Scissors lift and pump assembly

0

REV. ECN NO. DATE BY APPD. DESCRIPTION OF REVISION TOTAL #OF PAGES

PSS # xxxx-xxx-xxxOP – Complete Scissors Lift Assembly

Model Numbers

= TQC (Touch Quality Control) = CTQ (Critical to Quality)

MATERIALSC11003-01 – Battery box rear side panel

C11003-02 – Battery box base panelC11003-03 – Battery box divider panel

C11003-04 – Battery box mounting angle AC11003-05 – Battery box mounting angle B

C11003-06 – Battery box cable coverC11003-07 – Battery box front side panel

C11003-08 – Battery box vent guard (4 needed)C11003-09 – Battery box top coverC1000902 – 1/8” x 5/32” pop rivet

#8 washer (8 needed)

TOOLSRivet gunPower drill#16 drill bitBar clamp

Drawing No. C11003

Complete Scissors Lift Assembly 0000-000-000

PAGE 2

C11003-02C11003-01

C11003-03C11003-07

C11003-04

C1000902

C11003-04

#8 washer

C1000902

C11003-08

Fig. 1

Fig. 2

Fig. 3


C11003-02 – Battery box base panelC11003-07 – Battery box front side panel

B1004307 – Angle brace for battery106232 – Weld stud, #10-32 x ½ long

1001513 – M6 weld nut108115 – Phillips #10-32 x 0.375 round head screw

1075473 – #10 lock washer

PROCEDURESAssembling the battery box (continued)

Drawing No. C11003

Using the drawings as a guide, weld a stud to the base panel. The stud is used as a ground (Fig.1).

Tack weld 2 weld nuts to the bottom of the battery box base panel (Fig. 2)

Tap 2 holes near the edge of the base panel in the battery compartment and attach an angle brace for the battery using 2 screws and lock washers (Fig. 3).

Grind down the 2 angle brace screws protruding from the base panel for a smooth finish (Fig. 4).

TOOLSLeather welding gloves

Welding helmetWelding equipment

Phillips head screwdriverGrinding tool

Drawing No. C11003


PAGE 3

Fig. 1

Fig. 2

Fig. 3

Fig. 4


C11003-02 – Battery box base panelC11003-07 – Battery box front side panel

C1000902 – 1/8” x 5/32” pop rivet

PROCEDURESAssembling the battery box (continued)

Drawing No. C11003

When connecting the battery box base panel to the battery box assembly use a bar clamp to help line up the rivet holes (Fig. 1).

If necessary, use a power drill to expand the rivet holes and remove any flash (Fig. 2).

Using a rivet gun, punch in the rivets for a tight fit (Fig. 3).

TOOLSRivet gunPower drill#16 drill bitBar clamp

Drawing No. C11003


PAGE 4

Fig. 4Fig. 3Fig. 2

MATERIALSC1002602 – 12 V relay solenoid

236054 – Hose clamp

PROCEDURESMounting the solenoid to the hydraulic power unit

Using a metal-cutting tool, cut a slot, approximately ¾” long, into the center of each mounting bracket on the solenoid (Fig. 1).

Use a sanding disc to remove any burrs from the freshly cut bracket (Fig. 2).

Measure and mark about 3½” from the end of a hose clamp (Fig. 3).

TOOLSPencil grinderCutting discPower drill

Sanding discTape measure

Marker


PAGE 5

C1002602

C1002602

236054Fig. 1

Fig. 3

Fig. 2


236054 – Hose clamp

PROCEDURESMounting the solenoid to the hydraulic power unit (continued)

Using a cutting disc, cut off the marked area on the hose clamp (Fig. 1).

Remove any burrs or rough edges from the hose clamp (Fig. 2).

Thread the hose clamp through the slots in the solenoid mounting bracket (Fig. 3).

TOOLSPencil grinderCutting discPower drill

Sanding disc


PAGE 6

236054

C1002602

236054

Fig. 1

Fig. 3

Fig. 2


236054 – Hose clampC1002601 – Hydraulic power unit

PROCEDURESMounting the solenoid to the hydraulic power unit (continued)

Before mounting the solenoid, spray the hydraulic power unit with alcohol and wipe it clean with a lint-free cloth (Fig. 1).

Set the solenoid on top of the pump and secure it with the hose clamp (Fig. 2).

Tighten the hose clamp (Fig. 3).

