Serial number S09000 and after Replaces November 2012 REPAIR PARTS MANUAL

Transcription

1 Serial number S09000 and after Replaces November 202 REPAIR PARTS MANUAL Part Number August 204

2 The aerial platform is not electrically insulated. Death or serious injury will result from contact with, or inadequate clearance from, an energized conductor. Do not go closer than the Minimum Safe Approach Distance as defined by ANSI standards. Regard all conductors as energized. Allow for electrical wire sag and aerial platform sway. If the platform, scissors structure, or any part of the aerial platform contacts a high-voltage electrical conductor, the entire machine can become electrically charged. If that happens, remain on the machine and do not contact any other structure or object. This includes the ground, adjacent buildings, poles, and any other objects that are not part of the aerial platform. Such contact could make your body a conductor to the other object, creating an electrical shock hazard resulting in death or serious injury. If an aerial platform is in contact with an energized conductor the platform operator must warn ground personnel in the vicinity to stay away. Their bodies can conduct electricity creating an electrical shock hazard resulting in death or serious injury. Do not approach or leave the aerial platform until the electricity has been turned off. Do not attempt to operate the lower controls when the platform, scissors structure, or any part of the aerial platform is in contact with a high-voltage electrical conductor or if there is an immediate danger of such contact. Personnel on or near an aerial platform must be continuously aware of electrical hazards, recognizing that death or serious injury can result from contact with an energized conductor. California Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. Snorkel all rights reserved

3 Table of Contents Electrical Hazard... Inside front cover California Proposition Inside front cover General Information About This Manual... i Repairs and Maintenance... i Abbreviations... i Additional Information... i Service and Parts Information Ordering Parts... ii ANSI and OSHA Compliance... ii Manuals... ii Machine Information... ii Parts Order Form... iii Section Repair Parts Chassis, Steering and Brakes... 3 Pothole Protector...4 Tray Installation...7 Battery Tray Signet Charger...9 Hydraulic Tray... Pothole and Scissor Stack Switch Mounting Standard Installation...3 Pothole and Scissor Stack Switch Mounting CE Installation...5 Scissor Stack... 7 Platform Before August 4, Platform After August 3, Stack/Platform Installation Placards and Decals Section 2 Hydraulics Drive Speed Manifold... 3 Hydraulic Drive Motor...5 Manifold Valve...7 Steering Cylinder...9 Lift Cylinder... Section 3 Electrical Battery Tray Wiring Signet Charger... 3 Lower Control Box ANSI Before September Lower Control Box Internal Wiring Harness ANSI Before September Lower Control Box ANSI After August Lower Control Box Internal Wiring Harness ANSI After August Lower Control Box ANSI/AU After December 5, Lower Control Box Internal Wiring Harness ANSI/AU After December 5, Lower Control Box CE Before December 6, Lower Control Box Internal Wiring Harness CE Before December 6, Lower Control Box CE After December 5, Lower Control Box Internal Wiring Harness CE After December 5, Upper Control Box ANSI Before December 6, Controller Upper Control Box ANSI Before December 6, Upper Control Box ANSI After December 5, Controller Upper Control Box ANSI After December 5, Upper Control Box CE Before December 6, Controller Upper Control Box CE Before December 6, Upper Control Box CE/AU After December 5, Controller Upper Control Box CE/AU After December 5, Joystick GFCI Electrical Outlet... 4 Platform Control Cable Before December 6, Platform Control Cable After December 5, Limit Switch Before April, Magnetic Sensor After April 0, Main Wiring Harness Before December 6, Main Wiring Harness After December 5, Electrical System Pin ID After December 5, Overload System CE...59 Section 4 Options Flashing Light... 3 Key Switch... 5 Airline to Platform...7 Dual Lanyard Anchorage... 9 Canadian Standards Association Package... Battery Condition Indicator...3 Section 5 Maintenance Maintenance... 3 Daily Prestart Inspection... 5 Frequent Inspection and Maintenance... 7 Annual Maintenance... Major Repairs... 3 Lubrication Points... 5 Batteries...6 Fastener Torque Chart... 9 S2632E 42033

4 Appendix Electrical Schematics Hydraulic Schematic Limited Warranty Contact Information Europe, Middle East, Africa and Asia...Back cover North and South America...Back cover Australia...Back cover New Zealand...Back cover S2632E 42033

5 General Information About This Manual This manual covers S2632E aerial platforms. Information is included for machines that have been manufactured to conform to all applicable requirements of the following organizations: American National Standards Institute (ANSI) Canadian Standards Association (CSA) European Committee for Standardization (CE) Australian Standards (AS) certification Part pages include a drawing and a bill of material. The bill of material lists the item number that is on the drawing, the Snorkel part number, quantity used and a description of the item. Some callouts in the drawings may have a balloon with two numbers. The top number is the item number and the bottom number is the quantity of the item at that location. While Snorkel has attempted in every way to confirm that all information in this manual is correct, improvements are being constantly made to the machine that may not be reflected in this manual. If you find information in this manual that is not correct or is confusing, you are urged to report your findings to Snorkel for our evaluation. Your input is important to us and will be used in future printings of this manual. This machine is covered by a limited warranty that specifically identifies items warrantied by Snorkel and those items covered by original manufacturer's warranty. A copy of the Snorkel Limited Warranty is located on the inside of the back cover of this manual. Repairs and Maintenance Every person who maintains, inspects, tests or repairs the machine must be qualified and authorized to do so. Caution Do not modify this aerial platform without prior written consent of Snorkel Engineering Department. Modification may void the warranty, adversely affect stability or affect the operational characteristics of the aerial platform. Abbreviations The following abbreviations may be used in this manual. AC ANSI AR CCA cm DC ft GFCI in lbs mm no NPT psi qty rpm UL alternating current American National Standards Institute as required cold cranking amps centimeter direct current feet ground fault circuit interruptor inch pounds millimeter number national pipe thread pounds per square inch quantity revolutions per minute Underwriters Laboratories Inc. Additional Information All correspondence relative to this machine, such as field reports, discrepancy reports, requests for information, etc., should be directed to: Snorkel North America P.O. Box 60 St. Joseph, MO USA Phone: Snorkel Europe Vigo Centre Birtley Road Washington Tyne & Wear NE38 9DA Phone: +44 (0) S2632E i

6 Service and Parts Information Ordering Parts When placing an order for service or repair parts, please have the following machine information readily available. Model number Serial number Snorkel part number Description of part Quantity of parts required Your purchase order number Address for order to ship to The desired shipment method The parts order form on the following page may be mailed or faxed to the attention of the Parts Department at the following location: Snorkel North America P.O. Box 60 St. Joseph, MO USA Phone: Parts Fax: Snorkel Europe Vigo Centre Birtley Road Washington Tyne & Wear NE38 9DA Phone: +44 (0) Parts Fax: +44 (0) Attention: Parts Department For your convenience, our electronic on-line ordering system is available at the following Internet location: ANSI and OSHA Compliance All owners and users of the aerial platform must read, understand and comply with all applicable regulations. Ultimate compliance to OSHA regulations is the responsibility of the user and their employer. ANSI publications clearly identify the responsibilities of all personnel who may be involved with the aerial platform. A reprint of the Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors and Lessees of ANSI/SIA A Self-Propelled Elevating Work Platforms is available from Snorkel dealers or from the factory upon request. Manuals Manuals are available from Snorkel to support any of the machines that we produce. The specific manuals for S2632E aerial platforms are as follows: S930E/S932E/S2632E Operator s Manual ANSI Snorkel part number S930E/S932E/S2632E Operator s Manual CE Snorkel part number S930E/S932E/S2632E Operator s Manual AU Snorkel part number S930E/S932E/S2632E Operator s Manual Spanish Snorkel part number S2632E Repair Parts Manual Snorkel part number ANSI Manual of Responsibilities ANSI/SIA A Snorkel part number Machine Information Model Number: Serial Number: Date of Purchase: Purchased From: Snorkel Dealer or Distributor: Copies are also available from: Scaffold Industry Association, Inc. P.O. Box Phoenix, AZ USA ii S2632E 42033

7 Parts Order Form Fill out completely and fax attention Parts Department to: Snorkel USA Snorkel Europe +44 (0) Date: Company: Address: Account Number: Purchase Order Number: Model Number: Serial Number: Ship To: Contact Name: Phone Number: Fax Number: Shipping Method: Part Number Description Quantity Note: Backordered parts will be shipped as soon as available using the same shipping method as the original order unless otherwise indicated below. Ship complete order only. Do not backorder parts. Ship all available parts and disposition of backordered parts. Other instructions as specified: S2632E iii

