PARTS MANUAL (ANSI/CSA, CE, AS & KC) DC ELECTRIC SCISSORS MODELS AA June 206
This manual is based on Serial Numbers: 70 200 00 & Above Please refer to the website - www.skyjack.com for older Serial Numbers. Service Center 35 Swenson Ave. St. Charles, Illinois, 607 USA Phone: 630-262-0005 Toll Free: -800-275-9522 Fax: 630-262-0006 Email: service@skyjack.com Parts (North America) Toll Free: -800-965-626 Toll Free Fax: -888-782-825 E-mail: parts@skyjack.com Australia Pty Ltd. Coates Place Wetherill Park New South Wales 26 Australia Tel: +6 (0) 28786 3200 Fax: +6(0) 28786 3222 Parts & Service (Europe) Unit Maes Y Clawdd Maesbury Road Industrial Estate Oswestry, Shropshire SY0 8NN UK Phone: +-69-676-235 Fax: +-69-676-238 E-mail: info@skyjackeurope.co.uk Brasil Alameda Júpiter, 70 Loteamento American Park Empresarial Indaiatuba, SP, Brasil 337-653 Tel: +55 9 3936 032
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
Table of Contents.0 Platform Related Parts. Platform Group... 8.2 Main Platform and Extension Assembly... 0.3 Main Platform Assembly... 2. Extension Platform Assembly....5 Main Railings Assembly... 6.6 Extension Railing Assembly... 8.7 Full Gate Entrance Assembly... 20.8 Half Gate Entrance Assembly (ANSI/CSA, CE & KC)... 22.9 Quick Release Pin Assembly... 2.0 Gate Latch Assembly... 25. Extension Handrail Assembly... 26.2 Platform Control Box Assembly... 28.3 Control Console Assembly... 30. Enable Controller Assembly... 32.5 Platform A/C Outlet Assembly... 3 2.0 Scissor Related Parts 2. Scissor Group... 38 2.2 Scissor Mounting Hardware Assembly... 0 2.3 Scissor Connecting Hardware Assembly... 2 2. Lift Cylinder Assembly and Mounting Hardware... 2.5 Holding Valve Manifold Assembly... 6 2.6 Hydraulic Hose Connections - Scissors... 7 2.7 Scissors Limit Switch Assembly... 8 2.8 Horn Assembly... 50 2.9 Load Sensing and Transducer Module Assembly (CE & AS)... 5 2.0 Pressure Switch Assembly (KC Only)... 52 2. Flashing Light Assembly... 53 3.0 Base Related Parts 3. Base Assembly... 56 3. Base Assembly (Continued)... 58 3.2 Front Hub Assembly... 60 3.3 Steer Cylinder Assembly... 62 3. Rear Brake Assembly... 63 3.5 Drive Manifold Assembly... 6 3.6 Brake Release Manifold Assembly... 66 3.7 Hydraulic Hose Connections - Base... 67 3.8 Pothole Protection Assembly... 68 3.9 Wheel Assembly... 70 3.0 Tilt Switch and Bracket Assembly (ANSI/CSA & KC)... 7 3. Base Control Assembly... 72 3.2 Counter Reset (CE)... 7 Page
Table of Contents.0 Hydraulic Tray Related Parts. Hydraulic Tray Group... 76. Hydraulic Tray Group (Continued)... 78.2 Hydraulic Tank Lid Assembly... 80.3 Emergency Lowering Assembly... 8. Motor and Pump Assembly... 82.5 Main Manifold Assembly... 8.6 Hydraulic Hose Connections - Hydraulic Tray... 86 5.0 Battery Tray Related Parts 5. Battery Tray Assembly... 88 5.2 Battery Assembly... 90 5.3 Charger Assembly... 92 6.0 Electrical Related Parts 6. Electrical Panel Assembly... 96 6.2 Control Cable Assembly... 98 6.3 Rear Manifold Harness... 99 6. Main Manifold Harness... 00 6.5 Electrical Harnesses (Continued)... 0 6.6 Battery Cables... 06 6.7 Dual Flashing Light Harness (ANSI/CSA only)... 08 6.8 RST Wire Assembly... 09 7.0 Optional Equipment 7. Board Carrier Assembly (ANSI/CSA, CE & AS)... 3 7.2 Inverter Subgroup (ANSI/CSA)... 7.3 Inverter Wiring (ANSI/CSA)... 6 7. Inverter Assembly and Labels (ANSI/CSA)... 7 7.5 Dual Flashing Light Assembly (ANSI/CSA)... 8 7.6 Telematics Option - Morey (ANSI/CSA)... 9 7.7 Telematics Option - ZTR (ANSI/CSA)... 20 7.8 Telematics Harness (ANSI/CSA)... 2 7.9 Heavy Duty Pipe Rack Assembly (ANSI/CSA, CE & AS)... 23 7.0 Residual Current Device Assembly (CE)... 2 7. Aluminum Control Box Guard Assembly (CE)... 26 8.0 Labels 8. Label Kit... 27 8.2 Labels - Platform Control Console... 29 8.3 Labels - Miscellaneous... 30 8. Labels - Left & Right Side... 32 8.5 Labels - Front, Rear and Top... 3 9.0 Tables 9. Fluid Table... 37 Page 5
Notes Page 6
.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
. Platform Group 2 3 M69075AE Page 8
. Platform Group Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 69075 - PLATFORM ASSEMBLY, Full Gate B 7857 - 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
.2 Main Platform and Extension Assembly 2 3 M79AD Page 0
.2 Main Platform and Extension Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 79 - ASSEMBLY, Main Platform and Extension (Ref.) ASSEMBLY, Platform (For components, refer to Section.3) 2 (Ref.) ASSEMBLY, Extension Deck (For components, refer to Section.) 3 96029 BUMPER, Scissor 0606 NUT, Hex Nylon Lock (3/8-6, Gr. 5) Page
.3 Main Platform Assembly 2 6 7 5 3 M69086AE Page 2
.3 Main Platform Assembly Part - 69086 - ASSEMBLY, Platform NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 69082 WELDMENT, Platform 2 2522 2 ASSEMBLY, Pin - Rollout 3 2555 2 ROLLER, Wide 2533 SLIDER, Bushing 5 287 2 PIN, Cotter (/ x -/2 ) 6 9900 SLIDER, Roll out 7 60053 SCREW, Rambo - ST3.5 X 3 Page 3
. Extension Platform Assembly 6 7 5 3 2 M69087AD Page
. Extension Platform Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 69087 ASSEMBLY, Extension Deck 69085 WELDMENT, Extension Platform 2 6053 2 PIN, Roll Out 3 253 2 ROLLER, Narrow 2533 6 SLIDER, Bushing 5 202 STOP, Extension Deck 6 0398 2 NUT, Hex Nylon Lock (5/6-8, Gr B) 7 30006 2 BOLT, Button head (5/6-8 x 3/ ) Page 5