TOOLSIsopropyl alcohol in a spray bottle

Soft lint-free clothFlat-head screwdriver


Page | 7

C1002601

C1002601

C1002602

C1002601

C1002602

Fig. 1

Fig. 3

Fig. 2

MATERIALSC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit

5 MM lock washer8 MM lock washer

5 MM hex nut8 MM hex nut

PROCEDURESPreparing the hydraulic power unit

Hand tighten a lock washer and hex nut to each of the 4 studs on the solenoid. The top 2 studs have 5 MM threads and the 2 brass studs on the bottom have 8 MM threads (Fig. 1).

The solenoid relay sits on an angle. You will need to position it straight with the wires on top. Using a wrench loosen the bolt on the front of the relay (Fig. 2).

Turn the relay so that its wires are on top and tighten the bolt (Fig. 3).

TOOLS¾” box wrench


Page | 8

C1002601

C1002602

C1002601C1002602

C1002601

C1002602

Fig. 1

Fig. 3

Fig. 2


PROCEDURESPreparing the hydraulic power unit

Using an Allen wrench loosen and remove the bolt from the side of the power unit block (Fig. 1),

Remove the blue plug from the hole in the front of the block (Fig. 2).

Thread a bolt into the opening and tighten (Fig. 3).

TOOLS#5 Allen wrench

Needle-nose pliers


Page | 9

C1002602

C1002601

C1002601

C1002602

C1002601

C1002602Fig. 1

Fig. 3

Fig. 2


C1002597 – 1/8” NPT x ¼” BSPP Male adapter with flat washerLubricating fluid

PROCEDURESPreparing the hydraulic power unit (continued)

Using a 1/8” by ¼” male adapter, thoroughly lubricate the flat washer and slide it onto the ¼” end of the adapter (Fig. 1 and Fig. 2).

Thread the ¼” end of the adapter into the side of the block and tighten (Fig. 3).

TOOLSAdjustable wrench


Page | 10

Fig. 1

Fig. 3

Fig. 2


C1002597 – 1/8” NPT x ¼” BSPP male adapter with flat washer1300712 – Teflon tape

PROCEDURESPreparing the hydraulic power unit (continued)

Remove the protective cap from the 1/8” end of the adapter (Fig. 1).

Apply Teflon tape to the 1/8” male fittings. Starting at the second thread, wrap clockwise 4 complete turns (Fig. 2).

Replace the protective cap (Fig. 3).

TOOLS


Page | 11

Fig. 1

Fig. 3

Fig. 2

MATERIALS1003455 – 4 AWG red wire (22½” length and 12” length)

1003454 – 4 AWG black wire (7½” length and 8¾” length)

PROCEDURESPreparing the fuse and battery wires

Measure and cut a 6” section, a 12” section, and a 22½” section of 4 AWG red wire. Measure and cut a 7½” section and an 8¾” section of 4 AWG black wire (Fig. 1).

Using a wire stripper, remove approximately ¾” of the outer cover from both ends of each wire (Fig. 2 and Fig. 3).

TOOLSTape measure

Marker Wire cutters

Wire strippers


Page | 12

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004283 – ¼” Copper Penn crimps wire connectors for 4 AWG (enlarged to 5/16”)

TOOLSVice

Power drillStep bit


Page | 13

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004283 – ¼” Copper Penn crimps wire connectors for 4 AWG (enlarged to 5/16”)

1003455 – 4 AWG red wire (22½” length and 12” length)1003454 – 4 AWG black wire (7½” length and 8¾” length)

TOOLSCrimping tool


Page | 14

1003455

B1004283

B1004283

B1004283

1003455 Fig. 1

Fig. 3

Fig. 2

MATERIALS3M heat shrink tubing

1003455 – 4 AWG red wire (22½” length and 12” length)1003454 – 4 AWG black wire (7½” length and 8¾” length)

PROCEDURESApplying heat shrink tubing to connections

Measure and cut (8) 1½” sections of 3M heat shrink tubing (Fig. 1 and Fig. 2).

Slide the sections of shrink tubing over each crimped wire connection and use a heat gun to shrink the tubing for a tight fit (Fig. 3).