8 S2632E 42033

9 Repair Parts S2632E Repair Parts

10 Repair Parts 2 S2632E 42033

11 Chassis, Steering and Brakes Chassis, Steering and Brakes S2632E Repair Parts 3

12 Pothole Protector Pothole Protector Repair Parts 4 S2632E 42033

13 Chassis, Steering and Brakes/Pothole Protector Item Part No. Qty. Description WLDMT, FRAME S2632M BRG 55MM X 60MM X 20MM BRG 55MM X 60MM X 45MM BRG THR 55mm x 75mm x 4mm WLDMT, LH STEERING WLDMT, RH STEERING PLT, STEERING LINKAGE BRG FLG 25MM x 30MM x 2MM BSHG MACH 25MM X 38MM X 2MM SNAP RING.00 EXT HD WSHR LOCK M HHCS M8 x.25 x 6 G8.8 ISO 407 DIN MOTOR WHL 28.3 CU.5 TAPER RC (refer to hydraulics 5) HHCS M2 x.75 x 90 G8.8 DIN NUT HEX M2 X.75 GR 8.8 SELF LOCKING DIN CYLINDER, STEER (refer to hydraulics 9) STEER CYLINDER PIN WSHR FLAT 20MM PIN, COTTER.25 X TIRE WHEEL ASSY HYD BRAKE/HUB BK HHCS M2 x.75 x 50 G8.8 DIN PIN COTTER.250 DIA PLT. POTHOLE CAM BSHG FLG 2MM ID X 2MM LG PLT. POTHOLE LINKAGE BLT SHLDR 2mm x 40mm x M WSHR FLAT M NUT HEX M0 X.50 GR 8.8 SELF LOCKING DIN HHCS M2 x.75 x 65 G8.8 DIN HHCS M2 x.75 x 30 G8.8 DIN BRG FLG.500 ID.630 OD.00 OILITE PLT. VERTICAL LINK SPCR.656ID.3OD BRG FLG.500 ID.630 OD.630 OILITE WHSR SPECIAL BRG THR.500ID.00OD HHCS M2 x.75 x 00 G8.8 DIN NUT, HEX, THIN, M2 X.75 DIN SPRG POTHOLE EXTENSION SL-9E BLT SHLDR 2mm x 30mm x M WLDMT. POTHOLE SKID BSHG FLG 2MM ID X 5MM OD SWIVEL 90 SHORT SWIVEL 90 LONG FTG, HYD -6 MB TO -8 MJIC NUT HEX M8 X.25 GR 8.8 SELF LOCKING DIN 985 NOT shown Plate chassis cover bolt nut speed U type m washer lock steel flat washer m6 din25a zp spring washer m6 din27b gr8.8 zp Chassis, Steering and Brakes/Pothole Protector S2632E Repair Parts

14 Repair Parts 6 S2632E 42033

15 Item Part No. Qty. Description Tray Installation HYDraulic TRAY ASSEMBLY (refer to repair Parts ) PIN, SMALL CAM SETSCR M0-.25 x 2MM CONE PT BATTERY TRAY ASSEMBLY (refer to repair Parts 9) hhcs m2 x.75 x 90 g8.8 din nut hex m2 x.75 gr8.8 self locking washer flat m2 Tray Installation TRAYINSTALL S2632E Repair Parts 7

16 Repair Parts 8 S2632E 42033

17 Item Part No. Qty. Description Battery Tray Signet Charger weldment, battery tray latch rh tray rotary lock lockout lever assembly flange inlet 5a 25v nema battery 6 volt type t brg flg tray doors hhcs m4 x 0.7 x 20 gr8.8 iso 407 din m4 flat washer din nut hex m4 x 0.7 gr8.8 self locking din hhcs m5 x 0.8 x 2 gr8.8 iso 407 din nut hex m5 x 0.8 gr8.8 self locking din bolt hexhd m mm nut hex m8 x.25 gr8.8 self locking din nut hex m6 x.0 gr0.9 self locking din nut hex m6 x.0 din scr thumb m6-.0 x 25mm switch fuse fuse block fshcs m5-0.8 x boot battery cable end blk / boot battery cable end y-type signet charger global input 25a ac power cord not shown hhcs m6 x x 30 gr8.8 iso 404 din m6 flat washer din nut hex m6 x gr8.8 self locking din Battery Tray Signet Charger A S2632E Repair Parts 9

18 Repair Parts 0 S2632E 42033

19 Item Part No. Qty. Description Hydraulic Tray WLDMT. HYDRAULIC TRAY RESERVOIR HYDRAULIC 8367 cap FILTER RETURN IN TANK M6 FLAT WASHER DIN SLOTTED HEX WSHR HD SHT MTL SCR #4 X WASHER, FLAT,.375 STANDARD, PLATED BLT HEXHD GR SCISSORS MANIFOLD (refer to hydraulics 7) WSHR LOCK.500 SPLIT TYPE BLT HEXHD GR LCD SCREEN PG TRIONIC PG TRIONICS EZLIFT 230 CONTROLLER CONTACTOR, 24V SEALED MOTOR 24V PUMP MOUNT PUMP 2 SEC 6CC/4CC FLUIDTECH Continued on next page Hydraulic Tray S2632E Repair Parts

20 Item Part No. Qty. Description Hydraulic Tray WSHR LOCK.375 SPLIT TYPE BLT HEXHD GR FTG, HYD -8 MB TO -8 MJIC FTG, HYD -0 MB TO -8 MJIC ADAPTER 90 DEG ELBOW -8 SAE TO -8 JIC ADAPTER 90 DEG ELBOW SWIVEL -8 JIC FTG, HYD -6 MB TO -4 MJIC NIPPLE DIAGNOSTIC -4 SAE FTG, HYD -8 MB TO -6 MJIC LONG ADAPTER TEE SWIVEL -4 JIC TO -4 JIC FEMALE TO -4 JIC NIPPLE DIAGNOSTIC -4JIC FEMALE FTG, HYD -2 MB TO -8 MJIC BRG. FLG. TRAY DOORS HHCS M6 X x 30 G8.8 ISO 404_DIN NUT, HEX M6 X.0 GR 8.8 SELF LOCKING DIN HHCS M6 X x 40 G8.8 ISO 404_DIN M0 FLAT WASHER DIN HHCS M0 X.5 x 40 G8.8 DIN NUT HEX M0 X.50 GR 8.8 SELF LOCKING DIN LATCH LH TRAY ROTARY LOCK SCR THUMB M6-.0 X 25MM NUT, HEX, M6 X.0 DIN NUT HEX M8 X.25 GR 8.8 SELF LOCKING DIN M8 FLAT WASHER DIN HHCS M8 x.25 x 40 G8.8 ISO 404_DIN ADAPTER 45 DEG ELBOW SWIVEL -6 JIC ADAPTER 45 DEG ELBOW -8 SAE -8 JIC ADAPTER 45 DEG ELBOW SWIVEL -8 JIC ADAPTER 90 DEG ELBOW SWIVEL -4 JIC wire 2 r32 r37520 red wire 2 r33i r33i 2 sp-28/ hose -8-8s-8s 6 00r hose -8-8s-8s r wire 2 r33i r33i 2 sp wire 2 r375 r33 0 black harness onboard diagnostic diode wire assembly wire 2 r375i r32i 02 red wire 2 r375 r33 00 black diode wire assembly boot battery cable end black /0ga boot battery cable end Y type Hydraulic Tray Repair Parts 2 S2632E 42033

21 Pothole and Scissor Stack Switch Mounting/Standard Installation Before April, 202 Item Part No. Qty. Description switch assembly (refer to electrical 47) BLT, skthd M4 7 x 25mm BLT, skthd M4 7 x 30mm nut lkg m wshr flat m4 Pothole and Scissor Stack Switch Mounting/Standard Installation Before April, 202 A3604E A S2632E Repair Parts 3

22 Repair Parts 4 S2632E 42033

23 Pothole and Scissor Stack Switch Mounting/CE Installation Before April, 202 Item Part No. Qty. Description switch assembly (refer to electrical 47) term male 250Fi 6/ BLT, skthd M4 7 x 25mm BLT, skthd M4 7 x 30mm nut lkg nut lkg m wshr flat m4 A3604E A Pothole and Scissor Stack Switch Mounting/CE Installation Before April, 202 S2632E Repair Parts 5

