUT, 1-8 GR 2, HEX JAM CLR ZINC WASHER FLT STL YWZC.734 X X HUB ASSEMBLY (Includes Hub, Bearings & Seal) N/A WHEEL, 4.80 X 8.00 LRB (Includes Items 14a & 14b) a RIM 8.00 X HOLE b TIRE 4.00 X 8.00 LRC NUT, 1/2-20, TAPERED WHEEL NUT, 5/8-11 NYLOCK, ZINC ASSY, TIE ROD END - 1/2-20 LH THD W NUT, 1/2-20 GR A NE NYLON INSERT YWZ NUT, 1/2-20 GR 2 HEX JAM YWZC - LH THD SHAFT, STRG- IS11/ROVR HUB GREASE CAP

16 IS Parts Manual Section 2 Page 3 DUAL FRONT FORK SYSTEM

17 IS Parts Manual Section 2 Page 4 DUAL FRONT FORK SYSTEM (Continued) ITEM CPC PN DESCRIPTION QTY REF # RACE BEARING, L ROLLER BEARING, L SEAL BEARING, TB ASSY, TIE ROD END - 1/2-20 LH THD W NUT, 1/2-20 GR A NE NYLON INSERT YWZ NUT, 1/2-20 GR 2 HEX JAM YWZC -LH THD SHAFT, STEERING -LONG WELDM'T, DUAL FORK -FRONT ASSY, HUB FRONT WHEEL (Includes Items 19-23) WHEEL, 4.80 X 8.00 LRB (Includes Items 10a & 10b) a RIM 8.00 X HOLE b TIRE 4.00 X 8.00 LRC NUT, 1/2-20, TAPERED WHEEL B WASHER FLT STL 9/16 STD UNHARD BLK B NUT, 5/8-18 GR 2 SLOTTED HEX BLK MAX W PIN, COTTER 1/8 X 1 YELLOW/ZINC B WASHER, 3/4", STL FLAT, SAE MIL-CARB NUT, 3/4-16 SLOTTED HEX BLK, G5, YWZC PIN, 1/8" X 1-1/2", COTTER, ZNC HUB GREASE CAP WHEEL BOLT, 1/2-20 X 1-1/2 G5 YELLOW HUB ONLY, FRONT WHEEL SEAL, OIL BEARING BEARING NOTE: If servicing an IS12 equipped with Tranport Express see next page.

18 IS Parts Manual Section 2 Page 5 TRANSPORT EXPRESS FRONT FORK SYSTEM STANDARD DUAL FORK TRANSPORT EXPRESS DUAL FORK

19 IS Parts Manual Section 2 Page 6 TRANSPORT EXPRESS FRONT FORK SYSTEM (Continued) ITEM CPC PN DESCRIPTION QTY REF # Bearing, Tapered Cone/Cup Roller Bearing Bearing Race W Cotter Pin, 1/8 x B Washer, 3/ Nut, 3/ Seal, Hub Special Order Front Fork Assembly 1 C37037_06 9 Special Order Bearing Adaptor 1 C37037_03 NOTE: This change was documented in Service Bulletin SB16-006

20 IS Parts Manual Section 2 Page 7 STEERING WHEEL LINKAGE

21 IS Parts Manual Section 2 Page 8 STEERING WHEEL LINKAGE (Continued) ITEM CPC PN DESCRIPTION QTY REF # UPPER HUB WLDMNT BUSHING NYLON NN SCREW, 5/16-18 X 2" GRD 5 HHC YEL LOCKNUT, 5/16-18 HEX FLG WHIZ WASHER FLAT NYLON.76 ID 1.42 OD STEERING WHEEL SPROCKET WLDMNT GREASE FITTING, 1/4"-28, SELF-TAPPING BUSHING 3/4X1 1/2X LOWER HUB WLDMNT BUSHING NYLON NN WELDMENT, SPROCKET - LOWER PIN, COTTER 1/8 X 1.50 YELLOW/ZINC CHAIN, STEERING WHL - IS11/ROVR B WASHER FLT STL 5/16 BLK MAXCOAT NUT, 5/16-24, NYLOCK, GA, YWZC SHORT STEERING SHAFT NUT, 1/2-20 GR 2 HEX JAM YWZC ASSY, TIE ROD END - 1/2-20 RH THD W NUT, 1/2-20 GR A NE NYLON INSERT YWZ WELDMENT, BELL CRANK SHORT SHAFT BUSHING, FLANGED NYLON - NF B WASHER FLT STL YWZC.515 X.812 X W PIN, COTTER 1/8 X 1 YELLOW ZINC N/A Special Order SHAFT, STEERING 47 LONG See Note NUT, 1/2-20 GR 2 HEX JAM YWZC - LH THD ASSY, TIE ROD END - 1/2-20 LH THREAD N/A STEERING WHEEL, ROUND ROLL PIN, 1/4 X