TOOLSMarker

Tape measureUtility knifeHeat gun


Page | 15

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11003-02 – Battery box base panel

B1004293 – Rubber grommet (2 needed)C1003370 – Rubber grommet

B1004291 – Liquid-tight seal knock out3M Silicone Lubricant

PROCEDURESInserting the grommets and plugs into the battery box

The battery box uses 2 small rubber grommets, 1 large rubber grommet, and 1 liquid-tight seal knock out rubber plug. Lubricate each before inserting them into the battery box (Fig. 1).

Press a liquid-tight seal knock out into the hole on the base panel and using the end of a hammer, firmly seat the plug (Fig. 2).

Work the rubber grommets into their matching holes. The larger grommet fits into the hole at the rear side panel. The 2 smaller grommets fit into the divider panel and under the vent in the front side panel (Fig. 3).

TOOLSLong-handled hammerRubber-head hammer


Page | 16

C11003-02

C1003370

B1004291

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004223 – Fuse block

B1004224 – 63 amp fuse, type A4

PROCEDURESPreparing the fuse block

Separate the top and bottom sections of the fuse block. Remove the 2 grommets from inside the fuse block (Fig. 1).

Remove the set screw from the top of the fuse block and attach a 63 amp fuse (Fig. 2).

Firmly tighten the fuse by placing the top section of the block into a vice sandwiched between 2 pieces of foam. Be careful not to crack the top piece. Tighten the screw using a wrench and screwdriver combination (Fig.3).

TOOLSFlat-head screwdriver

Phillips head screwdriverAdjustable wrench


Page | 17

B1004223

B1004224

Grommet

B1004223

Fig. 1

Fig. 3

Fig. 2


1003455 – 4 AWG red wire (22½” length and 12” length)

PROCEDURESPreparing the fuse block (continued)

Remove the red terminal covers from the bottom of the fuse block (Fig. 1).

Slide the open end of the 22½” red wire through one of the grommets and into the fuse block (Fig. 2).

Make sure the 22½” red wire is positioned closest to the top mounting hole. The end of the wire should be even with the end of the brass plate (Fig. 3).

.



Page | 18

Top mounting hole

Make end even with brass plate

B1004223

B1004223

Grommet

B1004223

Fig. 1

Fig. 3

Fig. 2



PROCEDURESPreparing the fuse block (continued)

Tighten the screw to hold the wire in place (Fig. 1). Attach the 12” red wire to the other side making sure it is closest to the lower mounting hole and even with the brass plate.

Place the fuse block in a vice sandwiched between 2 pieces of foam. Use an adjustable wrench and screwdriver to firmly tighten each screw (Fig. 2).

Once tightened, work the grommets into the box to support the wires (Fig. 3).


Flat-head screwdriver2 pieces of foam for vice


Page | 19

B1004223

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11003-03 – Battery box divider panel

B1004223 – Fuse block1003455 – 4 AWG red wire (22½” length and 12” length)

1001745 –Button head socket head cap screw, M6-1.0 x 16

PROCEDURESAttaching the fuse block to the battery box

Feed the 22½” section of red wire through the grommet on the divider panel (Fig. 1).

Place the bottom section of the fuse block into the battery box opposite the grommets and line up the mounting holes (Fig. 2).

Slide flat washers onto 2 button head screws and thread them through the mounting holes and into the weld nuts on the base panel. Tighten slightly, adjust the fuse block so it is square, and then finish tightening the screws (Fig.3).

TOOLSPhillips head screwdriver


Page | 20

B1004223 B1004223

Fig. 2

C11003-03

Fig. 1

Fig. 3



PROCEDURESAttaching the fuse block to the battery box (continued)

With the fuse block secure, replace the red terminal covers (Fig. 1).

Slide the top of the fuse block onto its bottom section (Fig. 2).



Page | 21

B1004223

B1004223Fig. 1

Fig. 2


8 MM locking washer8 MM nuts

1003455 – 4 AWG red wire (6” section)

PROCEDURESPreparing the hydraulic power unit assembly

Remove the hand-tightened nuts and washers from the gold stud opposite the relay wires on the solenoid and remove the nuts and washers from the bottom of the power unit. Turn the hydraulic power unit on its side with the solenoid relay wires pointing down (Fig. 1).

Bend the 6” red wire into a U shape, which will act as a jumper wire between the hydraulic power unit and solenoid (Fig. 2).

Attach the jumper wire to the brass stud on the solenoid and the stud on the power unit and replace the washers and nuts (Fig. 3).