.5 Main Railings Assembly 9 9 7 8 2 Places 7 Places 9 3 3 7 2 5 6 8 5 6 5 6 5 2 0 Page 6 Places M69097AE
.5 Main Railings Assembly Part - 69097 ASSEMBLY, Railings - Main NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 9893 RAILING, Main Side Lower LH 2 989 RAILING, Main Side Lower RH 3 98929 RAILING, Main Side Upper LH 98928 RAILING, Main Side Upper RH 5 69095 2 PLATE, Kick 6 69096 GUARD, Cable 7 00702 2 PLUG, Plastic - Tube (-/ x -/ ) 8 25580 SPACER, Railing Retainer 9 (Ref.) 7 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) 0 259 PLATE, Cable Guard Cover - Right Hand 2595 PLATE, Cable Guard Cover - Left Hand 2 3202 RIVET, Pop (/ Diameter x 5/8 ) 3 0302 CLAMP, Single Clip (G8) 03632 5 BOLT, Self Tapping (/ - x 3/ ) 5 0398 8 NUT, Hex Nylon Lock (5/6-8, Gr B) 6 2737 8 BOLT, Carriage (5/6-8 x 2 ) 7 03995 WASHER, Flat (/ ) (If equipped) 8 57759 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
.6 Extension Railing Assembly 9 2 2 2 Places 3 5 0 5 3 7 6 M9773AC Page 8
.6 Extension Railing Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 9773 ASSEMBLY, Railings - Extension 98927 WELDMENT, Railing - Extension Deck Lower 2 98932 WELDMENT, Railing - Extension Deck Upper 3 (Ref.) 2 ASSEMBLY, Hand Rail - Extension Deck (For components, refer to Section.) 3037 2 TUBE, Round - Extensiond Deck Midrail 5 7293 BOX, Manual 6 260 NUT, K-Lock (#0-32) 7 069 WASHER, Flat (#0) 8 03962 SCREW, Round head machine (#0-32 x /2 ) 9 9902 PLATE, Mount - Info/Warning/Manual box 0 (Ref.) 2 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) 06950 2 PLATE, Retainer - Extension Deck Railing 2 00702 PLUG, Plastic tube (-/ x -/ ) 3 03885 2 BOLT, Hex head (5/6-8 x -3/ ) 03632 8 BOLT, Self tapping (/ - x 3/ ) 5 0398 2 NUT, Hex Nylon Lock (5/6-8, Gr B) 6 386 BOLT, Hex Head (3/8-6 x 5/8 ) 7 08575 NUT, Hex Head Jam (3/8-6) Page 9
.7 Full Gate Entrance Assembly 6 3 7 5 3 9 2 7 Places 6 2 0 2 7 20 8 5 8 9 M999AD Page 20
.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 97287 ASSEMBLY, Full Gate - Hinged 95995 WELDMENT, Railing - End Ent. Lower Left Hand, A 2 9599 WELDMENT, Railing - End Ent. Lower Right Hand, B 3 9896 WELDMENT, Railing - End Ent. Upper Left Hand, A 288 WELDMENT, Railing - End Ent. Upper Right Hand, B 5 2879 2 PLATE, Kick - End Entrance, A, B 6 (Ref.) ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) 7 2737 BOLT, Carriage (5/6-8 x 2 ), A, B 8 0398 NUT, Hex Nylon Lock (5/6-8, Gr B), A, B 9 00702 6 PLUG, Plastic Tube (-/ x -/ ) 0 2329 2 BOLT, Self Tapping (/ - x /2 ), A, B 97399 WELDMENT, Gate - Lower, C 2 2873 WELDMENT, Gate - Upper, C 3 (Ref.) ASSEMBLY, Door Spring Latch, C (For components, refer to Section.0) 3676 HINGE, Steel (3.5"), C 5 25577 2 BUMPER, Door, C 6 0693 PLATE, Latch - Gate Stop, C 7 03632 20 SCREW, Self tapping (/ - x 3/ ), C 8 992 CLAMP, Aluminum - Door Sweep, C 9 990 STRIP, Rubber - Door Sweep, C 20 995 RIVET, Wide Hd (/8" x 0.390"), C 2 7277 2 HINGE, Spring, C Page 2
.8 Half Gate Entrance Assembly (ANSI/CSA, CE & KC) 2 8 3 7 3 2 8 6 0 9 8 5 9 5 8 7 6 M7989AC Page 22
.8 Half Gate Entrance Assembly (ANSI/CSA, CE & KC) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 7898 ASSEMBLY, Entrance - Half Gate (ANSI/CSA, CE & KC) - 95996 ASSEMBLY, Railing - End Entrance 98967 WELDMENT, Railing - Upper 2 95995 WELDMENT, Railing - Left Hand 3 9599 WELDMENT, Railing - Right Hand 083 PAD, Entry Railing 5 2879 2 PLATE, Kick - End Entrance 6 2329 2 BOLT, Self tapping (/ - x ) 7 (Ref.) 2 ASSEMBLY, Pin - Quick Release Large Loop (For components, refer to Section.9) 8 2737 BOLT, Carriage (5/6-8 x 2 ) 9 0398 NUT, Hex Nylon Lock (5/6-8, Gr B) - 9729 ASSEMBLY, Half Gate - Hinged 0 9700 WELDMENT, Gate - Half (Ref.) ASSEMBLY, Gate Latch (For components, refer to Section.0) 2 7277 2 HINGE, Spring 3 00702 2 PLUG, Tube 990 STRIP, Rubber - Door Sweep 5 992 CLAMP, Aluminum - Door Sweep 6 25577 2 BUMPER, Door 7 03632 SCREW, Self tapping (/ - x 3/ ) 8 0693 PLATE, Latch - Gate Stop 9 995 RIVET, Wide Head Page 23
.9 Quick Release Pin Assembly 3 2 5 6 M068AA_2 Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 258 - ASSEMBLY, Quick Release Pin - Large Loop 00509 PIN, Quick release (3/8 diameter x 2 ) 05807 LANYARD, Plastic coated (6 ) 2 03873 BOLT, Hex head (3/8-6 x 2-/2, Gr 5) 3 0372 2 WASHER, Flat (3/8 ) 0606 NUT, Hex Nylon Lock (3/8-6, Gr. 5) 5 257 - ASSEMBLY, Quick Release Pin - Small Loop 00509 PIN, Quick release (3/8 diameter x 2 ) 05807 LANYARD, Plastic coated (6 ) 6 2329 BOLT, Self tapping (#8-8 x /2 ) Page 2
.0 Gate Latch Assembly 3 2 5 M060AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 082 - ASSEMBLY, Latch - Gate 09377 PIN, Latch 2 0532 GUIDE, Nylon spring 3 05307 PLATE, Gate latch release 00950 PIN, Roll (/8 x ) 5 0307 SPRING, Compression Page 25
. Extension Handrail Assembly 3 2 5 3 M62535AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 977 ASSEMBLY, Handrail - Extension Deck (Hinged) 9775 HANDRAIL, Extension - Deck 2 03550 3 PLUG, Slider 3 03865 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) 6 03632 3 BOLT, Self tapping (/ - x 3/ ) Page 26
Notes Page 27
.2 Platform Control Box Assembly 7.25" 3 3.375" 2 Places 3 5 2 8 7 6 0 9 2 7 8 5 6 M6387AD5 Page 28