24 Repair Parts 6 S2632E 42033

25 Item Part No. Qty. Description Scissor Stack HHCS M0 X.5 x 25 G8.8 DIN WELDMENT, PIVOT ARM SLIDE BLOCK WLDMT, EMER BLEED DOWN PIN, LIFT CYLINDER PIN, LIFT CYLINDER SLIDE BLOCK,CHASSIS PIN, SLIDE BLOCK CHASSIS WLDMT. 4TH OUTER ARM, LH WLDMT. 4TH OUTER ARM, RH WLDMT. 4TH INNER ARM PIN, PLATFORM MOUNT, REAR PIN STACK CENTER MM SHAFT BRG RETAINER WLDMT, 3rd OUTER ARM WLDMNT. 3RD INNER ARM WLDMNT. 2nd INNER ARM WLDMNT, 2nd OUTER ARM PIN STACK SHORT WLDMNT. st INNER ARM wldmnt, st OUTER ARM RH WLDMNT, st OUTER ARM RH WLDMNT, PLATFORM SLIDE SLIDE PAD SAFETY PROP S2632M WLDMT. POTHOLE ACTIVATOR BKT BRG 32MM x 36MM x 40MM LG HHCS M6 X x 2 G8.8 ISO 407_DIN HHCS M0 X.5 x 40 G8.8 DIN HHCS M0 X.5 x 65 G8.8 DIN NUT HEX M0 X.50 GR 8.8 SELF LOCKING DIN NUT HEX M8 X.25 GR 8.8 SELF LOCKING DIN FSHCS M8 X.25 X 30 CLASS 8.8 DIN SNAP RING, EXTERNAL 32MM LIFT CYLINDER 26/32 (refer to hydraulics ) HHCS M8 x.25 x 65 G8.8 ISO 404_DIN WSHR LOCK M6 DIN 27 Scissor Stack S2632E Repair Parts 7

26 Repair Parts 8 S2632E 42033

27 Item Part No. Qty. Description Platform Before August 4, snap pin w/lanyard WELDMENT narrow nut hex m8 x.25 gr8.8 self locking din weldment handrail main weldment handrail weldment extension weldment handrail weldment handrail extension weldment front tube mid handrail roller platform extension deck lower pin roll m slide pad 25mm 6mm thick roller platform hhcs m8 x.25 x 00 gr8.8 iso 407 din m2 flat washer din hhcs m8 x.25 x 50 gr8.8 iso 404 din hhcs m8 x.25 x 70 gr8.8 iso 404 din aluminum pop rivet lghd 4.8 x 9.2 steel mandrel slide pad lever pivot bracket weldment spring latch lever bracket hhcs m6 x x 20 gr8.8 iso 407 din nut hex m6 x gr8.8 self locking din hhcs m8 x.25 x 80 gr8.8 iso 404 din 93 Platform Before August 4, S2632E Repair Parts 9

28 Repair Parts 20 S2632E 42033

29 Item Part No. Qty. Description Platform After August 3, WELDMENT narrow weldment extension extension deck lower rails main deck lower side rail extension deck upper hinged rail weldment handrail top weldment handrail top main deck end handrail WELDMENT handrail extension WELDMENT handrail extension assembly Upper control Box ansi (refer to electrical 25 to 3) assembly Upper control Box ce/au (refer to electrical 33 to 39) platform extension deck end weldment swing spring hinge drilled latch striker set compartment literature m8 flat washer din hhcs m8 x.25 x 50 gr8.8 iso 404 din nut hex m8 x.25 gr8.8 self locking din hhcs m8 x.25 x 45 gr8.8 iso 404 din snap pin w/lanyard lever pivot bracket weldment hhcs m8 x.25 x 25 gr8.8 iso 404 din lever bracket spring latch slide pad roller platform extension deck lower pin roll.375 dia roller platform hhcs m0 x.5 x 80 gr8.8 din nut hex m0 x.5 gr8.8 self locking din slide pad aluminum pop rivet lghd 4.8 x 9.2 steel mandrel hhcs m6 x x 45 gr8.8 iso 404 din nut hex m6 x gr8.8 self locking din Platform After August 3, A S2632E Repair Parts 2

30 Repair Parts 22 S2632E 42033

31 Item Part No. Qty. Description Stack/Platform Installation STACK ASSEMBLY S2632E PLATF ASSY INSTALL TRAYS HHCS M0 X.5 x 50 G8.8 DIN NUT HEX M2 X.75 GR 0.9 SELF LOCKING DIN SENSOR MAGnetic (refer to electrical 49) PIN, STACK PIVOT HHCS M0 X.5 x 65 G8.8 DIN NUT HEX M0 X.50 GR 8.8 SELF LOCKING DIN HHCS M4 X 0.7 x 6 G8.8 ISO 407 DIN NUT HEX M4 X 0.70 GR 8.8 SELF LOCKING DIN WLDMT, STEP M2 FLAT WASHER DIN HHCS M2 x.75 x 40 G8.8 DIN NUT HEX M2 X.75 GR 8.8 SELF LOCKING DIN 985 Stack/Platform Installation S2632E Repair Parts 23

32 Repair Parts 24 S2632E 42033

33 Placards and Decals 2 inch 6.3 inch C S A A n chor O p tio n 2 inch A n chor O p tio n C S A O N E O N E A C H W H E E L ONE ABOVE E A C H W H E E L ONE AS SHOW N AND ONE IN S ID E T R AY C O M PA R T M E N T Placards and Decals S2632E Repair Parts 25

34 Item Part No. Qty. Description Placards and Decals Placard caution serial number ANSI only Placard caution serial number AU only Decal 25 volt 5 amp US only Decal manual holder Decal notice manual re-order Decal wheel load S2632E Decal cylinder failure per cylinder Decal power to platform US only Decal machine complies with ANSI Placard operators checklist Decal danger shearing US only Decal danger towing US only Decal danger tipover hazard Decal hydraulic oil level Decal Snorkel S2632E Decal danger safety prop A/R Decal platform capacity 500# Decal emergency bleed down S2632E Placard battery charger information Lester charger Before August 8, Placard battery charger information Signet charger After August 7, Decal danger tipover/electrical hzrd Decal tie down Decal battery charger plug US only Decal check battery before charging Decal hydraulic fluid level Decal do not alter switch Compartment literature Decal Snorkel logo S2632E Decal Snorkel logo S930E/S932E Ground strap Decal fork lift A/R Decal warning stripe sold by roll Placard upper controls S2632E ANSI Placard upper controls S2632E CE/AU Bolt Placard lower controls S930E/S932E/S2632E ANSI Before December 6, Placard lower controls S930E/S932E/S2632E All After December 5, Washer flat Nut locking Cushion tube 8 inch US only Decal Snorkellift.com Decal lug nut torque 5 lug wheels only Decal attach fall restraint option only Decal CSA compliant CSA only CE ONLY Placard battery disconnect switch Decal foot crushing hazard Decal CE logo Decal platform capacity 500# No wind rating S930E/S2632E Only Decal battery charger plug Decal emergency stop E Decal do not reach symbol CE Decal danger towing CE Placard caution serial number CE Decal danger tipover/electrical hzrd CE/AU Placards and Decals Repair Parts 26 S2632E 42033

35 Hydraulics S2632E Hydraulics

36 Hydraulics 2 S2632E 42033

37 Item Part No. Qty. Description Drive Speed Manifold MANIFOLD DRIVE SPEED SOLENOID VALVE DUAL SPADE COIL 20 VDC FLOW DIVIDER NEEDLE VALVE 5 4 7MM PERMANENT PLUG Non-serviceable part VALVE BODY, DRIVE SPEED Drive Speed Manifold A S2632E Hydraulics 3

38 Hydraulics 4 S2632E 42033

39 Item Part No. Qty. Description Hydraulic Drive Motor Hydraulic drive motor Seal repair kit Front housing bearing Housing Front thrust washer Front thrust bearing thrust washer Rear thrust bearing Drive link Manifold Rotor assembly Balance plate with 3 balls drive link spacer End cover Assembly bolts Shaft Shaft key Shaft nut Hydraulic Drive Motor A S2632E Hydraulics 5

40 Hydraulics 6 S2632E 42033

41 Item Part No. Qty. Description Manifold Valve MAIN MANIFOLD VALVE FLOW DIVIDER SEQUENCE VALVE CHECK VALVE RELIEF VALVE SOLENOID VALVE RELIEF VALVE SOLENOID VALVE SOLENOID VALVE SOLENOID VALVE VALVE COUNTER BALANCE SHUTTLE VALVE SOLENOID VALVE COIL,20VDC DUAL SPADE COIL 20 VDC ORIFICE CHECK VALVE PILOT CHECK (MAN O/R) KNOB & LOCK RING KIT HAND PUMP PUSH RELEASE SAE O-RING PLUG FLUSH HEAD O-RING PLUG FLUSH HEAD VALVE BODY Manifold Valve A S2632E Hydraulics 7