TOOLS


Page | 22

C1002602

C1002602

C1002602

1003455Fig. 1

Fig. 3

Fig. 2


C1002601 – Hydraulic power unit8 MM locking washer

8 MM nuts1003455 – 4 AWG red wire (6” and 22½” sections)

1003454 – 4 AWG black wire (7 1/16” section)

PROCEDURESPreparing the hydraulic power unit assembly (continued)

Turn the hydraulic power unit upright to tighten the bolts (Fig. 1).

Attach one end of the 7 1/16” black wire to the bottom stud on the hydraulic power unit and tighten with a wrench (Fig. 2).

Set the hydraulic power unit inside the battery box positioning the capped adapter by the large center grommet. Set the 22½” red wire from the fuse block on top of the power unit. This way, the weight of the power unit will not damage the wire (Fig. 3).

TOOLSRatchet

13 MM socket


Page | 23

C1002602C1002602

C1003370

C1002602

1003454

1003455Fig. 1

Fig. 3

Fig. 2

MATERIALS113068 – Anti-seize compoundC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit

C11003-02 – Battery box base panel112081 – 3/8”-16 x 1.0 hex head bolt

C100004 – 3/8” wide flat washer1075973 – 3/8” lock washer

PROCEDURESMounting the hydraulic power unit inside the battery box

Turn the battery box on its side. Apply an anti-seize compound to the bolts, lock washers, and flat washers that are used to mount the hydraulic power unit (Fig. 1).

Working from the bottom of the battery box, thread the bolts and washer part way through the mounting holes on the base panel while positioning the power unit so it lines up with the bolts (Fig. 2).

Once aligned, firmly tighten the bolts (Fig. 3).

TOOLSRatchet

19 MM socket


Page | 24

C100004 and 1075973

C1002601

C100004 and 1075973

112081

C11003-02

112081

Fig. 1

Fig. 3

Fig. 2

MATERIALSC1002599 – Directional flow control

TOOLS2.5M Allen wrench


Page | 25

C1002599C1002599

C1002599

Fig. 1

Fig. 3

Fig. 2

MATERIALSC1002599 – Directional flow control

C1002601 – Hydraulic power unit

PROCEDURESAttaching the flow control to the hydraulic power unit

With the flow control adjusted, remove the cap from the 1/8” adapter on the hydraulic power unit (Fig. 1).

Thread the flow control onto the taped fitting (Fig. 1).

Tighten the open end of the flow control to secure it (Fig. 2).



Page | 26

C1002599

C1002599

Remove cap

Fig. 1

Fig. 1

Fig. 2

MATERIALSC11003-01 – Battery box rear/side panelC1002599 – Directional flow control valve

C1002598 – 1/8” NPT x 1/8” BSPP Male adapter with flat washer and cap1300712 – Teflon tape

PROCEDURESAttaching the male adapter to the flow control

Remove the cap from the 1/8” x 1/8” male adapter and apply Teflon tape to fittings. Starting at the second thread, wrap clockwise 4 complete turns (Fig. 1)..

Thread the adapter onto the flow control (Fig 2).

Tighten the adapter with an adjustable wrench and replace the cap (Fig. 3).


Scissors Lift Pump Assembly 0000-000-000

PAGE 27

C1002598

C11003-01

C1002598

C1002598

Fig. 1

Fig. 3

Fig. 2


C1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit1001432 – M8-1.25 x 20 SHCS

1001687 – M8-1.25 hex nut1003455 – 4 AWG red wire (22½” section)

1003454 – 4 AWG black wire (8¾” and 7 1/16” sections)

PROCEDURESConnecting the wires from the fuse box to the hydraulic power unit

With both the hydraulic power unit and the fuse block mounted inside the battery box, remove the hand-tightened lock washer and nut from the brass stud on the solenoid opposite the jumper. Attach the 22½” red wire from the fuse block to the brass stud, replace the lock washer and nut and tighten (Fig. 1).

Using an 8 MM screw, attach the 8¾” black wire to the divider panel (Fig. 2).

Attach the 7 1/16” black wire leading from the hydraulic power unit to the other end of the 8 MM screw, add a hex nut, and tighten. Both black wires are used as grounding wires (Fig. 3).