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23 IS12 Parts Manual Section 3 Rear Axle Components & Brakes / Motor

24 IS Parts Manual Section 3 Page 1 REAR AXLE / WHEEL / BRAKES

25 IS Parts Manual Section 3 Page 2 REAR AXLE / WHEEL / BRAKES (Continued) ITEM CPC PN DESCRIPTION QTY REF # A WELDMENT, AXLE, a A WELDMENT, AXLE, W SCREW, HX HD CAP 3/8-24 X 3 ¼ G WASHER, FLAT STL BLK ZINC 3/8 STD NUT, 3/8-24 GR A NE NYLON INSERT LOCK B BRAKE ASSY, RH AUTO ADJ (USED ON LH) BS SCREW, 5/16-18 X 3/4 HHCS, GRADE B NUT, 5/16-18, 3-WAY CENTER LOCK KIT, HUB & DRUM (Includes item 9) BOLT, WHEEL ½-20 x 1½ SPACER, WHEEL -4 HOLE NUT, 5/8-18, LOCKING FLANGE W PIN, COTTER 1/8 X 1 YELLOW/ZINC RESILIENT BUMPER-ELEC MOTOR MOTOR, ELECT., 48V, SEPARATELY EXCITED PANEL - CONTROLLER MTG SCREW, HEX HEAD CAP 1/4-20 X 1-1/4 G B WASHER, LOCK 1/4 REGULAR BLK ZINC B WASHER, FLAT STL 1/4 SAE UNHARD BLK WHEEL, 4.80 X 8.00 LRB (Includes Items 14a & 14b) a RIM 8.00 X HOLE b TIRE 4.00 X 8.00 LRC c WHEEL, 4.80 X 8.00 LRB (FOAM FILLED) d TIRE/WHL ASSY, 4-H, 4.8X8NM. LRC NUT, 1/2-20, TAPERED WHEEL B CABLE ASS'Y, BRAKE " B BRAKE ASSY, LH AUTO ADJ (USED ON RH) E-RING,.562 REINFORCED PHOS CLEVIS PIN, Ø5/16 X 1 ZINC/CLEAR COTTER RING ZINC PIVOT POINT #RUE

26 IS Parts Manual Section 3 Page 3 REAR AXLE COMPONENTS

27 IS Parts Manual Section 3 Page 4 REAR AXLE COMPONENTS (Continued) ITEM CPC PN DESCRIPTION QTY REF # 1 N/A HOUSING, AXLE 1 N/A 2 N/A BOLT, DIFFERENTIAL CAP 4 N/A 3 N/A SHAFT, INPUT (See Gear Set Page) 1 N/A RING, SNAP O-RING BEARING, BALL BEARING, BALL N/A PLUG, END CAP 2 N/A BEARING, BALL N/A SHAFT, INTERMEDIATE GEAR (See Gear Set Page) 1 N/A O-RING NA GEAR, FINAL DRIVE (See Gear Set Page) 1 N/A BEARING, BALL DIFFERENTIAL CASE ASSEMBLY N/A SCREW, CAP 4 N/A 16 N/A NUT, LOCK 4 N/A PLATE, COVER PLUG, DRAIN/FILL N/A SCREW, CAP 10 N/A VENT N/A SCREW, FLANGE HEAD 4 N/A NUT, LOCK B ASSEMBLY, BRAKE (Vehicle LH side) B ASSEMBLY, BRAKE (Vehicle RH side) SHAFT, AXLE, LH (Long) SHAFT, AXLE, RH (Short) PIN, COTTER SEAL, OIL RING, RETAINING BEARING, BALL * - ASSEMBLY, HUB, WHEEL (Includes Item No. 32 & 43) BOLT, WHEEL (1.68 Long) " * N/A DRUM, BRAKE (See Item 40) NUT, 5/8-18, HEX, FLANGE, LOCKING Local Purchase SEALANT, ANAEROBIC, GASKET - N/A 36* - KIT, INPUT GEAR (See Gear Set Page) 1 N/A 37* - KIT, GEAR (See Gear Set Page)) 1 N/A 40* KIT, HUB/DRUM (Includes Items 31 & 33) * OILSEAL INPUT SHAFT * KIT, INPUT BEARING * O-RING (Includes Items 4-7 & 41) U 43* A AXLE, COMPLETE ASSEMBLY, GEAR RATIO 12.44: * A AXLE, COMPLETE ASSEMBLY, GEAR RATIO 16.99:

28 IS Parts Manual Section 3 Page 5 GEAR SETS ITEM CPC PN DESCRIPTION QTY REF # BEARING, BALL, INNER BEARING, BALL, OUTER O-RING SNAP RING SEAL, OIL, INPUT SHAFT N/A NO LONGER APPLICABLE BEARING, BALL O-RING SNAP RING PLUG, END CAP RING BEARING, BALL KIT, PINION SEAL (Includes items 1-5) U KIT, INPUT GEAR + (Includes items 1-5), Ratio KIT, INPUT GEAR + (Includes items 1-5), Ratio Special Order KIT, INTERMEDIATE AND RING GEAR, Ratio Special Order KIT, INTERMEDIATE AND RING GEAR, Ratio

29 IS Parts Manual Section 3 Page 6 MECHANICAL BRAKE ASSEMBLY ITEM CPC PN DESCRIPTION QTY REF # C SET, SHOE & LINING ASSEMBLY (2 Shoes) B KIT, SPRING (Includes items in drawing circled in red) SPRING, RETURN SPRING, SELF ADJUSTER SPRING, SHOE RETAINING SPRING CLIP, SHOE RETAINER PIN, SHOE RETAINING B MECH. BRAKE ASSY, LH (Includes all items shown) B MECH. BRAKE ASSY, RH (Includes all items shown)

30 IS Parts Manual Section 3 Page 7 MOTOR, SEP EX IS/IR/IT ITEM CPC PN DESCRIPTION QTY REF # BEARING BRUSH ASSY. (Includes Fasteners) BRUSH BOX ASSY. (Includes Fasteners) MOTOR, STANDARD DUTY, COMPLETE

31 IS12 Parts Manual Section 4 Body Components & Console

32 IS Parts Manual Section 4 Page 1 BODY COMPONENTS ITEM CPC PN DESCRIPTION QTY REF # 1 Special Order WELDMENT, CHASSIS ONLY CTWT W/ 3 1/2" HOLE SPACER, 3/4" OD X.438" ID X 1 3/4" LG - RD WASHER FLT STL BLK ZNC 3/8 STD SCREW, 3/8-16 X 4 HHCS GR NUT,3/8-16,GA,NE,NYLON INSERT,YWZC WELDM'T, SEATBACK SCREW 1/2-13 X 2-1/4 HEX CAP NUT, 1/2-13 A NTE SYLON LOCK CUSHION - SEAT BACK, BLACK B WASHER, 1/4, SA, FW, STL, HC BLACK B SCREW, HEX HEAD CAP 1/4-20 X 1/2 G CONSOLE, STOCKCHASER B SCREW, #10 X 3/4 HWH TEK # PLATE, MTG - RAIL BS SCREW, 5/16-18 X 3/4 HHCS, GRADE LOCKNUT, 5/16-18 HEX FLG WHIZ Special Order DECK BOARD, MEZZTREAD a DC/DC CONVERTER 24V - 12V b DC/DC CONVERTER 36/48V - 12V NUT, 1/4-20 NYLOCK