42 Hydraulics 8 S2632E 42033

43 Item Part No. Qty. Description Steering Cylinder Cylinder, steering EM.C seal kit is not available for em.c cylinder Steering Cylinder D S2632E Hydraulics 9

44 Hydraulics 0 S2632E 42033

45 Lift Cylinder Item Part No. Qty. Description Cylinder, lift Green Seal kit Green (includes items 9 through 4) gland,cyl set screw check valve, lift cyl solenoid valve assy 20V DC (includes items 5 and 6) solenoid 20v dc cartridge valve rod assembly barrel assembly 9 Kit item 2 split bronze ring not sold separately 0 Kit item O-ring not sold separately Kit item Back-up not sold separately 2 Kit item wear ring not sold separately 3 Kit item Rod seal ur not sold separately 4 Kit item rod wiper not sold separately Lift Cylinder B S2632E Hydraulics

46 Hydraulics 2 S2632E 42033

47 Electrical S2632E Electrical

48 Electrical 2 S2632E 42033

49 Item Part No. Qty. Description Battery Tray Wiring Signet Charger wire 2 r32 R red wire 2 r375 r375 9 black wire 2 r32 r black ied c4 to us plug wire 2 r375 ir.32 i02 red wire 2 r375 ir.32 i00 black TO H Y D R A U L IC T R AY Z IP T IE A S N E E D E D 2/AW G R E D /AW G B LK /AW G B L A C K 0 4 R E D W IR E 2 /AW G R E D 0 B L A C K W IR E R E M O V E P L U G F R O M H O U S IN G A N D IN S E R T P L U G F R O M C H A R G E R S L IT B O O T A N D W R A P W IT H TA P E A S N E C E S S A R Y W H IT E 6 AW G W IR E R E P L A C E P 5 - O N C O N TA C TO R B LA C K 6AW G W IR E B U T T S P L IC E TO P 5- W IR E F R O M M A IN H A R N E S S Battery Tray Wiring Signet Charger A S2632E Electrical 3

50 Electrical 4 S2632E 42033

51 Lower Control Box ANSI Before September 20 Item Part No. Qty. Description WLDMT, LOWER CONTROL BOX SW TGL SPDT (ON/NONE/ON) SW TGL SPDT (ON) OFF (ON) PUSH/PULL SW ASSY W/NC CONTACT HOURMETER, 2 TO 60 VDC, SQUARE ALARM, ECCO BEEPING 6-28VDC PLAC GROUND CONT BOX LWR HARNESS CONN LWR HARNESS DUETSCH CONN Lower Control Box ANSI Before September C S2632E Electrical 5

52 Lower Control Box Connector Pin ID ANSI Before September 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 VALVE SUPPLY P3-2 6 DRIVE SELECT SWITCH P3-6 7 LIFT SELECT SWITCH P3-7 8 STEER RIGHT SWITCH P3-8 9 STEER LEFT SWITCH P3-9 0 TRIGGER SWITCH P3-2 EMS GROUND P4-2 LIFT DOWN SWITCH P4-4 3 LIFT UP SWITCH P4-5 4 GROUND ALARM OUTPUT P5-0 5 GROUND 3 6 HOUR METER CONTROL HOUR 7 EMERGENCY STOP SWITCH EMS 8 TORQUE/TRACTION SWITCH P3-3 9 OVERLOAD LAMP P-8 20 SPARE 2 SPARE 22 SPARE 23 SPARE 24 SPARE Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 DRIVE SELECT SWITCH P3-6 6 PLATFORM EMS PLAT EMS 7 TORQUE/TRACTION SWITCH P3-3 8 LIFT SELECT SWITCH P3-7 9 STEER RIGHT SWITCH P3-8 0 STEER LEFT SWITCH P3-9 TRIGGER SWITCH P3-2 2 SPARE Lower Control Box Connector Pin ID ANSI Before September 20 Electrical 6 S2632E 42033

53 Lower Control Box Internal Wiring Harness ANSI Before September 20 Item Part No. Qty. Description TERM STRIP (4) 45/90 DEG WIRE 8 FEM 88I FEM 88I WIRE 8 FEM 88I FEM 250FI WIRE 8 R6I FEM 88I WIRE 8 R6I FEM 88I WIRE 8 SPECIAL WIRE 8 R6I R6I WIRE 8 R6I SPADE8I WIRE FUSE HOLDER WIRE 8 R6I FEM 88I FUSE 5 AMP 8 REF REF Lower Control Box Internal Wiring Harness ANSI Before September 20 S2632E Electrical C

54 Electrical 8 S2632E 42033

55 Lower Control Box ANSI After August 20 Item Part No. Qty. Description WLDMT, LOWER CONTROL SW TGL SPDT (ON/NONE/ON) SW TGL SPDT (ON) OFF (ON) HOURMETER, 2 TO 60 VDC, SQUARE PLAC GROUND CONT BOX LWR HARNESS CONN PUSH/PULL SW ASSY W/NC CONTACT ALARM, ECCO BEEPING 6-28VDC LWR HARNESS DUETSCH CONN LATCH Lower Control Box ANSI After August D S2632E Electrical 9

56 Lower Control Box Connector Pin ID ANSI After August 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 VALVE SUPPLY P3-2 6 DRIVE SELECT SWITCH P3-6 7 LIFT SELECT SWITCH P3-7 8 STEER RIGHT SWITCH P3-8 9 STEER LEFT SWITCH P3-9 0 TRIGGER SWITCH P3-2 EMS GROUND P4-2 LIFT DOWN SWITCH P4-4 3 LIFT UP SWITCH P4-5 4 GROUND ALARM OUTPUT P5-0 5 GROUND 3 6 HOUR METER CONTROL HOUR 7 EMERGENCY STOP SWITCH EMS 8 TORQUE/TRACTION SWITCH P3-3 9 OVERLOAD LAMP P-8 20 SPARE 2 SPARE 22 SPARE 23 SPARE 24 SPARE Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 DRIVE SELECT SWITCH P3-6 6 PLATFORM EMS PLAT EMS 7 OVERLOAD LAMP P-8 8 LIFT SELECT SWITCH P3-7 9 STEER RIGHT SWITCH P3-8 0 STEER LEFT SWITCH P3-9 TRIGGER SWITCH P3-2 2 GROUND 3 Lower Control Box Connector Pin ID ANSI After August 20 Electrical 0 S2632E 42033

57 Lower Control Box Internal Wiring Harness ANSI After August 20 Item Part No. Qty. Description TERM STRIP (4) 45/90 DEG WIRE 8 FEM88I FEM88I WIRE 8 FEM88I FEM250FI WIRE 8 R6I FEM88I WIRE 8 R6I FEM88I WIRE 8 SPECIAL WIRE 8 R6I R6I WIRE 8 R6I SPADE8I WIRE FUSE HOLDER WIRE 8 R6I FEM88I FUSE 5 AMP P 3-8 P 3-7 P 3-6 P R E F P 4-4 P 4 - P 3-2 P - 5 H O U R P -3 P 3-3 P -4 P -8 P 3 - P P 5-0 P P - P -3 P -4 P 3 - P 3-2 P 3-6 P P 3-9 P 3-8 P R E F P 3-7 P 3-3 P L AT H O U R P L AT P P P 4-4 P P 4-5 P -3 2 P 3-2 P -4 3 P 3-9 P P P P 3-7 PLAT EMS 6 7 P L IF T /D O W N S W IT C H 0 8 S E L E C ST W IT C H E -S TO P H O U R M E T E R + - A L A R M Lower Control Box Internal Wiring Harness ANSI After August 20 S2632E Electrical D

58 Electrical 2 S2632E 42033

59 Lower Control Box ANSI/AU After December 5, 20 Item Part No. Qty. Description WLDMT, LOWER CONTROL LWR HARNESS CONN LWR HARNESS CONN LATCH HOURMETER, 2 TO 60 VDC, SQUARE PUSH/PULL SW ASSY W/NC CONTACT ALARM, ECCO BEEPING 6-28VDC SW TGL SPDT (ON/NONE/ON) PLAC GROUND CONT BOX SW TGL SPDT (ON) OFF SELECTOR SWITCH SPARE KEY SOLD IN PAIRS QTY DECAL, LOWER CONTROL Lower Control Box ANSI/AU After December 5, B S2632E Electrical 3