.2 Platform Control Box Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 6367 - ASSEMBLY, Control Box (ANSI/CSA, CE, & KC) B 6387 - ASSEMBLY, Control Box (AS) C 630 - ASSEMBLY, Control Box (Long Cable Option) (Ref.) - ASSEMBLY, Control Console (For components, refer to Section.3) 2 60355 PLATE, Outside - Control Box, A, C 2 7372 PLATE, Outside - Control Box, B 3 60262 TUBE, Control Box, A, C 3 620 PLATE, Guard - Control Box, B 2098 6 RIVET, Pop (3/6 x.0 ), A, C 57759 RIVET, Pop (3/6 x /2-3/8 ), B 5 2327 9 SCREW, Hex Hd (#8-8 x /2 ) 6 030 WASHER, Lock (5/6 ), A, C 6 229 WASHER, Lock (8-32 ), B 7 03986 NUT, Hex head (#8-32) 8 03957 SCREW, Round Hd (#8-32 x /2-3/8 ) 9 02956 2 PLUG (7/8" hole) 0 (Ref.) - CONTROL CABLE, 6 Pin - Platform Control Box (For components, refer to Section 6.2) 300788 STRAIN RELIEF 2 6993 HOUSING, Male connector (9 pin) (to controller harness) 3 973 30 EDGE MOLDING, Control Box, B 58209 CLAMP, Control Cable Railing, C 5 (Ref.) ASSEMBLY, Pin - Quick Release Large Loop, C (For components, refer to Section.9) 6 03596 BOLT, Hex Hd (3/8-6 x 2 ), C 7 0606 NUT, Hex Nylon Lock (3/8-6, Gr. 5), C 8 0372 WASHER, Flat (3/8 ), C Page 29
.3 Control Console Assembly 2 7 9 L 3 8 6 5 3 M6368AA Page 30
.3 Control Console Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 6368 - ASSEMBLY, Control Console 56923 PLATE, Control Console 2 (Ref.) - ASSEMBLY, Enable Controller (For components, refer to Section.) 3 9729 SWITCH ASSEMBLY, Emergency Stop 705 HEAD, Emergency stop switch 7056 LATCH 7053 2 BLOCK, N.C. contact 706 LED BLOCK, 2V (red) 68 SWITCH ASSEMBLY, Horn 7058 HEAD, Pushbutton 7056 LATCH 705 BLOCK, N.O. contact 5 6382 SWITCH, Toggle - (Lift/Off/Drive) 6 557 SWITCH, Torque 7 8 2 GUARD, Toggle switch 8 06 2 SEAL, Panel bushing 9 22093 INDICATOR, Battery charge L (Ref) - LABELS (For components, refer to Section 8.) Page 3
. Enable Controller Assembly 3 9 5 6 7 8 2 0 2 3 5 6 7 8 9 20 2 22 26 27 23 2 25 28 29 30 M520AD Page 32
. Enable Controller Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 59 ASSEMBLY, Enable Controller 59055 ASSEMBLY, Handle 2 59057 HANDLE, Front Half 3 22879 SCREW, Controller Handle 59065 2 SCREW, Plastite (#-20 x 5/6 ) 5 59060 HOLDER, Micro Switch 6 5963 ASSEMBLY, Rocker Micro - Left/Right Steer 7 3 AXLE, Rocker 8 577 ROCKER 9 2287 BOOT, Rocker 0 59063 WASHER 59062 BOOT, Plunger Switch 2 5906 SPRING 3 5906 SWITCH, Plunger 59067 SWITCH, Micro Lever - Enable 5 59066 2 SCREW, Plastite (#2-28 x /2 ) 6 59068 INSULATOR, Micro 7 2296 COUPLING (8mm) 8 22960 2 SCREW, Set 9 578 SCREW (#6-32 x 5/8 ) 20 59058 HANDLE, Back Half 2 2296 NUT, Controller Lever 22 59059 LEVER, Trigger 23 2779 BOOT & GASKET 2 5965 WASHER 25 5966 E-CLIP 26 2286 SCREW 27 2287 WASHER 28 733 SCREW 29 5968 MICROINSULATOR 30 22869 SWITCH, Micro - Neutral Page 33
.5 Platform A/C Outlet Assembly 3 L 6 9 7 0 5 9 2 8 3 2 5 M9538AB Page 3
.5 Platform A/C Outlet Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 9538 - ASSEMBLY, Platform A/C Outlet (ANSI) B 7837 - ASSEMBLY, Platform A/C Outlet (Cable Only) (CE, AS & KC) 05269 660 CABTIRE, /3, A 9726 660 CABTIRE, /3, B 2 5685 ASSEMBLY, Wire - Ground 3 0527 INLET, Connector - 0V 3227 SEAL, Tite Cover - 0V 5 09699 PLATE, Receptacle 6 36328 BOX, Outlet - 0V 7 09698 GFCI, Receptacle 8 03857 BOLT, Hex Hd (/ -20 x ) 9 03995 WASHER, Flat (/ ) 0 0000 WASHER, Lock (/ ) 03980 NUT, Hex Hd (/ -20) 2 993 2 RIVET, Pop (5/32 x 0.665 ) 3 30 2 RIVET, Pop (/ x 0.70 ) 5663 PLATE, Cover - Ontario Hydro 0 (Without Gate) 5 56636 PLATE, Cover - Ontario Hydro 0 (With Gate) L (Ref) - LABELS (For components, refer to Section 8.) Page 35
Notes Page 36
2.0 SCISSOR RELATED PARTS 2.2 Scissors - Mounting Hardware 2.3 Scissors - Connecting Hardware 2 2. Scissors 2.7 Limit Switch 2.0 2.5 2. 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
2. Scissor Group 23 23 6 0 5 0 7 5 2 0 26 2 3 9 2 2 22 2 25 8 9 8 6 20 7 2 3 Page 38 27 23 2 23 M705AB
2. Scissor Group Part - 206 ASSEMBLY, Scissors NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 2063 WELDMENT, Scissor - Inside (Level ) 2 207 WELDMENT, Scissor - Inside (Level 2) 3 2082 WELDMENT, Scissor - Inside (Level 3) 208 WELDMENT, Scissor - Inside (Level ) 5 2087 WELDMENT, Scissor - Inside (Level 5) 6 2089 WELDMENT, Scissor - Inside (Level 6) 7 20308 WELDMENT, Scissor - Outside (Level ) 8 2030 WELDMENT, Scissor - Outside (Level 2) 9 2032 WELDMENT, Scissor - Outside (Level 3) 0 203 3 WELDMENT, Scissor - Outside (Level,5 & 6) 3080 BUMPER, Scissor - Bottom 2 2373 BOLT, Hex Head (M2-.25 x 6mm) 3 60026 2 WASHER, Flat (M2) 2860 20 BUMPER, Scissor - Upper 5 2250 3 SCREW, Machine (3/8-6 x 5/8 ) 6 02929 CLAMP, Single (G0) 7 03078 5 CLAMP, Double (G0) 8 3993 3 BOLT, Hex Hd (3/8-6 x 7/8 ) 9 0372 3 WASHER, Flat (3/8 ) 20 3953 2 WASHER, Flat (7/8 ) 2 95657 ASSEMBLY, Stand - Upper Maintenance Support 2 9563 WELDMENT, Stand - Upper Maintenance Bar 2 66829 BOLT, Hex Hd (5/6-8 x 2-3/ ) 2 0398 NUT, Hex Nylon Lock (5/6-8, Gr B) 22 95656 ASSEMBLY, Stand - Lower Maintenance Support 22 9769 WELDMENT, Stand - Lower Maintenance Bar 22 66829 BOLT, Hex Hd (5/6-8 x 2-3/ ) 22 0398 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