33 IS Parts Manual Section 4 Page 2 INSTRUMENT CONSOLE

34 IS Parts Manual Section 4 Page 3 INSTRUMENT CONSOLE (Continued) ITEM CPC PN DESCRIPTION QTY REF # CONSOLE, STOCKCHASER HORN SWITCH A HOUR METER VOLT DC a BDI METER, 24V, VOLTMETER b BDI METER, 48V, VOLT METER KEYSWITCH, UNIVERSAL A W/ HARDWARE SWITCH, TOGGLE PLUG, POWER INLET 120V SEALED SEE TABLE KEYSWITCH, POWER, 2 POSITION 1 See Table DECAL, CONSOLE -IS12/R23/IT LABEL, POWER, ON/OFF SEE TABLE KEYSET, 2 KEYS WITH KEYRING (SVC) 1 See Table ASSY, KEY, NON-REMOVABLE, W/COVER INDICATOR, LED GREEN STANDARD KEYSET TABLE 2 POSITION POWERSWITCH STANDARD KEYS KEYSET CPC PN REF # CPC PN REF # A B B B C C C D D D E E E

35 IS Parts Manual Section 4 Page 4 VEHICLE LABEL SET ITEM CPC PN DESCRIPTION QTY REF # LABEL SET

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37 IS12 Parts Manual Section 5 Electrical System

38 IS Parts Manual Section 5 Page 1 BATTERY AND CHARGER SYSTEM

39 IS Parts Manual Section 5 Page 2 BATTERY & CHARGER SYSTEM (Continued) ITEM CPC PN DESCRIPTION QTY REF # BATTERY BOX, PAINTED a BATTERY, 6V, DEEP CYCLE, (US2200) 4/ b BATTERY, 6V, DEEP CYCLE, (US-145) 4/ c BATTERY, 6V, AGM SEALED 4/ A ROD, BATTERY HOLD DOWN 1/ PLATE, BATTERY HOLD DOWN 1/ WASHER FLT STAINLESS.28 X X.06 1/ NUT 1/4-20 NE 316 STAINLESS NYLON 1/ B SCREW, HX HD CAP 3/8-16 X 1-3/4 G WASHER FLT STL BLK ZNC 3/8 STD NUT, 3/8-16 GR A NE NYLON INSERT BRKT, CHARGER, BTRY - DELTA Q B SCREW, HEX HEAD CAP 1/4-20 X 3/4 G B WASHER FLT STL 1/4 SAE UNHARD BLK B NUT 1/4-20 GR A SERRATED FLNG LOCK SCREW, HEX HEAD CAP 1/4-20 X 1-1/4 G CHARGER, DELTA Q (See Page 5-3) CHARGER CORD, 6 (L) 14/3 WIRE - BLACK " PLUG, POWER INLET 120V SEALED BATTERY CONNECTOR * CABLE ASSY, 4 GA X 37 INCH * CABLE ASSY, 4 GA X 8.75 INCH 1/ * CABLE ASSY, 4 GA X INCH * BOOT, INSULATOR CABLE TERMINAL 4/ * A EXTENSION CORD

40 IS Parts Manual Section 5 Page 3 DELTA Q CHARGER WITH REMOTE LED BRACKET ITEM CPC PN DESCRIPTION QTY REF # LED REATINING CLIP & RING LED FRONT LABEL a CHARGER, DELTA Q 24V W/LED, STANDARD b CHARGER, DELTA Q 48V W/LED, STANDARD c CHARGER, DELTA Q 24V W/LED, AGM d CHARGER, DELTA Q 48V W/LED, AGM PLUG, POWER INLET 120V SEALED CHARGER CORD LED CABLE N/A ASSEMBLY, CORD W/ RECEPTACLE (Includes 4 & 5)

41 IS Parts Manual Section 5 Page 4 CONTROL PANEL ITEM CPC PN DESCRIPTION QTY REF # MOUNTING BRACKET - PANEL CONTROLLER A CONTROLLER, SEVCON REGEN SEPEX 24/48C W SCREW, 1/4-20 X 1 GRD 5 HHC YEL B WASHER FLAT, STL 1/4 SAE UNHARD BLK NUT 1/4-20 GR A NE NYLON INSERT LCK CONTACTOR & MTG BRACKET, 24V W SCREW, #10-24 X 5/84" NUT GR A NM MACH NYLON LOCK A HORN 12V B SCREW, HEX HEAD CAP 1/4-20 X 3/4 G B NUT 1/4-20 GR A SERRATED FLNG LOCK A AUDIBLE ALARM, 12/48VDC, SLOW PLUSE