60 Lower Control Box Connector Pin ID ANSI/AU After December 5, 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 VALVE SUPPLY P3-2 6 DRIVE SELECT SWITCH P3-6 7 LIFT SELECT SWITCH P3-7 8 STEER RIGHT SWITCH P3-8 9 STEER LEFT SWITCH P3-9 0 TRIGGER SWITCH P3-2 EMS GROUND P4-2 LIFT DOWN SWITCH P4-4 3 LIFT UP SWITCH P4-5 4 GROUND ALARM OUTPUT P5-0 5 GROUND 3 6 HOUR METER CONTROL HOUR 7 EMERGENCY STOP SWITCH EMS 8 TORQUE/TRACTION SWITCH P3-3 9 OVERLOAD LAMP P-8 20 SPARE 2 SPARE 22 SPARE 23 SPARE 24 SPARE Item Pin ID Connector Position Description Wire P- 2 P-3 3 P-4 4 P3-5 P3-6 6 PLAT EMS 7 P3-3 8 P3-7 9 P3-8 0 P3-9 P3-2 2 P P SPARE Lower Control Box Connector Pin ID ANSI/AU After December 5, 20 Electrical 4 S2632E 42033

61 Lower Control Box Internal Wiring Harness ANSI/AU After December 5, 20 Item Part No. Qty. Description TERM STIP (4) 45/90 DEG WIRE SPADE8I SPADE8I WIRE SPADE8I R6I WIRE R6I FEM88I WIRE FEM88I FEM250FI WIRE SPECIAL WIRE 8 R6I FEM88I WIRE FEM88I SPADE8I WIRE FUSE HOLDER FUSE 5 AMP WIRE 8 R6I R6I 5 P 3-8 P 3-7 P 3-6 P P 4-4 P 4 - P 3-2 P - 5 H O U R P -3 P 3-3 P -4 P -8 P 3 - P P 5-0 P P - P -3 P -4 P 3 - P 3-2 P 3-6 P P P 3-8 P 5-0 P 3-6 P LATE M S P 3-3 P 3-7 P 3-3 H O U R P L AT P -4 P -3 P - 5 P 3-7 P 3-9 P L AT P 3 - P -8 P 4 - P 4-4 P P 3-2 P 3-2 P P -8 3 P E N A B L E G R O U N D P L AT F O R M L IF T /D O W N S W IT C H 0 3 S W IT C H 2 E -S TO P - + H O U R M E T E R + - A L A R M B Lower Control Box Internal Wiring Harness ANSI/AU After December 5, 20 S2632E Electrical 5

62 Electrical 6 S2632E 42033

63 Lower Control Box CE Before December 6, 20 Item Part No. Qty. Description WLDMT, LOWER CONTROL BOX SW TGL SPDT (ON) OFF (ON) PUSH/PULL SW ASSY W/NC CONTACT HOURMETER, 2 TO 60 VDC, SQUARE ALARM, ECCO BEEPING 6-28VDC PLAC GROUND CONT BOX LWR HARNESS CONN LWR HARNESS DUETSCH CONN SW TGL SPDT (ON) OFF SELECTOR SWITCH SPARE KEY SOLD IN PAIRS QTY Lower Control Box CE Before December 6, C S2632E Electrical 7

64 Lower Control Box Connector Pin ID CE Before December 6, 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 VALVE SUPPLY P3-2 6 DRIVE SELECT SWITCH P3-6 7 LIFT SELECT SWITCH P3-7 8 STEER RIGHT SWITCH P3-8 9 STEER LEFT SWITCH P3-9 0 TRIGGER SWITCH P3-2 EMS GROUND P4-2 LIFT DOWN SWITCH P4-4 3 LIFT UP SWITCH P4-5 4 GROUND ALARM OUTPUT P5-0 5 GROUND 3 6 HOUR METER CONTROL HOUR 7 EMERGENCY STOP SWITCH EMS 8 TORQUE/TRACTION SWITCH P3-3 9 OVERLOAD LAMP P-8 20 SPARE 2 SPARE 22 SPARE 23 SPARE 24 SPARE Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 DRIVE SELECT SWITCH P3-6 6 PLATFORM EMS PLAT EMS 7 OVERLOAD LAMP P-8 8 LIFT SELECT SWITCH P3-7 9 STEER RIGHT SWITCH P3-8 0 STEER LEFT SWITCH P3-9 TRIGGER SWITCH P3-2 2 GROUND 3 Lower Control Box Connector Pin ID CE Before December 6, 20 Electrical 8 S2632E 42033

65 Lower Control Box Internal Wiring Harness CE Before December 6, 20 Item Part No. Qty. Description TERM STRIP (4) 45/90 DEG WIRE SPADE8I SPADE8I WIRE SPADE8I R6I WIRE R6I FEM 88I WIRE FEM 88I FEM250FI WIRE 8 SPECIAL WIRE 8 R6I FEM 88I WIRE FEM 88I SPADE8I WIRE FUSE HOLDER FUSE 5 AMP WIRE 8 R6I R6I 5 P 3-8 P 3-7 P R E F P 3-2 P 4-4 P 4 - P 3-2 P - 5 H O U R P -3 P 3-3 P -4 P -8 P 3 - P P 5-0 P P - P -3 P -4 P 3 - P 3-2 P 3-6 P P P 3-8 P R E F P 3-7 P 3-3 H O U R P L AT P L AT P 4 - P 3 - P 4-4 P - 3 P -8 P 4-5 P -3 2 P 3-2 P -4 3 P P P P 3-6 P L AT E M S P 3-7 P E N A B L E G R O U N D P L AT F O R M L IF T /D O W N S W IT C H 0 3 S W IT C H 2 E -S TO P - + H O U R M E T E R + - A L A R M C Lower Control Box Internal Wiring Harness CE Before December 6, 20 S2632E Electrical 9

66 Electrical 20 S2632E 42033

67 Lower Control Box CE After December 5, 20 Item Part No. Qty. Description WLDMT, LOWER CONTROL LWR HARNESS CONN LWR HARNESS CONN LATCH HOURMETER, 2 TO 60 VDC, SQUARE PUSH/PULL SW ASSY W/NC CONTACT ALARM, ECCO BEEPING 6-28VDC SW TGL SPDT (ON/NONE/ON) PLAC GROUND CONT BOX SW TGL SPDT (ON) OFF SELECTOR SWITCH SPARE KEY SOLD IN PAIRS QTY DECAL, LOWER CONTROL Lower Control Box CE After December 5, D S2632E Electrical 2

68 Lower Control Box Connector Pin ID C After December 5, 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 JOYSTICK ANALOG INPUT P-4 4 EMS PLATFORM P3-5 VALVE SUPPLY P3-2 6 DRIVE SELECT SWITCH P3-6 7 LIFT SELECT SWITCH P3-7 8 STEER RIGHT SWITCH P3-8 9 STEER LEFT SWITCH P3-9 0 TRIGGER SWITCH P3-2 EMS GROUND P4-2 LIFT DOWN SWITCH P4-4 3 LIFT UP SWITCH P4-5 4 GROUND ALARM OUTPUT P5-0 5 GROUND 3 6 HOUR METER CONTROL HOUR 7 EMERGENCY STOP SWITCH EMS 8 TORQUE/TRACTION SWITCH P3-3 9 OVERLOAD LAMP P-8 20 SPARE 2 SPARE 22 SPARE 23 SPARE 24 SPARE Item Pin ID Connector Position Description Wire P- 2 P-3 3 P-4 4 P3-5 P3-6 6 PLAT EMS 7 P3-3 8 P3-7 9 P3-8 0 P3-9 P3-2 2 P P SPARE Lower Control Box Connector Pin ID CE After December 5, 20 Electrical 22 S2632E 42033

69 Lower Control Box Internal Wiring Harness CE After December 5, 20 Item Part No. Qty. Description TERM STRIP (4) 45/90 DEG WIRE SPADE8I SPADE8I WIRE SPADE8I R6I WIRE R6I FEM 88I WIRE FEM 88I FEM250FI WIRE 8 SPECIAL WIRE 8 R6I FEM 88I WIRE FEM 88I SPADE8I WIRE FUSE HOLDER FUSE 5 AMP WIRE 8 R6I R6I 5 P 3-8 P 3-7 P 3-6 P P 4-4 P 4 - P 3-2 P - 5 H O U R P -3 P 3-3 P -4 P -8 P 3 - P P 5-0 P P - P -3 P -4 P 3 - P 3-2 P 3-6 P P P 3-8 P 5-0 P 3-6 P L AT E M S P 3-3 P 3-7 P 3-3 H O U R P L AT P -4 P -3 P - 5 P 3-7 P 3-9 P L AT P 3 - P -8 P 4 - P 4-4 P P 3-2 P 3-2 P P -8 3 P 3-8 E N A B L E G R O U N D P L AT F O R M L IF T /D O W N S W IT C H 0 3 S W IT C H 2 E -S TO P - + H O U R M E T E R + - A L A R M Lower Control Box Internal Wiring Harness CE After December 5, D S2632E Electrical 23