2.2 Scissor Mounting Hardware Assembly Platform Slider Assembly 2 Places Platform Mounting Bracket Assembly 2 Places 0 5 3 2 3 2 3 5 9 Base Slider Assembly 2 Places Base Mounting Assembly 2 Places 8 6 2 3 7 3 2 M705AB_MountHardware Page 0
2.2 Scissor Mounting Hardware Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 20958 2 PIN, Inside Scissors (3/ dia. x ) 2 287 2 PIN, Cotter (/ x -/2 ) 3 2330 2 BEARING, Plain (3/ I.D. x 7/8" O.D. x -/2 ) 2570 CASTING, Bracket - Platform Mount 5 3369 SHIM, Platform Mount (0.035 ) 6 69906 PIN, Roller - Bottom 7 20697 ROLLER, Scissor 8 7099 SPACER, Pin - Bottom Roller 9 9867 PIN, Upper Slider 0 2077 CASTING, Slider - Platform 20772 PAD, Slider 2 95223 SPACER, Slider 3 03892 BOLT, Hex Hd (/ -20 x 5/8 ) 03995 WASHER, Flat (/ ) 5 0000 WASHER, Lock (/ ) Page
2.3 Scissor Connecting Hardware Assembly End Pin Assembly - Small Pin Places End Pin Assembly - Big Pin 0 Places 3 2 2 5 Center Pin Assembly 2 Places Limit Switch Pin Assemby Place 6 7 0 5 8 9 3 3 M705AB_ConnectHardware Page 2
2.3 Scissor Connecting Hardware Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 20958 PIN, Inside Scissors (3/ DIA x ) 2 2080 PIN, Inside Scissors (" DIA x -9/6") 3 2330 2 BEARING, Plain (3/ I.D. x.5 ) 3 287 PIN, Cotter (/ x -/2 ) 233 BEARING, Plain (-/ I.D. x.0" O.D. x -3/6 ) 5 20673 PIN, Center Scissor 6 2875 PIN, Cotter (5/6 DIA x 2 ) 7 2703 WASHER, Thrust (/6 ) 8 22502 WASHER, Flat (/8 ) 9 0520 WASHER, Flat - Nylon (/8 ) 0 3993 BOLT, Hex Hd (3/8-6 x 7/8 ) 0372 WASHER, Flat (3/8 ) 2 2677 PIN, Limit Switch - Scissors 5 207 2 BEARING, Plain ( I.D. x -/8" O.D. x -/2") Page 3
2. Lift Cylinder Assembly and Mounting Hardware 9 7 3 6 2 5 8 2 3 7 6 5 8 0 9 M9758AA_ Page
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. 7003 Cylinder, Lift -.0 x 9 2 99203 GLAND 3 9920 WELDMENT, Rod 99205 WELDMENT, Tube 5 99206 SPACER 6 99207 ROD EYE 7 05686 BOLT, Hex (3/"-6 x 3") 8 99202 PISTON 9 (Ref.) - ASSEMBLY, Manifold - Holding Valve (For components, refer to Section 2.5) 0 9632 WELDMENT, Pin 0550 ORIFICE, One Way (3/32 dia) 2 0303 SEAL, O-Ring 3 578 FITTING, 90D Elbow (06 JICM - 0 ORBM), A 3 579 FITTING, Tee (06 JICM - 06 JICM - 06 ORBM), B 03865 BOLT, Hex head (5/6-8 x 2 ) 5 98599 8 BOLT, Hex Hd (3/8-6 x ) 6 03996 WASHER, Flat (5/6 ) 7 030 WASHER, Lock (5/6 ) 8 25959 8 WASHER, Flat (3/8 ) 9 83 BUSHING, Fiberglide (-/2 dia x -/ ) K 9920 KIT, Seal (Not Shown) Page 5
2.5 Holding Valve Manifold Assembly 5 5 6 Lower Cylinder Manifold 3 2 M95256AC Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 95256 2 ASSEMBLY, Manifold - Holding 30 ASSEMBLY, Manifold - Transducer Auxilary Lowering 3037 MANIFOLD, Transducer Auxilary Lowering 08052 PLUG, Expander 2 95259 VALVE, Relief 3 03655 2 VALVE, Poppet - Solenoid Cartridge 2250 FITTING, Plug (0 ORB Hex) (ANSI/CSA & KC only) 5 95260 2 COIL (20 VDC) 6 33 ASSEMBLY, Pressure Transducer (CE & AS only) 6 37668 TRANSDUCER, Pressure - 2000 PSI 6 2377 SET SCREW, Cup (#8-32 x /8") 6 39266 LABEL, Mylar Cable Page 6
2.6 Hydraulic Hose Connections - Scissors 2 M78AB Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 78 HOSE CONNECTIONS, Scissors H5060300 HOSE, Hydraulic (Main Manifold to Lower Cylinder Tee) 2 H5060230 HOSE, Hydraulic (Lower Cylinder Tee to Upper Cylinder) Page 7
2.7 Scissors Limit Switch Assembly 2 9 9 8 6 2 0 3 8 20 7 5 7 3 2 6 5 M95393AB, M30559AD Page 8
2.7 Scissors Limit Switch Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 95393 ASSEMBLY, Limit Switch - Scissors - 30560 SUB-ASSEMBLY, Limit Switch - Scissors - 30559 LIMIT SWITCH, Scissors 2975 3 LIMIT SWITCH, Sealed 2 7582 CONNECTOR, Receptacle - 8 Pin 3 758 CONNECTOR, Receptacle - 8 Pin Wedge 7590 8 CONNECTOR, Contact Pin 6-8 5 5963 LABEL, LSA 6 596 LABEL, LSB 7 5965 LABEL, LS6 8 2867 BRACKET, Limit Switch 9 2868 GUARD, Limit Switch 0 0000 WASHER, Lock (/ ) 03860 2 BOLT, Hex Hd (/ -20 x -3/ ) 2 03980 NUT, Hex Hd (/ -20, Gr 8) 3 03995 8 WASHER, Flat (/ ) 03858 2 BOLT, Hex Hd (/ -20 x -/ ) 5 2908 2 BUSHING, Snap-In (3/ I.D) 6 2869 CLAMP, Gear #0 (2-/2 ) 7 00967 2 CAM, Limit Switch 8 069 2 WASHER, Flat (#0) 9 30050 2 NUT, Lock (#0-32) 20 2009 2 SCREW, Round Hd (0-32 x 5/8 ) 2 0302 CLAMP, Single Page 9
2.8 Horn Assembly 2 3 M668AA_2 Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 668 ASSEMBLY, Horn 569 NUT, Hex (/ -20) 2 2867 BOLT, Hex Hd (/ -20 x ) 3 2868 WASHER, Flat (/ ) 669 HORN, 2V - Low Tone Page 50
2.9 Load Sensing and Transducer Module Assembly (CE & AS) 5 8 6 7 2 8 9 0 3 2 5 3 6 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 2 70620 BEEPER, SP-08 3 9959 MODULE, Overload Sensing Controller, A 3 58226 MODULE, Overload Sensing Controller, B 3068 BRACKET, Control Module 5 2298 2 SCREW, Round Hd (#0-32 x -/") 6 0562 SCREW, Round Hd (#0-32 x ") 7 9639 2 SCREW, Round Hd (#6-32 x 5/8") 8 069 6 WASHER, Flat (#0) 9 9833 2 WASHER, Flat (#6) 0 03955 2 WASHER, Flat (/") 085 6 WASHER, Lock (#0) 2 06099 2 WASHER, Lock (#6) 3 0000 2 WASHER, Lock (/") 0003 2 NUT, Hex (#0-32) 5 03985 2 NUT, Hex (#6-32) 6 03892 2 BOLT, Hex Hd (/"-20 x 5/8") Page 5
2.0 Pressure Switch Assembly (KC Only) 2 M97698AA Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 97698 ASSEMBLY, Pressure Switch (KC only) 98738 SWITCH, Pressure (0ORSM) 2 98679 FITTING, Straight (0ORBM-0ORSF) Page 52