42 IS Parts Manual Section 5 Page 5 POWER SYSTEM

43 IS Parts Manual Section 5 Page 6 POWER SYSTEM (Continued) ITEM CPC PN DESCRIPTION QTY REF # 1a BDI METER, 24V, VOLT METER b BDI METER, 48V, VOLT METER HOUR METER, 10-80VDC SWITCH, TOGGLE CONTROLLER STATUS INDICATOR, LED KEYSWITCH, UNIVERSAL W/HARDWARE SEE TABLE KEYSWITCH, POWER, 2 POSITION 1 SEE TABLE LINEAR ACCELERATOR DEVICE A AUDIBLE ALARM, 12/48VDC,SLOW PULSE FUSE, 5 AMP ATO/ATC CONTACTOR & MOUNTING BRACKET, 24 V FUSE, 1 AMP ATO/ATC A CONTROLLER, SEVCON REGEN, SEPEX CHARGER (See Page 5-3) MOTOR,ELECT., 48V, SEP EX, STD DUTY HARNESS, MAIN CABLE ASSY,4GA X 25.5, 5/16TERMINALS " * WIRE MARKER, A1" * WIRE MARKER, F1 BRADY * WIRE MARKER, F2 BRADY * WIRE MARKER, A2" CABLE ASSY,4GA X 16.75, 5/16TERMINALS " * WIRE MARKER, POSITIVE CABLE ASSY, 4GA X * WIRE MARKER, NEGATIVE CABLE ASSY, 4 GA X * INSULATOR BOOT, CABLE TERMINAL * 9990-W ZIP TIE,.18 X 8-1/2" BATTERY, 6V, DEEP CYCLE (US2200) 4/ * BATTERY, 6V, DEEP CYCLE (US-145) 4/ B BATTERY, 6V DEEP CYCLE AGM 4/ HARNESS, MAIN, WIRING STANDARD KEYSET TABLE 2 POSITION POWERSWITCH STANDARD KEYS KEYSET CPC PN REF # CPC PN REF # A B B B C C C D D D E E E

44 IS Parts Manual Section 5 Page 7 MAIN WIRE HARNESS WIRING DIAGRAM

45 IS Parts Manual Section 5 Page 8 MAIN WIRE HARNESS WIRING DIAGRAM (Continued) CIRCUIT NO. COLOR GAGE CIRCUIT NO. COLOR GAGE 1 RED RED 18 2 GRN WHT 16 3 GRY BLK 18 4 BLK BLK 18 5 BLK GRY 16 6 BLK RED 18 7 BLK BLK 12 8 BLK RED 16 9 BLK RED GRN RED BLK BLK WHT YEL BLK WHT RED RED BLK BLK RED RED RED RED 18

46 IS Parts Manual Section 5 Page 9 MAIN WIRE HARNESS SCHEMATIC

47 IS12 Parts Manual Section 6 Accessories & Options

48 IS Parts Manual Section 6 Page 1 BATTERY WATERING SYSTEM ITEM CPC PN DESCRIPTION QTY REF # WATERING ASSEMBLY PUMP

49 IS Parts Manual Section 6 Page 2 4/6 STEP LADDER ITEM CPC PN DESCRIPTION QTY REF # 1 * WLDMNT, 4-STEP LADDER * SCREW, 1/2-13 X 2 1/2 G5 HHCS NUT, 1/2-13 A NTE SYLON LOCK THREADED INSERT, 5/16-18, YWZC B WASHER, 5/16 R-SPLIT B WASHER FLT STL 5/16 BLK MAXCOAT SCREW, HEX HEAD CAP 5/16-18 X 7/8 G CUSHION SEAT BACK B WASHER FLT STL 1/4 SAE UNHARD BLK SCR, 1/4-20 X 1 1/2 HEX CAP " CTWT W/ 3 1/2 HOLE -JAG " WASHER FLT STL BLK ZNC 3/8 STD SCREW, 3/8-16 X 4 HHCS GR NUT,3/8-16,GA,NE,NYLON INSERT,YWZC * WELDM'T, EXTENDED LADDER * HAND GRIP KIT, 4 STEP LADDER (Includes Items 1 14 & 16) U N/A KIT, 6 STEP LADDER (Includes Items 1 15) U