70 Electrical 24 S2632E 42033

71 Upper Control Box ANSI Before December 6, 20 Item Part No. Qty. Description WLDMT, UPPER CONTROL BOX PLAC, UPPER CONTROL JOYSTICK (REFER TO ELECTRICAL 40.) PUSH/PULL SW ASSY W/NC CONTACT SW TGL SPDT (ON/NONE/ON) SW TGL SPST ON OFF DECAL, EMERGENCY STOP HHCS M4 X 0.7 x 25 G8.8 ISO 407 DIN NUT LKG M PLT, PLAT CONT SCR SLFTPG M6 X 5LG HARNESS PLATF CONTROL HOLE PLUG.25 Upper Control Box ANSI Before December 6, C S2632E Electrical 25

72 Upper Control Box Connector Pin ID ANSI Before December 6, 20 Item Pin ID Connector Position Description Wire A 5V TO JOYSTICK P- B 0V TO JOYSTICK P-3 C JOYSTICK ANALOG INPUT P-4 D EMS PLATFORM P3- E DRIVE SELECT SWITCH P3-6 F PLATFORM EMS PLAT EMS G TORQUE/TRACTION SWITCH P3-3 H LIFT SELECT SWITCH P3-7 J STEER RIGHT SWITCH P3-8 K STEER LEFT SWITCH P3-9 L TRIGGER SWITCH P3-2 M OVERLOAD LAMP P-8 N GROUND 3 P SPARE Upper Control Box Connector Pin ID ANSI Before December 6, 20 Electrical 26 S2632E 42033

73 Controller Upper Control Box ANSI Before December 6, 20 Item Part No. Qty. Description WIRE 8 R6I SPADE8I WIRE 8 R6I R6I5 NOT SHOWN HARNESS DIODE FOR JOYSTICK Controller Upper Control Box ANSI Before December 6, C S2632E Electrical 27

74 Electrical 28 S2632E 42033

75 Upper Control Box ANSI After December 5, 20 Item Part No. Qty. Description WLDMT, PLATFORM PLAC, PLATFORM CONTROL BOX JOYSTICK (REFER TO ELECTRICAL 40.) PUSH/PULL SW ASSY W/NC CONTACT SW TGL SPDT (ON/NONE/ON) SW TGL SPST ON OFF DECAL, EMERGENCY STOP HHCS M4 X 0.7 x 25 G8.8 ISO 407 DIN NUT HEX M4 X 0.70 GR 8.8 SELF LOCKING DIN PLT, PLAT CONT SCR SLFTPG M6 X 5LG UPPER HARNESS PLATF CONTROL HOLE PLUG.25 Upper Control Box ANSI After December 5, A S2632E Electrical 29

76 Upper Control Box Connector Pin ID ANSI After December 5, 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 GROUND 3 4 JOYSTICK ANALOG INPUT P-4 5 EMS PLATFORM P3-6 POWER FROM LCB P3-2 7 DRIVE SELECT SWITCH P3-6 8 PLATFORM EMS PLAT EMS 9 TORQUE/TRACTION SWITCH P3-3 0 LIFT SELECT SWITCH P3-7 STEER RIGHT SWITCH P3-8 2 STEER LEFT SWITCH P3-9 3 TRIGGER SWITCH P3-2 4 OVERLOAD LAMP P-8 5 SPARE 6 SPARE 7 SPARE 8 SPARE 9 SPARE 20 SPARE 2 SPARE Upper Control Box Connector Pin ID ANSI After December 5, 20 Electrical 30 S2632E 42033

77 Controller Upper Control Box ANSI After December 5, 20 Item Part No. Qty. Description WIRE 8 R6I SPADE8I WIRE 8 R6I R6I5 NOT SHOWN HARNESS DIODE FOR JOYSTICK Controller Upper Control Box ANSI After December 5, A S2632E Electrical 3

78 Electrical 32 S2632E 42033

79 Upper Control Box CE Before December 6, 20 Item Part No. Qty. Description WLDMT, UPPER CONTROL BOX JOYSTICK (REFER TO ELECTRICAL 40.) HHCS M4 X 0.7 x 25 G8.8 ISO 407 DIN NUT LKG M PUSH/PULL SW ASSY W/NC CONTACT SW TGL SPDT (ON/NONE/ON) SW TGL SPST ON OFF PLAC, UPPER CONTROL PLT, PLAT CONT SCR SLFTPG M6 X 5LG HARNESS PLATF CONT ALARM MINI SIREN SW PUSH BUTTON DECAL, HORN DECAL, EMERGENCY STOP LIGHT RED 24 VDC BATTERY GAUGE Upper Control Box CE Before December 6, A S2632E Electrical 33

80 Upper Control Box Connector Pin ID ANSI Before December 6, 20 Item Pin ID Connector Position Description Wire A 5V TO JOYSTICK P- B 0V TO JOYSTICK P-3 C JOYSTICK ANALOG INPUT P-4 D EMS PLATFORM P3- E DRIVE SELECT SWITCH P3-6 F PLATFORM EMS PLAT EMS G TORQUE/TRACTION SWITCH P3-3 H LIFT SELECT SWITCH P3-7 J STEER RIGHT SWITCH P3-8 K STEER LEFT SWITCH P3-9 L TRIGGER SWITCH P3-2 M OVERLOAD LAMP P-8 N GROUND 3 P SPARE Upper Control Box Connector Pin ID ANSI Before December 6, 20 Electrical 34 S2632E 42033

81 Controller Upper Control Box CE Before December 6, 20 Item Part No. Qty. Description WIRE 8 R6I SPADE8I WIRE SPECIAL WIRE R6I FEM88I WIRE 8 FEM250FI R WIRE 8 R6I R6I 5 3 Controller Upper Control Box CE Before December 6, A S2632E Electrical 35

82 Electrical 36 S2632E 42033

83 Upper Control Box CE/AU After December 5, 20 Item Part No. Qty. Description WLDMT, PLATFORM JOYSTICK (REFER TO ELECTRICAL 40.) HHCS M4 X 0.7 x 25 G8.8 ISO 404_DIN NUT HEX M4 X 0.70 GR 8.8 SELF LOCKING DIN PUSH/PULL SW ASSY W/NC CONTACT SW TGL SPDT (ON/NONE/ON) SW TGL SPST ON OFF PLAC, PLAT CONT BOX PLT, PLAT CONT SCR SLFTPG M6 X 5LG HARNESS PLATF CONT ALARM MINI SIREN SW PUSH BUTTON DECAL, HORN DECAL, EMERGENCY STOP LIGHT RED 24VDC BATTERY GAUGE Upper Control Box CE/AU After December 5, A S2632E Electrical 37

84 Upper Control Box Connector Pin ID ANSI After December 5, 20 Item Pin ID Connector Position Description Wire 5V TO JOYSTICK P- 2 0V TO JOYSTICK P-3 3 GROUND 3 4 JOYSTICK ANALOG INPUT P-4 5 EMS PLATFORM P3-6 POWER FROM LCB P3-2 7 DRIVE SELECT SWITCH P3-6 8 PLATFORM EMS PLAT EMS 9 TORQUE/TRACTION SWITCH P3-3 0 LIFT SELECT SWITCH P3-7 STEER RIGHT SWITCH P3-8 2 STEER LEFT SWITCH P3-9 3 TRIGGER SWITCH P3-2 4 OVERLOAD LAMP P-8 5 SPARE 6 SPARE 7 SPARE 8 SPARE 9 SPARE 20 SPARE 2 SPARE Upper Control Box Connector Pin ID ANSI After December 5, 20 Electrical 38 S2632E 42033

85 Controller Upper Control Box CE/AU After December 5, 20 Item Part No. Qty. Description WIRE 8 R6I SPADE8I WIRE SPECIAL WIRE R6I FEM88I WIRE 8 FEM250FI R WIRE 8 R6I R6I 5 NOT SHOWN HARNESS DIODE FOR JOYSTICK P -4 P 3-2 P 3-9 P -3 P 3-8 P - Controller Upper Control Box CE/AU After December 5, A S2632E Electrical 39