2. Flashing Light Assembly 6 2 3 5 7 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 2 0370 WASHER, Lock (/2") 3 09598 NUT, Hex Hd (/2"-20) 0373 FLASHER, 2-2 Volt, A 5 32793 CLAMP, Plastic (-/ ), A 6 03962 BOLT, Machined (#0-32 x /2 ), A 7 0003 NUT, Machined (#0-32), A 8 9999 INSTRUCTIONS, Flashing Light Page 53
Notes Page 5
3.0 BASE RELATED PARTS Drive Manifold 3.5 Brake Release Manifold 3.6 Counter Reset (CE) Tilt Switch and Bracket (ANSI/CSA & KC) 3.2 3.0 3. Base Control Base Group 3. 3 Wheels Rear Brakes 3.9 3. 3.8 Pothole Protection Device 3.2 Front Hub 3.3 Steer Cylinder 3.7 Hydraulic Hose Connections - Base Page 55
3. Base Assembly 0 9 30 3 32 33 3 23 2 8 7 6 22 5 25 3 26 27 28 29 2 2 8 2 6 7 5 20 9 M7053AD Page 56
3. Base Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 7053 GROUP, Base - 9660 ASSEMBLY, Base 6926 WELDMENT, Base 2 9725 SWITCH, Main Power Disconnect 3 9922 7 TRIM, Protective / - /2 25798 2 BOLT, Carriage (/2-3 x -/2 ) 5 0799 2 NUT, Hex Hd Jam (/2-3) 6 9608 2 COVER, Spacer 7 0000 WASHER, Lock (/ ) 8 03892 BOLT, Hex Hd (/ -20 x 5/8 ) - 95576 ASSEMBLY, Base Cover 9 727 WELDMENT, Cover 0 977 PLATE, Base Cover - Rear 30 8 RIVET, Pop (/ x 0.70 ) 2 5005 ASSEMBLY, Static Trap 2 520 STRAP, Ground 2 0632 BOLT, Hex Hd (3/8-6 x 3/ ) 2 03999 WASHER, Lock (3/8 ) 2 03978 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
3. Base Assembly (Continued) 0 9 30 3 32 33 3 23 2 8 7 6 22 5 25 3 26 27 28 29 2 2 8 2 6 7 5 20 9 M7053AD Page 58
3. Base Assembly (Continued) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. Parts list continued from the previous page. - 9657 ASSEMBLY, Ladder 26 7279 WELDMENT, Ladder 27 0373 BOLT, Hex Hd (3/8-6 x ) 28 03999 WASHER, Lock (3/8 ) 29 0372 WASHER, Flat (3/8 ) 30 9625 COUNTERWEIGHT (ANSI) 30 967 COUNTERWEIGHT (CE/AS/KC) 3 067 BOLT, Hex Hd (/2-3 x 2-/ ) 32 0368 WASHER, Flat (/2 ) 33 702507 NUT, Lock (/2-3) Page 59
3.2 Front Hub Assembly 2 9 3 9 2 23 22 8 7 2 2 3 K 6 5 0 6 5 7 8 20 M9898AD_2 Page 60
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 2 789 MOTOR, Wheel - 22.8 cu.in. 3 992 BEARING, Front Roller 9762 NUT (-/8"-8) 5 99250 SHAFT KEY, Rounded (-/2") 6 9905 BUSHING, Center Boss 7 9880 BUSHING, Center Boss 8 988 2 WASHER, Kingpin 9 9882 ASSEMBLY, Pin - Steering Long 0 738 ASSEMBLY, Pin - Steering Short - 975 ASSEMBLY, Arm - Steering 9752 ARM, Steering 2 0353 FITTING, Straight - Grease (/ -28) 3 9883 PIN, Cylinder End 7362 HUB, -/2 5 03969 WASHER, Lock - Internal Tooth (-/8 ) 6 32256 2 FITTING, 90D (08JICM - 0ORBM) 7 0379 WASHER, Flat - Hard (/2 ) 8 0370 WASHER, Lock (/2 ) 9 030 2 WASHER, Lock (5/6 ) 20 96596 BOLT, Hex Hd (/2-3 x 3 ) 2 833 2 BOLT, Hex Hd (5/6-8 x 5/8 ) 22 9887 RETAINER, Drive Link 23 70256 SCREW, FHCS (/ -20 x ) 2 0397 PIN, Cotter (/8 dia x -/2 ) K 39520 SEAL KIT (Not Shown) Page 6
3.3 Steer Cylinder Assembly 5 8 2 K K 3 K K 6 0 9 7 M9823AB Part - 9823 ASSEMBLY, Cylinder - Steer NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 9807 CYLINDER, Steer 9982 TUBE 2 9988 WELDMENT, ROD AND PISTON 3 9985 2 ROD COVER 9986 2 SPACER 5 9822 2 END, Rod - Steel Ball Joint w/ Grease Fitting 6 537 2 FITTING, Straight (06JICM - 06ORBM) 7 5693 2 ORIFICE, Steer (0.035") 8 0650 2 NUT, Hex Hd (3/ -6) 9 03789 2 WASHER, Lock - Internal Tooth ( ) 0 0797 2 NUT, Hex Hd ( -) K 9987 SEAL KIT Page 62
3. Rear Brake Assembly 8 7 3 5 6 2 9 0 M7057AD Part - 7057 2 ASSEMBLY, Rear Brake NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 7056 BRAKE, Rear 2 9762 NUT (-/8"-8) 3 99250 SHAFT KEY, Rounded (-/2") 9270 BOLT, Hex Hd (/2-3 x ) 5 0379 WASHER, Flat (/2 ) 6 702507 NUT, Lock (/2-3) 7 2628 FITTING, Straight (0JICM - 0ORBM) 8 2250 FITTING, Plug (07 ORBM) 9 03969 WASHER, Lock - Internal Tooth (-/8 ) 0 7362 HUB, -/2 (Ref.) - BRAKE OIL, SAE 20W (For components, refer to Section 9.0) Page 63
3.5 Drive Manifold Assembly 9 8 5 3 3 2 0 6 2 5 6 7 7 M732AC Page 6
3.5 Drive Manifold Assembly Part - 732 ASSEMBLY, Manifold - Drive NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 785 MANIFOLD, Drive 2 9922 ORIFICE, Plug - Crossover (0.020 ) 3 9923 ORIFICE, Disc - Differential (0.00") 992 2 VALVE, Solenoid - 3-Way Spool 5 66038 VALVE, Solenoid - 2-Way Spool 6 997 VALVE, Flow Divider 7 0336 VALVE, Needle - Positive Shut-Off 8 999 2 COIL, 20 VDC 9 998 COIL, 20 VDC 0 02665 2 FITTING, 90D (06JICM - 08ORBM) 25883 FITTING, 90D (0JICM - 0ORBM) 2 02659 FITTING, Straight (08JICM - 08ORBM) 3 2250 PLUG, Port (#) 70956 FITTING, Straight (6 SAE - JIC) 5 0372 2 WASHER, Flat (3/8 ) 6 03999 2 WASHER, Lock (3/8 ) 7 0387 2 BOLT, Hex Hd (3/8-6 x 2.750 ) Page 65
3.6 Brake Release Manifold Assembly 6 7 2 3 5 M3653AE Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 3653 ASSEMBLY, Manifold - Brake Release - 3650 MANIFOLD, Brake Release 6563 BLOCK, Manifold - Brake Release 2 656 ASSEMBLY, Valve 2 6562 HANDLE, Valve 3 6559 ASSEMBLY, Pump 3 6560 HANDLE, Pump 7095 3 FITTING, Straight ( JIC) 5 257 2 BOLT, Hex head (3/8-6 x 7/8, Grade 8) 6 0372 2 WASHER, Flat (3/8 ) 7 03999 2 WASHER, Lock (3/8 ) K 656 SEAL KIT (Not Shown) Page 66