50 IS Parts Manual Section 6 Page 3 TRANSPORT EXPRESS

51 IS Parts Manual Section 6 Page 4 TRANSPORT EXPRESS (Continued) ITEM CPC PN DESCRIPTION QTY REF # EXTENDED BED 29 W X 60 L HANDRAIL BACK CUSHION BOTTOM CUSHION HAND RAIL FOOTREST FRAME SUPPORT RAIL PLATE ZZ BLACK VINYL MAT CAPLUG FP B SCREW, 5/16-18X2 CARR G SCREW, HHC, 5/16-18X7/8 G BUMPER, BLACK BS SCREW, 5/16-18X1 CARR G B WASHER, 5/ NUT, 5/16-18 NYLOCK

52 IS Parts Manual Section 6 Page 5 TRANSFER STAND

53 IS Parts Manual Section 6 Page 6 TRANSFER STAND (Continued)

54 IS Parts Manual Section 6 Page 7 TRANSFER STAND (Continued) ITEM CPC PN DESCRIPTION QTY REF # 1 * STAND * RELEASE LEVER * PUSH ACTUATOR A/ * WARNING LABEL * LATCH SAFETY * BOX STORAGE * PIN, 1/8X1 1/4 COTTER * BEARING, FLANGED ROLLER GRAVITY * 3/8-16x1.5 EYEBOLT BUMPER 7/8X PLUG FINISH * CAPLUG FP B SCREW 8/32X1/2 PHILLIPS B* SCREW #10X3/4 HWH TEK # SCREW 5/16-18X2 HHC W* SCREW 5/16-18X1 1/4 HHC * SCREW 3/8-16X2 HHC BS* SCREW 5/16-18X1 1/2 CARR B WASHER 5/16 STD WASHER 1/2 FLT STL * WASHER 3/8 FLT STL BLK B* WASHER 5/16 BLACK WASHER 5/16X1X.036 NYLON NUT 3/8-16 SERR FLG W NUT #8-32 NYLOCK NUT 5/16-18 NYLOCK B NUT 5/16-24 HEX NUT 3/8-16 NYLOCK SPRING ROTARY SWITCH RATCHET, ROPE & HOOK ASSEMBLY * SPRING, COMPRESSION,.91 X.568 X 75 X * PALLET JACK COMPLETE ASSEMBLY

55 IS Parts Manual Section 6 Page 8 BATTERY ROLL-OUT HARDWARE ITEM CPC PN DESCRIPTION QTY REF # 1 ** SAFETY LATCH a* ** 24V PORTABLE CHARGER ASSY (Includes Charger, cord and connector) b* ** 48V PORTABLE CHARGER ASSY (Includes Charger, cord and connector) ** CONNECTOR ASSEMBLY ** SECONDARY LATCH ** MANUAL RELEASE, TRUCK BRACKET

56 IS Parts Manual Section 6 Page 9 MOBILE CART ITEM CPC PN DESCRIPTION QTY REF # 1 * CORRAL, SHOPPING CART ASSEMBLY, REEL, CART DOCK * MT, GUIDE PANEL - CORRAL * SHEET, PROTECTIVE - CORRAL * PANEL, GUIDE - SMALL, CORRAL * SPACER, CASTER TRAILER COUPLER, 1-7/8 BALL " CASTER, 8 X 2 FLAT TREAD ** CAM JAM CLEAT - JAG * 3/8-16 X 1.5 THD 2.50 SHANK, EYEBOLT - CLOSED ** ROPE, 1/2 POLY WHITE (Item 2 holds 85 ) CAPLUG, FP-161, 1 SQ X.120 WALL " ** 2653-B SCREW, #10 X 3/4 HWH TEK # SCREW, 1/2-13 X 3 GRD 5 HHC BS SCREW, 1/4-20 X 1-3/4 HHCS, G5 HCBLK SCREW, 1/4-20 X 2-1/2, HHCS, G5, YW ZC SCRew, 1/2-20 X 4½ HEX HD CAP G ** 5215 EYE BOLT, 5/16-18 X 1.125, YWZC WASHER FLT STL UNHARD YWZC.513 ID WASHER FLT STL BLK ZNC 3/8 STD B WASHER,5/16,SAE,F/W,BLK MAX B WASHER,1/4,SAE,F/W,BLK MAX NUT, 3/8-16 GR A SERRATED FLG NUT 1/2-13, GR A, NYLON LOCK NUT, 1/4-20, NYLOCK, GA, YWZC NUT,5/16-18,L/N,NYLOK,NE,GA,BLKMAX NUT,3/8-16,GA,NE,NYLON INSERT,YWZC W NUT, 1/2-20 GR A NE NYLON INSERT YWZ