86 Electrical 40 S2632E 42033

87 Joystick Item Part No. Qty. Description JOYSTICK INCLUDES ITEMS THROUGH RING, RETAINING, BOOT BOOT, BH HANDLE SPACER, PLASTIC ACTUATOR, BH HANDLE LEVER, ENABLER, BH HANDLE GASKET, BH HANDLE GASKET, BH HANDLE PUSHBUTTON, MOMENTARY (BLACK) MICROSWITCH, BH HANDLE SCREW, BH HANDLE SCREW, BH HANDLE MACHINE SCREW M5 X 6 PAN H Joystick B S2632E

88 40.2 S2632E 42033

89 Item Part No. Qty. Description GFCI Electrical Outlet JUMPER WIRE 4 /2 LG ELECTRICAL BOX DRILLED PLUG MALE STR BLT GR WASHER FLAT WASHER LOCK CIRCUIT BREAKER 5 AMP CONN RECEPTACLE GFCI OUTLET 20 AMP COVER GFCI OUTLET WEATHERPROOF CUSHION CLAMP #8 / SCR SLFTPG THREAD CUTTING TERM SPADE 8I 2/ TERM R8I 2/ CABLE 4 GAUGE/3 CONDUCTOR X 38 FEET LONG Outlet Box Wiring GFCI Electrical Outlet D S2632E Electrical 4

90 Electrical 42 S2632E 42033

91 Platform Control Cable Before December 6, 20 Item Part No. Qty. Description CONN AMP 24 PIN PLUG AMP SOCKETS CONTACTS CONN 4-PIN DEUTSCH PLUG SOCKET CONTACT SIZE 6 6/8GA A/R CABLE 8GA/4 CONDUCTOR WIRE Platform Control Cable Before December 6, B S2632E Electrical 43

92 Electrical 44 S2632E 42033

93 Platform Control Cable After December 5, 20 Item Part No. Qty. Description CONN AMP 24 PIN PLUG AMP SOCKETS CONTACTS DEUTSCH PLUG HD36-8-2SN SOCKET CONTACT #20 6/8AWG SEALING PLUG-20 DEUTCH A/R CABLE 8GA/8 CONDUCTOR WIRE PLUG 2 WHITE PLUG 20 WHITE PLUG 9 WHITE SPARE WHITE SPARE WHITE SPARE WHITE SPARE 5 5 WHITE P WHITE P3-2 3 WHITE P WHITE P3-8 9 WHITE P WHITE P WHITE PLAT EMS 8 6 WHITE P WHITE P WHITE P3-5 4 WHITE P WHITE WHITE P WHITE P- WHITE WIRE NUMBERS LOCATION CONNECTOR A LOCATION CONNECTOR B WIRE COLOR Platform Control Cable After December 5, A S2632E Electrical 45

94 Electrical 46 S2632E 42033

95 Item Part No. Qty. Description Limit Switch Before April, SWITCH LIMIT MUST BREAK PIN, CONTACT (-6) DEUTSCH CONNECTOR, 4-PIN DEUTSCH RECEP LOCKWEDGE,W4P 4-PIN DEUTSCH PLUG BLACK REFERENCE BROWN BLUE BLACK/WHITE SCHEMATIC schematic before may 3, BLACK REFERENCE BROWN BLUE BLACK/WHITE schematic after May 2, 20 Limit Switch Before April, F S2632E Electrical 47

96 Electrical 48 S2632E 42033

97 Item Part No. Qty. Description Magnetic Sensor After April 0, SENSOR MAGNETIC CONNECTOR, 4-PIN DEUTSCH RECEP LOCKWEDGE,W4P 4-PIN DEUTSCH PLUG PIN, CONTACT (-6) DEUTSCH Magnetic Sensor After April 0, B S2632E Electrical 49

98 Electrical 50 S2632E 42033

99 Main Wiring Harness Before December 6, 20 Item Part No. Qty. Description CONN AMP 24 PIN PLUG AMP SOCKET CONTACTS TERM R32I 6/ TERM R0I 6/ SOCKET CONTACT -6 DEUTSCH TER FEM250FI 6/ A/R WIRE 6GA SINGLE COND BLK A/R WIRE 6GA SINGLE COND WHT CONN 4 PIN DEUTSCH PLUG LOCK WEDGE 4 PIN DEUTSCH PLUG SEALING PLUG -6 DEUTSCH CONN 2 PIN DEUTSCH LOCK WEDGE 2 PIN DEUTSCH PLUG CONN AMP 2 PIN PLUG CONN AMP 9 PIN PLUG AMP SOCKET CONTACT 20/ CONN 3 PIN AMP SOCKET 6/8 GA Main Wiring Harness Before December 6, C S2632E Electrical 5

100 Main Wiring Harness Before December 6, 20 Main Wiring Harness Before December 6, C Electrical 52 S2632E 42033

101 C AV C K T C AV C K T IN T E R L O C K C AV C K T C AV C K T C AV C K T C AV L E F T P P 5-9 B C AV R IG H T P C K T C K T C AV L E F T P 5-2B P C K T R IG H T P C AV C K T L E F T P P 2-8 B R IG H T P P R E S S U R E S E N S O R C AV C AV C K T C K T L E F T P P 2-3 B R IG H T P L E F T K 3 M C AV R IG H T 3 B 3 C 3 D 3 E 3 F C K T C AV C AV C K T C K T L E F T P 2-7 B P 2-7 C P 2-7 D P R IG H T P C AV C AV C K T C K T C AV C K T C AV L E F T P C K T R IG H T P P C AV C K T C AV C K T C AV C AV C K T L E F T P C K T R IG H T P 5 - P C AV C AV C K T C K T C AV C K T C AV C K T Main Wiring Harness After December 5, 20 Item Part No. Qty. Description CONNECTOR 2-WAY PLUG GRAY WEDGELOCK 2-WAY SOCKET CONNECTOR 4-WAY PLUG GRAY WEDGELOCK 4-WAY SOCKET PLUG CAVITY SIZE 2 AND RECEPTACLE BLUE CONNECTOR 3-WAY PLUG NATURAL CONNECTOR PLUG SEALED 5 PLUG CAVITY RING TERMINAL #0 STUD INSULATED BLUE RING TERMINAL 5/6IN STUD INSULATED BLUE CONNECTOR 9-WAY PLUG NATURAL CONNECTOR 2-WAY PLUG NATURAL CONNECTOR 2-WAY PLUG NATURAL IT E M 5 Section Refer to Page 54 L IF T C Y L IN D E R Part # IT E M P 5-2 B 2 P 2-8 B 2 4 IT E M 4 Part # P 2-7 D 2 P P 2-3 B 3 C O N T R O L B O X IT E M 6 IT E M 6 IT E M 7 Part # C AV C K T C AV C K T Part # Part # Part # IN T P E M S P - 3 P 4-5 F W D VA LV E S T E E R VA LV E U P VA LV E 2 P -3 4 P P P 3-6 P S P E M S 6 P P P P -8 8 P P P P P IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # Part # Part # P B 3 R E V VA LV E 3 P D P F S T E E R R VA LV E IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # Part # Part # P C P E D U M P VA LV E P IT E M 8 P Part # C AV C K T P P -3 4 P P IT E M 9 P 3 IT E M 8 P 2 Part # C AV C K T -- 2 P P P P P IT E M Part # P S P L -P 5-2 S P L Part # C AV C K T P 3-2 P P P P P S P L -P 2-8 S P L -P 2-3 S P L 3 S P L -P 2-7 S P L -5 8 P P P 3-2 IT E M 2 P O T H O LE S W Part # P 2-7 B 3 P S P L -P IT E M 4 A N G LE T R A N S Part # Section 2 Refer to Page IT E M 9 P 4 Part # C AV C K T P P P P P IT E M 0 P art # IN T 2 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # P 5-9 B P K 3 M IT E M 2 S TA C K S W Part # P P 4-6 P 2-7 C 2 P P IT E M 9 P 5 Part # C AV C K T P 5-2 P P P P P P 5-0 P 5-2 P 5-2 Section 3 Refer to Page 56 Main Wiring Harness After December 5, B S2632E Electrical 53