3.7 Hydraulic Hose Connections - Base 8 9 7 3 0 2 5 M7323AB Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 7323 HOSE CONNECTIONS, Base 36572 HOSE, Hydraulic (Drive Manifold BRP. to Brake Manifold) 2 968 HOSE, Hydraulic (Drive Manifold M to Right Motor A) 3 968 HOSE, Hydraulic (Drive Manifold M2 to Left Motor B) 968 HOSE, Hydraulic (Drive Manifold M3 to Right Motor B) 5 968 HOSE, Hydraulic (Drive Manifold M to Left Motor A) 6 9833 HOSE, Hydraulic (Hose Main Manifold H-2 to Steer - LH Turn) 7 9833 HOSE, Hydraulic (Hose Main Manifold H-23 to Steer - RH Turn) 8 H5000360 HOSE, Hydraulic (Left Brake to Brake Manifold) 9 H5000380 HOSE, Hydraulic (Right Brake to Brake Manifold) 0 09 0 SLEEVE, Nylon - Hose Protection (HG-28) 09 0 SLEEVE, Nylon - Hose Protection (HG-28) Page 67
3.8 Pothole Protection Assembly 5 3 33 32 6 30 3 25 23 9 7 3 20 8 2 9 27 35 28 0 2 29 26 3 5 6 2 23 2 22 29 8 7 M70235AB Page 68
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 9029 2 LOCK, Tray cam 2 9339 PIN, Pothole Hinge 3 935 2 PIN, Spring (0.09 x 0.875 ) 939 8 PIN, Spring (0.09 x 0.625 ) 5 8690 2 PIN, Lock - Stainless 6 936 6 BUSHING, Fiberglide (3/8 dia x 5/8 ) 7 938 BUSHING, Fiberglide (7/6 dia x 3/8 ) 8 693 WELDMENT, Angle - Pothole Bar Hydraulic Side, A 8 6930 WELDMENT, Angle - Pothole Bar Battery Side, B - 70235 ASSEMBLY, Pothole Protection 9 7903 2 BAR, Pothole Lever 0 932 6 BUSHING, Fiberglide (7/6 dia x /2 ) 9325 2 PIN, Cotter (3/32" x 2 30209 PIN, Clevis (7/6 dia x -/ ) - 25776 ASSEMBLY, CAM LOCK 3 8730 PIN, Guide - Pothole Spring (3/ dia x 8 ) 878 LOCK, Driver - Pothole 5 93 SPRING, Pothole 6 8729 LOCATOR, Pothole Pin 7 8778 BUSHING, Self Lubricating (3/ dia x ) 8 999 LOCK, Cam - Pothole 9 9728 2 WASHER, Flat (-/6 ) 20 983 PIN, Spring (3/32 dia x -3/8 ) 2 367 2 ASSEMBLY, Compression Rod - Pothole 2 39386 ROD ASSY, Pothole Compression 2 230 BOLT, Carriage (3/ -0 x 2, Gr 5) 2 00252 NUT, Hex Hd (3/ -0, Gr B) 22 9322 2 BAR, Kicker - Pothole 23 8689 2 PIN, Clevis (7/6 x 53/6 ) 2 932 2 SPRING, Compression - Pothole 25 3007 GUARD, Pothole - Battery Side 25 3009 GUARD, Pothole - Hydraulic Side 26 32530 2 PIN, Clevis (7/6 x -3/ ) 27 958 SCREW, Socket Hd (#8-32 x -/ ) 28 38765 NUT, Lock - Nylon (#8-32) 29 933 8 WASHER, Flat (7/6 ) 30 75 SET SCREW, Square Hd (3/8-6 x 3/, Gr 5 ZN) 3 03550 6 BUSHING, Handrail Slide 32 03855 BOLT, Hex Hd (/"-20 x /2", Gr 5) 33 0000 WASHER, Lock (/ ) 3 03995 WASHER, Flat (/ ) 35 33600 LIMIT SWITCH, Pothole - Hydraulic Tray, A (ANSI/CSA & KC) 35 25885 LIMIT SWITCH, Pothole - Hydraulic Tray, A (CE & AS) 35 66007 LIMIT SWITCH, Pothole - Battery Tray, B (ANSI/CSA & KC) 35 66003 LIMIT SWITCH, Pothole - Battery Tray, B (CE & AS) Page 69
3.9 Wheel Assembly 2 M689AB Part - 689 ASSEMBLY, Wheel NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 689 TIRE, Grey - Non-Marking (6x5x2) 2 0399 20 BOLT, Wheel Page 70
3.0 Tilt Switch and Bracket Assembly (ANSI/CSA & KC) 7 3 2 5 8 6 M7376AC Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 7375 ASSEMBLY, Tilt Switch and Bracket (ANSI/CSA & KC) 7560 ASSEMBLY, Tilt Switch (.5 x 3.5) 2 0000 2 WASHER, Lock (/ ) 3 03980 2 NUT, Hex Hd (/ -20, Gr 8) 03857 2 BOLT, Hex Hd (/ -20 x, Gr 5) 5 602 PLATE, Mount - Tilt Switch 6 0003 2 NUT, Machine (#0-32) 7 2009 2 SCREW, Round Hd (#0-32 x 5/8 ) 8 085 2 WASHER, Lock (#0) Page 7
3. Base Control Assembly L 9 0 3 2 3 7 6 5 A B C D E F 2 8 M7693AC Page 72
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 58308 ASSEMBLY, Base Control (AS) - 95889 ASSEMBLY, Cover - Base Control 95890 COVER, Base Control 2 789 ASSEMBLY, Key Switch - 3 Way (Off/Platform/Base), A, C 2 7896 ASSEMBLY, Key Switch - 3 Way (Off/Platform/Base), B 2 7893 HEAD, Key Switch - 3 Position, A, C 2 7895 HEAD, Key Switch - 3 Way, B 2 37 HOUSING, Connector - 6 Way 2 3836 NUT, Key Switch 2 3837 KEY, #55 2 3838 BOOT, Key Switch 3 979 ASSEMBLY, Switch - Emergency Stop 3 705 SWITCH HEAD, Emergency Stop 3 7053 BLOCK, Contact (N.C.) 3 706 BLOCK, Led - 2V (Red) 3 7056 LATCH 977 ASSEMBLY, Key Switch - 2 Way (Lower/Neutral/Raise) 7069 SWITCH HEAD, Selector 705 2 BLOCK, Contact (N.O.) 7056 LATCH 5 7582 CONNECTOR, Receptacle 6 758 CONNECTOR, Wedge 7 7590 CONNECTOR, Contact Pin 8 02888 2 CONTROL CABLE, 6/0 9 958 PLATE, Mount - Base Control L (Ref.) - LABELS (For components, refer to Section 8.) 0 0000 2 WASHER, Lock (/ ) 958 2 BOLT, Hex Hd (/ -20 x 3-/ ) Page 73
3.2 Counter Reset (CE) 6 3 2 7 8 5 9 M9903AA Part NOTE : Part Numbers followed by a DG indicate dark grey painted parts. - 9903 ASSEMBLY, Counter Reset (CE only) 98975 BRACKET, 0V Outlet 2 36328 BOX, 0V Outlet - Assembled 3 99005 COVER, Black - 0V Outlet (Ref.) HARNESS, Reset Fuse (For components, refer to Section 6.5) 5 03857 2 BOLT, Hex Hd (/ -20 x, Gr 5) 6 03856 2 BOLT, Hex Hd (/"-20 x 3/", Gr 5) 7 03995 2 WASHER, Flat (/") 8 0000 WASHER, Lock (/") 9 03980 NUT, Hex Hd (/ -20, Gr 8) Page 7
.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
. Hydraulic Tray Group 50 55 56 7 27 20 0 8 2 3 Detail A 3 0 25 2 23 22 2 33 2 37 38 26 39 6 9 3 3 36 37 9 35 37 5 52 53 32 2 28 29 30 3 5 5 Detail A 7 8 6 7 5 TO MAIN DISCONNECT + TO BATTERY TRAY - 6 9 8 5 M9532AB_ Page 76