57 IS Parts Manual Section 6 Page 10 HITCHES ITEM CPC PN DESCRIPTION QTY REF # PINDLE HOOK HITCH * 7812-w NUT, 1/2-20 NYLOK GR A (Used with Item 1) * 4010 SCREW, 1/2-20x1.5 HHCS G5 (Used with Item 1) a HITCH BALL, CHROME 1 7/ b HITCH BALL, HITCH MOUNT BRACKET * 4716-W SCREW, 3/8-16X1 1/4 HHCS G5 (Used with Item 3) * 7778 NUT, 3/8-16 NYLOCK (Used with Item 3)

58 IS Parts Manual Section 6 Page 11 AMBER POLE/LADDER STROBE LIGHT ITEM CPC PN DESCRIPTION QTY REF # LIGHT POLE A ** LADDER LIGHT POLE ** HARNESS STROBE LIGHT AMBER * CABLE TIE 5 3/ * CABLE TIE * CABLE TIE MOUNTING BRACKET * CABLE TIE BLACK, 11 3/ * 2339 SCREW, #10-24X3/4, HH * 3407 SCREW, 1/2-13X2 1/4 HHCS, G * 3787-B SCREW 1/4-20X3/4 HHCS G * 7624 NUT, NYLOCK * 7685 NUT 1/2-13 GR A, NYLON INSERT LOCK (Pole only) * 7692 NUT 1/4-20 NYLOCK (Ladder only) * KIT, POLE STROBE LIGHT AMBER (Includes Items 1, 2, 1 3, 4, 6, 7, 8, 9, 11, & 12) U 15* KIT LADDER STROBE LIGHT AMBER (Includes Item 1A, 2, 3, 5, 6, 8, 10, 11 & 13) U

59 IS Parts Manual Section 6 Page 12 CLIPBOARD HOLDER ITEM CPC PN DESCRIPTION QTY REF # 1 ** CLIPBOARD * 3787-B SCREW, 1/4-20X3/4 HHC, G * 6703-B WASHER, 1/4 SAE * 7724-B NUT, 1/4-20, L/N, SER-FLG GA * KIT, CLIPBOARD HOLDER (Includes above Items) U

60 IS Parts Manual Section 6 Page 13 FOLDING SIDE RAIL ITEM CPC PN DESCRIPTION QTY REF # WELDM'T, FOLDING RAIL PLATE, MTG-A, RAIL PLATE, MTG-B, RAIL B SCREW, 1/4-20X3/4, HHCS, G5, BLK B WASHER,1/4,SAE,F/W,BLK MAX NUT, 1/4-20, NYLOCK, GA, YWZC KIT, FOLDING SIDE RAILS (Includes above) U

61 IS Parts Manual Section 6 Page 14 INNER FENDERS ITEM CPC PN DESCRIPTION QTY REF # FRONT INNER FENDER INNER FENDER BRACKET, LH INNER FENDER BRACKET, RH FENDER SHIELD, RH FENDER SHIELD, LH W SCREW, 10-24X5/8 HWH, TRD, ROL WASHER #10, SAE F/W, BLK

62 IS Parts Manual Section 6 Page 15 HEAD & TAIL LIGHTS ITEM CPC PN DESCRIPTION QTY REF # 1 N/A NUT (Included with Item 4) 1 N/A 2 N/A WASHER (Included with Item 4) 1 N/A B WASHER, FRONT HEADLIGHT SPACER,.75X.50X HEADLIGHT BRACKET ** TAIL LIGHT ASSEMBLY ** TAIL LIGHT GROMMET TAIL LIGHT BRACKET B W SCREW, 1/4-20X1 HHC, G5 (Existing backrest hardware.) WASHER 1/4 (Existing backrest hardware.) * ** TAIL LIGHT HARNESS ADAPTER * V ACCESSORY HARNESS * TOGGLE SWITCH ** TAIL LIGHT HARNESS COVER (See Note) * A KIT, TAIL LIGHT UPGRADE (Includes Items 7-9, 12 & 15) U 17* KIT, HEAD & TAIL LIGHT U