102 Main Wiring Harness After December 5, 20 Section Refer to Page 53 Lift Cylinder IT E M LIFT CYLINDER Part # C AV C K T P 5-2 B 2 P 2-8 B Scissor Stack CE Only P R E S S U R E S E N S O R Part # C AV IT E M 4 C K T P 2-7 D 2 P P 2-3 B S P L -P 5-2 L E F T R IG H T Lift Cylinder Part # C AV IT E M C K T P P 5-2 B P 5-2 P P S P L -P L E F T R IG H T P P 2-8 P 2-8 B -- IT E M 2 P O T H O L E S W Part # C AV C K T P 2-7 B 3 P Chassis S P L -P 5-9 L E F T R IG H T P P 5-9 P 5-9 B IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # C AV C K T C AV C K T C AV C K T C AV C K T P 5-9 B P K 3 M 2 IT E M 0 IN T E R L O C K P a rt # C AV C K T IN T 2 3 Battery Charger Drive Speed Manifold 3 4 S TA C K S W Part # C AV IT E M 2 C K T P P 4-6 Scissor Stack A N G L E T R A N S Part # C AV IT E M 4 C K T P 2-7 C 2 P P Scissor Stack CE Only Main Wiring Harness After December 5, B Electrical 54 S2632E 42033

103 Main Wiring Harness After December 5, 20 Section 2 Refer to Page 53 Lower Controls IT E M 5 C O N T R O L B O X Part # C AV C K T C AV C K T P - 3 P P -3 4 P P P 3-6 P S P E M S 6 P P P P -8 8 P P P P P F W D VA LV E S T E E R VA LV E U P VA LV E IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # Part # Part # C AV C K T C AV C K T C AV C K T C AV C K T C AV C K T C AV C K T P B P D P F 3 R E V VA LV E 3 Manifold Valve S T E E R R VA LV E IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 IT E M 3 Part # Part # Part # Part # Part # Part # C AV C K T C AV C K T C AV C K T C AV C K T C AV C K T C AV C K T P P C P E 3 D U M P VA LV E S P L 4 L E F T R IG H T P 5 - P P S P L-P 2-3 S P L 3 S P L-P 2-7 S P L-5 L E F T R IG H T L E F T R IG H T L E F T R IG H T L E F T R IG H T P P 2-3 B P K 3 B 3 C P 2-7 B P 2-7 P 2-7 C -- P P P M 3 D P 2-7 D E P F Main Wiring Harness After December 5, B S2632E Electrical 55

104 Main Wiring Harness After December 5, 20 Contactor IT E M 6 Part # IT E M 6 IT E M 7 Part # Part # C AV C K T C AV C K T C AV C K T 6 IN T P E M S 7 C AV IT E M 8 P Part # C K T Section 3 Refer to Page P P -3 4 P P C AV IT E M 8 P 2 Part # C K T -- 2 P P P P 2-7 IT E M 9 P 3 Part # P C AV C K T P 3-2 P P P P 3-7 Control Module EZlift P P P IT E M 9 P 4 Part # C AV C K T P P P P P C AV IT E M 9 P 5 Part # C K T P 5-2 P P P P P P 5-0 P 5-2 P 5-2 Main Wiring Harness After December 5, B Electrical 56 S2632E 42033

105 Electrical System Pin ID After December 5, 20 P Output and Analog Input Wire Description P- 5V to Joystick (low current) P-2 Spare analog input P-3 0V to Joystick (low current) P-4 Joystick analog input P-5 CAN H (optional CANbus) P-6 CAN L (optional CANbus) P-7 Tilt lamp output (0V=active) P-8 Overload lamp output (0V=active) P-9 Platform alarm output (0V=active) P2 Connects to Sensors Wire Description P2-5V (low current, for sensors only) P2-2 EZfit height sensor # input P2-3 0V (low current, for sensors only) P2-4 Pressure sensor input P2-5 EZfit height sensor #2 input (optional) P2-6 Spare analog input P2-7 B+ feed (low current, for switches only) P2-8 Lift down valve return (0V=active) P2-9 Spare lamp output (0V=active) Wire P3 Upper Controls Description P3- EMS Platform (B+ during platform mode) P3-2 Valve supply (high current B+ during platform mode, supplies all valve outputs) P3-3 Torque/traction switch (B+=active) P3-4 Reverse/Down joystick switch (B+=active) P3-5 Forward/Up joystick switch (B+=active) P3-6 Drive select switch (B+=active) P3-7 Lift select switch (B+=active) P3-8 Steer right switch (B+=active) P3-9 Steer left switch (B+=active) P3-0 Spare switch input (B+=active) P3- Spare switch input (B+=active) P3-2 Trigger switch (B+=active) Electrical System Pin ID After December 5, 20 S2632E Electrical 57

106 Electrical System Pin ID After December 5, 20 P4 Lower Controls Wire Description P4- EMS Ground (B+ during ground mode) P4-2 Spare switch input P4-3 Spare switch input P4-4 Lift down switch (B+=active in ground mode only) P4-5 Lift up switch (B+=active in ground mode only) P4-6 Elevation switch (B+=lowered, open=elevated) P4-7 Spare switch input P4-8 Spare switch input P4-9 Spare switch input P4-0 Spare switch input P4- Spare switch input P4-2 Spare switch input P5 Valve Outputs Wire Description P5- Line contactor output (B+ when active) P5-2 Forward valve output (B+ when active) P5-3 Reverse valve output (B+ when active) P5-4 Brake Valve output (B+ when active) P5-5 Motion light output (B+ when active) P5-6 Steer left valve output (B+ when active) P5-7 Down valve output (B+ when active) P5-8 Steer right valve output (B+ when active) P5-9 Torque valve output (B+ when active) P5-0 Overload and motion alarm output (B+ when active) P5- Up valve output (B+ when active) P5-2 Spare valve output P6 Connects to EZcal Hand-Held Device Wire Description P6- Supply P6-2 Receive P6-3 Transmit P6-4 0 V Return Electrical System Pin ID After December 5, 20 Electrical 58 S2632E 42033

107 Item Part No. Qty. Description Overload System CE PRESSURE TRANSDUCER FTG RDCR/EXP -6S-4S STL ANGLE TRANSDUCER SCREW RHD MACHINE 0-24 X.75 2 APPLY LOCTITE Overload System CE E S2632E Electrical 59

108 Electrical 60 S2632E 42033

109 Options S2632E Options

110 Options 2 S2632E 42033

111 2 3 4 Item Part No. Qty. Description Flashing Light Flashing light assembly includes items 2, 3, 4 and Flashing light, yellow Connector 2 pin Pin, contact Lock wedge 2 pin plug Guard, flashing light Machine screw #0-24 x /2 inch long round head Machine screw #0-24 x 3/4 inch long round head Washer #0 medium flat Nut #0-24 self locking Wire harness, flashing light Wire harness, flashing light adapter inside lower control box Connector 2 pin inside lower control box Lock wedge 2 pin plug inside lower control box Clamp Flashing Light 0363 A S2632E Options 3

112 Options 4 S2632E 42033

113 Key Switch Item Part No. Qty. Description Key switch wire 8 r6i r6i 0 blk decal, key switch on/off o-ring Key Switch A S2632E Options 5

114 Options 6 S2632E 42033

115 Item Part No. Qty. Description Airline to Platform airline to platform OPTION Not shown PARKER AIR LINE QUICK ATTACH PARKER AIR LINE QUICK CONNECT GROMMET.25ID.75DIAX.094GRV NUT HEX LKG WSHR FLAT BLT HEXHD GR5-Z/P SCR RDH MACH NUT HEX LKG CLP CUSH.750 VINYL COATED HOSE GUARD WSHR FLAT HOSE.50 ID AIR HOSE Airline to Platform S2632E Options 7

116 Options 8 S2632E 42033

117 Item Part No. Qty. Description Dual Lanyard Anchorage dual lanyard anchorage TIE DOWN D RING BRACKET, LANYARD ATTACHMENT PLATE, LANYARD ATTACHMENT BoLT HEXHD GRade WaSHeR FLAT HARD NUT HEX LKG DECAL ATTACH FALL RESTRAINT Dual Lanyard Anchorage A36030A S2632E Options 9

118 Options 0 S2632E 42033

119 Item Part No. Qty. Description Canadian Standards Association Package csa OPTION DECAL ATTACH FALL RESTRAINT DECAL, CSA COMPLIANT BRACKET, LANYARD ATTACHMENT TIE DOWN D RING PLATE, LANYARD ATTACHMENT BoLT HEXHD GRade NUT HEX LKG WaSHeR FLAT DECAL, PLATform CAPacity 500# W/WIND Not shown MANUAL, Parts S2632E MANUAL, CSA INSPection & MAINTenance CHECKLIST Canadian Standards Association Package A37025C S2632E Options

120 Options 2 S2632E 42033

121 Item Part No. Qty. Description Battery Condition Indicator upper control assembly ansi battery condition indicator WIRE A Battery Condition Indicator S2632E Options 3

122 Options 4 S2632E 42033

123 Maintenance S2632E Maintenance