. Hydraulic Tray Group Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 9532 - ASSEMBLY, Hydraulic Tray (ANSI) B 69690 - ASSEMBLY, Hydraulic Tray (CE/AS/KC) - 6936 ASSEMBLY, Tray - Hydraulic 69338 WELDMENT, Tray - Hydraulic 2 (Ref.) ASSEMBLY, Pothole Protection (For components, refer to Section 3.8) 3 9609 ASSEMBLY, Latch - Hydraulic Tray Rotary 2307 LATCH, Rotary 5 03980 NUT, Hex Hd (/ -20, Gr 8) 6 0386 3 BOLT, Hex Hd (5/6-8 x ) 7 03857 BOLT, Hex Hd (/ -20 x, Gr 5) 8 0000 WASHER, Lock (/ ) 9 53 KNOB, Latch - 25780 INSTALLATION, Tray to Base 0 006 PIN, Eccentric - Upper Tray ( dia x 2-/6 ) 8983 PIN, Bottom Tray (0.750 dia x -7/8 ) 2 9922 TRIM, Protective - Standard Double Lip 3 00335 2 BUSHING, Bronze - 770 ASSEMBLY, Plug - Tank (3/ -6 Magnetic Thread) 9606 PLUG, Drain - Magnetic Thread Gasket 5 2090 WASHER, Drain Sealing Plug 6 80 BOLT, Carriage (3/8-6 x ) 7 25798 BOLT, Carriage (/2-3 x -/2 ) 8 0799 NUT, Hex jam (/2-3) 9 08575 NUT, Hex jam (3/8-6) 20 (Ref.) ASSEMBLY, Lid - Hydraulic Tank (For components, refer to Section.2) - 720 ASSEMBLY, Cylinder - Cushion 2 25827 CYLINDER, Cushion 22 0297 2 BRACKET, Conduit 23 03995 2 WASHER, Flat (/ ) 2 0000 2 WASHER, Lock (/ ) 25 03855 2 BOLT, Hex Hd (/"-20 x /2", Gr 5) 26 6380 WELDMENT, Counterweight - Hydraulic Tray 27 (Ref.) ASSEMBLY, Motor/Pump -.8CC (For components, refer to Section.) 28 3390 2 BOLT, Hex head (/2-3 x 3-3/ ) 29 0368 2 WASHER, Flat (/2 ) 30 0370 2 WASHER, Lock (/2 Gr 5) - 7200 ASSEMBLY, Level Indicator 3 03236 INDICATOR, 3 Level 32 23 2 BOLT, Hex head (/ -20 x /2 ) Parts list continued on the following page. Page 77
. Hydraulic Tray Group (Continued) 50 55 56 7 27 20 0 8 2 3 Detail A 3 0 25 2 23 22 2 33 2 37 38 26 39 6 9 3 3 36 37 9 35 37 5 52 53 32 2 28 29 30 3 5 5 Detail A 7 8 6 7 5 TO MAIN DISCONNECT + TO BATTERY TRAY - 6 9 8 5 M9532AB_ Page 78
. Hydraulic Tray Group (Continued) Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. Parts list continued from the previous page. - 69956 SUBGROUP, Motor Controller - 7206 ASSEMBLY, Motor Controller 33 5207 CONTROLLER, Pump/Motor (2VDC, 360 Amp) 3 03856 3 BOLT, Hex Hd (/"-20 x 3/", Gr 5) 35 03857 BOLT, Hex Hd (/ -20 x, Gr 5) 36 0000 WASHER, Lock (/ ) 37 03995 9 WASHER, Flat (/ ) 38 03078 CLIP, Double (G0) 39 03980 NUT, Hex Hd (/ -20, Gr 8) - 7207 ASSEMBLY, Contactor 0 65865 KIT, Contactor - Motor Controller 03855 2 BOLT, Hex Hd (/"-20 x /2", Gr 5) 2 03995 2 WASHER, Flat (/ ) 3 0000 2 WASHER, Lock (/ ) - 6665 KIT, Power Cable 9550 CABLE, Welding - Main Contactor Positive to Main Disconnect Positive 5 2025 CABLE, Welding - Main Contactor Negative to Battery Negative 6 232 CABLE, Welding - Battery Tray Negative to Battery Negative 7 6669 CABLE, Welding - Pump/Motor Positive to Motor Positive 8 6668 CABLE, Welding - Pump/Motor Negative to Battery Negative 9 708 INSULATOR, Boot (Red) 50 (Ref.) - ASSEMBLY, Manifold - Main (For components, refer to Section.5) 5 03873 BOLT, Hex head (3/8-6 x 2-/2, Gr 5) 52 0372 WASHER, Flat (3/8 ) 53 03999 WASHER, Lock (3/8 ) 5 (Ref.) - ASSEMBLY, Emergency Lowering (For components, refer to Section.3) - 96593 ASSEMBLY, Hose - Suction 55 985 HOSE, Tank Truck (3/ x.00 ) 56 02 2 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
.2 Hydraulic Tank Lid Assembly 3 7 6 2 3 5 2 8 9 0 M29602AD Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 29602 ASSEMBLY, Lid - Hydraulic Tank 09267DG WELDMENT, Hydraulic Tank Lid - 62220 ASSEMBLY, Manifold - Manual Lowering w/ Fittings - 0793 SUB-ASSEMBLY, Manifold - Manual Lowering 2 32 MANIFOLD, VC0-2 3 08052 3 PLUG, Expander 0727 VALVE, Directional - Manual 5 03069 FITTING, Straight - Connector (06 JICM - 06 ORBM) 6 09568 FILTER, Hydraulic Inlet 7 09052 FITTING, Straight - Connector (#2 ORB - #6) 8 0298 6 HOSE, Filter to Tank 9 03320 Clamp, Gear - #6 0 02693 ASSEMBLY, Filler/Cap 03962 7 SCREW, Machine (#0-32 x /2 ) 2 8298 GASKET, Hydraulic tank 3 0386 2 BOLT, Hex head (5/6-8 x ) 0398 2 NUT, Hex Nylon Lock (5/6-8, Gr B) Page 80
.3 Emergency Lowering Assembly 5 0 9 8 3 6 7 2 M95582AC Part NOTE : Part Numbers followed by a DG indicate dark grey painted parts. - 95582 - ASSEMBLY, Emergency Lowering - 9902 ASSEMBLY, Toggle Switch - E-Lower 9900 SWITCH, Toggle - SPST 2 95583 BRACKET, Switch - E-Lower 3 08526 2 BREAKER, 0 Amp 692 SCREW, Round Hd (#8-32 x 5/8 ) 5 38765 NUT, Lock (#8-32) 6 97252 COVER, Breaker - Red 7 97253 COVER, Breaker - Black (Switch) 8 999 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
. Motor and Pump Assembly 7 9 8 2 0 3 6 Page 82 M9532AB
. Motor and Pump Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. - 69955 - GROUP, Motor/Pump -.8cc - 6938 ASSEMBLY, Motor/Pump -.8cc 69260 MOTOR, 2VDC 2 9996 PUMP, Hydraulic 3 058 FITTING, 90 (2 BEAD - 0 ORBM) 9999 BOLT, Socket Hd (M8 x 95, CL2.9 ZN) (Not Shown) 5 69623 KIT, Brush Repair (Not Shown) 6 9020DG PLATE, Mount - Motor Universal 7 03887 BOLT, Hex Hd (5/6-8 x 3/ ) 8 03996 WASHER, Flat (5/6 ) 9 030 WASHER, Lock (5/6 ) 0 02665 FITTING, Elbow 90 (06 JICM - 08 ORBM) K 69535 KIT, Seal (Not Shown) Page 83
.5 Main Manifold Assembly 8 23 9 2 25 22 5 2 9 5 3 2 2 7 6 2 7 3 9 2 0 3 5 8 20 2 9 5 2 6 22 M96592AC_ Page 8
.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 08052 9 PLUG, Expander 2 5320 FITTING, Plug (#8) 3 03605 2 COIL, 2 Volt 03623 VALVE, 3-Way 5 053 2 VALVE, System Relief 6 0560 COIL, 2 Volt 7 06273 VALVE, Solenoid 8 02856 PLUG (#3) 9 037 6 FITTING, Plug (06 ORBM) 0 7889 VALVE, Counterbalance 09 PLUG (/6 NPT) 2 03069 7 FITTING, Straight (06 JICM - 06 ORBM), A 2 03069 6 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) 5 578 2 FITTING, Elbow 90 (06 JICM - 0 ORBM) 6 07666 NUT, Cap (06 JICF), A 6 2220 ASSEMBLY, Quick Disconnect, B 6 22385 COUPLER, B 6 52 COVER, Dust, B 6 2228 FITTING, Straight (06 ORBM - 06 ORBM), B 7 03655 VALVE, Solenoid 8 5333 VALVE ASSY, Directional 8 53335 COIL, 2 Volt 9 99986 VALVE ASSY, Directional - Open Center 20 03920 BOLT, SHC (#0-2 x 2 ) 2 0399 BOLT, SHC (#0-2 x -3/ ) 22 0267 2 HOSE, Hydraulic Line (Main Manifold to Cushion Cylinder) 23 323 ORIFICE, Pressure Plug (0.3 ) 2 25892 BUMPER, Rubber Male 25 29 SCREW, Hex Hd Machine (/ -20 x ) Page 85