63 IS Parts Manual Section 6 Page 16 12V ACCESSORY HARNESS ITEM CPC PN DESCRIPTION QTY REF # HARNESS, WIRE, ACCESSORY 1

64 IS Parts Manual Section 6 Page 17 12V ACCESSORY SCHEMATIC WITH BRAKE & TAIL LIGHTS (NOT AVAILABLE WITH FLASHING FRONT AND REAR LIGHTS FOR IT 34)

65 IS Parts Manual Section 6 Page 18 12V ACCESSORY SCHEMATIC WITH FLASHING FRONT AND REAR LIGHTS (NOT AVAILABLE WITH BRAKE & TAIL LIGHTS FOR IR 23)

66 IS Parts Manual Section 6 Page 19 12V ACCESSORY (Continued) ITEM CPC PN DESCRIPTION QTY REF # 1a CONVERTER DC/DC 24V-12V b CONVERTER DC/DC 36V-48V, 13.4V, FUSED FUSE, 15 AMP ATO/ATC SWITCH, TOGGLE FUSE, 10 AMP ATO/ATC ASSEMBLY, 12V RECT, BRAKE LIGHT HEADLIGHT ASSEMBLY, FLASHER MODULE 12-48V A ASSEMBLY, 12V RECT, AMBER LIGHT

67 IS Parts Manual Section 6 Page 20 FLASHING HEAD AND STROBE LIGHTS ITEM CPC PN DESCRIPTION QTY REF # FRONT BRACKET - HEADLIGHT/STROBE HEADLIGHT B WASHER,.515 ID X.812 OD X.134 THK A 12V RECTANGULAR AMBER LIGHT SCREW, #10-24 X 2.5, PHILLIPS PAN RUBBER WASHER,.25 ID WASHER, #10, SAE, FW NUT 10-24, NM MACH NYLON LOCK, GR A COVER BRACKET - LIGHT B WASHER, 1/4, SA, FW, STL B SCREW, 1/4-20 X 3/4, HHCS, GR RAIL - FRONT KNURLED COMPRESSION INSERT, 5/ B WASHER, 5/16, STD FW B WASHER, 5/16, REGULAR SPRING LOCK SCREW, 5/16-18 X 7/8, HHCS, GR WASHER, 3/8, STD FW, STL NUT, 3/8-16, NE NYLOC, GR A SCREW, 3/8-16 X 4, HHCS, GR * V, BULB SP-8 (For Item 4) * VDC BULB, TYPE 1156 (For Item 4)

68 IS Parts Manual Section 6 Page 21 STRONGBOX W/CLIPBOARD LID

69 IS Parts Manual Section 6 Page 22 STRONGBOX W/CLIPBOARD LID (Continued) ITEM CPC PN DESCRIPTION QTY REF # ClIP, STEMCO, 3 STAINLESS MOLDING, BLACK, LONG SCREW, X ½ PHILLIPS PHM B SCREW, ¼ - 20 X ¾, CARRIAGE, GB, BLKMAX B WASHER ¼, SAE, F/W, BLKMAX NUT, GR A NM NYLOK, YW ZC NUT, ¼-20, NYLOK, GA, YW ZC Special Order RIVET #48, 1/8, DH, BLIND Special Order WLDMT, IS12, STRG W CLIPBOARD LID 1 C Special Order LID, IS12, STRG W CLIPBOARD LID 1 C Special Order HINGE, IS12, STRG W CLIPBOARD LID 1 C

70 IS Parts Manual Section 6 Page 23 DEADMAN FOOT PRESENCE SWITCH ITEM CPC PN DESCRIPTION QTY REF # CABLE TIE, BLACK,.18 X 11 ¾, STD, 50LB SCREW, #8 X ½, HEX WASHER HEAD, TAP Special Order ASM, FOOT DEADMAN SWITCH 1 C

71 ADDITIONAL NOTES

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