.6 Hydraulic Hose Connections - Hydraulic Tray 3 2 6 5 M9532AB_Hoses Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. H06060020 HOSE, Hydraulic (Main Manifold to Pump Outlet) 2 263 HOSE, Hydraulic (Main Manifold to Manual Lowering Valve) 3 36563 HOSE, Hydraulic (Main Manifold to Filter Inlet) 3775 HOSE, Hydraulic (Drive Manifold Brake to Main Manifold Brake) 5 0656 HOSE, Hydraulic (Main Manifold H-6 to Drive Manifold IN) 6 0656 HOSE, Hydraulic (Main Manifold H-5 to Drive Manifold INR) Page 86
5.0 BATTERY TRAY RELATED PARTS Battery Tray Assembly 5. Battery 5.2 5.3 Battery Charger 5 Page 87
5. Battery Tray Assembly 3 5 2 2 8 6 7 3 5 6 9 0 M6933AC Page 88
5. Battery Tray Assembly Part - 96589 - ASSEMBLY, Battery Tray NOTE: Part Numbers followed by a DG indicate dark grey painted parts. 69307 WELDMENT, Battery Tray 2 9608 ASSEMBLY, Latch - Battery Tray Rotary 3 2308 LATCH, Rotary Right Hand 0386 3 BOLT, Hex head (5/6-8 x ) 5 03857 BOLT, Hex Hd (/ -20 x, Gr 5) 6 0000 WASHER, Lock (/ ) 7 03980 NUT, Hex Hd (/ -20, Gr 8) 8 53 KNOB, Latch - 37637 INSTALLATION, Tray to Base 9 006 PIN, Eccentric - Upper Tray (.00 dia x 2-/6 ) 0 8983 PIN, Bottom Tray (3/ dia x -7/8 ) 00335 2 BUSHING, Bronze 2 80 BOLT, Carriage (3/8-6 x ) 3 25798 BOLT, Carriage (/2-3 x -/2 ) 08575 NUT, Hex jam (3/8-6) 5 0799 NUT, Hex jam (/2-3) 6 (Ref.) - ASSEMBLY, Pothole Protection (For components, refer to Section 3.8) Page 89
5.2 Battery Assembly L L 3 2 2 5 3 5 5 7 8 5 8 3 5 9 7 5 0 6 M78AD Page 90
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 95225 - ASSEMBLY, Battery - Standard (AS) C 9523 - ASSEMBLY, Battery - AGM (ANSI/CSA & CE) 97296 PLYWOOD (3/8" x " x 33"), A, C 97585 NEOPRENE SHEET (/" x " x 28.50"), B 2 95227 3 SPACER, Plastic (2" x 3" x ") 3 97295 BATTERY, 2V, A, B 3 7855 BATTERY, 2V - AGM, C 99582 INSULATOR, Boot - Black 5 9958 INSULATOR, Boot - Red 6 708 INSULATOR, Boot - Red 7 2025 2 CABLE, Welding - #Ga (5/6" x 6" x 5/6") 8 9793 2 CABLE, Welding - #Ga (5/6" x 0" x 5/6") 9 9569 CABLE, Battery - 300A In-line Fuse 0 9550 CABLE, Welding - #Ga (5/6" x 8" x 3/8") (+,+) 03068 INSULATOR, Fuse 2 3905 TERMINAL, Boot - Red 3 0000 2 WASHER, Lock (/") 03995 WASHER, Flat (/") 5 03855 2 BOLT, Hex Hd (/"-20 x /2", Gr 5) L (Ref.) - LABELS (For components, refer to Section 8.) Page 9
5.3 Charger Assembly 3 2 M97633AA Page 92
5.3 Charger Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 97633 - ASSEMBLY, Charger - Signet (ANSI/CSA & AS) B 97635 - ASSEMBLY, Charger - Signet (CE & KC) C 97638 - ASSEMBLY, Charger - AGM (ANSI/CSA) D 207760 - ASSEMBLY, Charger - AGM (CE) 707 CHARGER, 750W Chord - Signet, A 708 CHARGER, 750W Socket - Signet, B 9975 CHARGER, 750W Chord - AGM, C 20776 CHARGER, 750W Socket - AGM, D 2 03856 BOLT, Hex Hd (/"-20 x 3/", Gr 5) 3 03995 WASHER, Flat (/") 0000 WASHER, Lock (/") 5 20790 CORD, Charger - 220V, B, D Page 93
Notes Page 9
6.0 ELECTRICAL RELATED PARTS 6 Electrical Panel 6.. 6.2 Control Cable Assembly 6.3 6. 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
6. Electrical Panel Assembly 3 5 8 6 20 2 KC 3 0 8 CE/AS 7 ANSI/CSA 5 9 2 L 7 2 6 9 23 2 25 22 M96050AB_ Page 96
6. Electrical Panel Assembly Part NOTE: Part Numbers followed by a DG indicate dark grey painted parts. A 96050 - ASSEMBLY, Electrical Panel (ANSI/CSA) B 9855 - ASSEMBLY, Electrical Panel (CE) C 96052 - ASSEMBLY, Electrical Panel (AS) D 96053 - ASSEMBLY, Electrical Panel (KC) - - ASSEMBLY, Electrical Panel 63057DG WELDMENT, Electrical Panel 2 9590 HOURMETER, Digital, A, C, D 2 70787 HOURMETER, Counter, B 3 7325 2 BREAKER, Circuit - 5 Amp 08589 6 RELAY, 2 Volt, A 08589 RELAY, 2 Volt, B 08589 0 RELAY, 2 Volt, C 08589 7 RELAY, 2 Volt, D 5 32793 CLAMP, Plastic (-/ ) 6 030 TERMINAL BLOCK, 9P 7 030 2 TERMINAL BLOCK, 2P 8 25893 BUMPER, Rubber - Female 9 03956 9 SCREW, Round Hd (#6-32 x ) 0 03962 6 SCREW, Round Hd (#0-32 x /2 ), A 0 03962 SCREW, Round Hd (#0-32 x /2 ), B 0 03962 0 SCREW, Round Hd (#0-32 x /2 ), C 0 03962 7 SCREW, Round Hd (#0-32 x /2 ), D 03957 SCREW, Round Hd (#8-32 x /2 ) 2 03985 9 NUT, Hex (#6-32) 3 0003 6 NUT, Hex (#0-32), A 3 0003 NUT, Hex (#0-32), B 3 0003 0 NUT, Hex (#0-32), C 3 0003 7 NUT, Hex (#0-32), D 03986 NUT, Hex (#8-32) 5 085 6 WASHER, Lock (#0), A 5 085 WASHER, Lock (#0), B 5 085 0 WASHER, Lock (#0), C 5 085 7 WASHER, Lock (#0), D 6 0000 WASHER, Lock (/ ) 7 03995 WASHER, Flat (/ ) 8 03980 NUT, Hex Hd (/ -20, Gr 8) 9 03892 BOLT, Hex Hd (/ -20 x 5/8 ) 20 03057 BEEPER, Slow Pulsing - -28VDC, A 20 03057 2 BEEPER, Slow Pulsing - -28VDC, D 2 3938 PLUG (-/8 dia), A 2 3938 2 PLUG (-/8 dia), B, C 22 20776 RESISTOR ASM,.5 Ohm, A, B, C 22 207707 RESISTOR ASM, 7.5 Ohm - AGM Option A, B 23 03855 BOLT, Hex Hd (/"-20 x /2", Gr 5) 2 0000 WASHER, Lock (/ ) 25 0302 2 CLAMP, Single, A, C, D 25 02929 2 CLAMP, Single, B L (Ref.) - LABELS (For components, refer to Section 8.) Page 97