TOOLSRatchet

13 MM socket#5 Allen wrench


PAGE 28

1001432

C1002601

C1002602

1001687

C1002602

C1002601

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11003-01 – Battery box rear side panelC11003-07 – Battery box front side panel

C11003-02 – Battery box base panelC11003-03 – Battery box divider panel

19610 – Grounding label1003454 – 4 AWG black wire (7 1/16” and 8¾” lengths)

PROCEDURESAdding grounding stickers to the battery box

Wipe the inside of the battery box, including the exposed divider and base panel areas, with a soft lint-free cloth sprayed with alcohol (Fig. 1).

Add a grounding label to the divider panel next to both grounding wire connections (Fig. 2).

Add a second grounding label next to the weld stud on the bottom panel (Fig. 3).


Soft lint-free cloth


PAGE 29

19610

19610

1001432

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11003-03 – Battery box divider panel

107086 – Tie anchors231130 – Neoprene double-backed tape

PROCEDURESPlacing the tie anchors

Using a utility knife, peel the backing off tie anchors (Fig. 1).

Press new double-backed tape onto each tie anchor (Fig. 2).

Place 3 tie anchors, evenly spaced, onto the fuse block side of the divider panel. Also place a tie anchor on the front side panel near the fuse block (Fig. 3).

TOOLSUtility knife


Page | 30

107574

C11003-03 Fig. 1

Fig. 3

Fig. 2

MATERIALS1014005 – 14 AWG blue wire (105” length)

1014007 – 14 AWG brown wire (105” length)1014004 – 14 AWG red wire (105” length)

1014001 – 14 AWG black wire (105” length — 2 needed)1014001 – 14 AWG black wire (10½” length — 2 needed)

1001298 – Ring terminals

PROCEDURESPreparing wires to attach battery box components to control panel

Measure and cut a 105“ length of blue, brown, red, and black 14 gauge wire. Also cut (2) 10½” sections of 14 AWG black wire, which will be used as ground wires (Fig. 1).

Strip the ends of each wire (Fig. 2).

Use solder to tin the stripped ends of the wires (Fig. 3).

Add a ring terminal to 1 end of the red wire and add ring terminals to 1 end of the (2)105” black wires (Fig. 4).

TOOLSTape measure

Wire cuttersWire stripperCrimping toolSoldering iron

Wire solder


Page | 31

Fig. 4

1001298

Fig. 2Fig. 3

Fig. 1

MATERIALSB106483 – Small ring terminal crimp connectors

C1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit

1014005 – 14 AWG blue wire (105” length)1014007 – 14 AWG brown wire (105” length)

1014001 – 14 AWG black wire (10½” length — 2 needed)

PROCEDURESPreparing wires to attach battery box components to control panel (continued)

Add small ring terminal crimp connectors to one end of the brown and blue wires and to both ends of the 10½” black ground wires (Fig. 1).

Stretch the left red solenoid relay wire, the one closest to the solenoid, to the back of the hydraulic power unit. Estimate the length to the back of the flow control block and cut off the excess wire (Fig. 2).

Estimate the distance of the second solenoid relay wire to the weld stud on the base panel and cut off the excess (Fig. 3).

TOOLSCrimping toolWire cutters


Page | 32

C1002601

C1002602

B106483 Fig. 1

Fig. 3

Fig. 2


1078088 – #10-32 hex nut for weld studB106483 – Small ring terminal crimp connectors

1001298 – Ring terminals1014001 – 14 AWG black wire (10½” length — 2 needed)

PROCEDURESConnecting grounding wires inside the battery box

Strip and tin the ends of the 2 solenoid relay wires (Fig. 1).

Attach a small ring terminal crimp connector to the solenoid relay ground wire and connect it, along with the end of a 10½” black ground wire, to the weld stud on the base panel in the battery box. Thread on a hex nut and tighten (Fig. 2).

Attach the open end of the 10½” black ground wire to the 5 MM stud on the solenoid, closest to the jumper (Fig. 3).

TOOLSRatchet

8 MM socketWire strippersCrimping toolSoldering iron

Wire solder3/8” nut driver


Page | 33

1001298C1002602

1001298

1078088 Fig. 1

Fig. 3

Fig. 2

MATERIALSC1003483 – Male disconnect terminals

C1005342 – Female disconnect terminalsC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit

1014007 – 14 AWG brown wire (105” length)

PROCEDURESConnecting the wires inside the battery box

Disconnect terminals use either male or female connectors (Fig. 1).

Attach a female disconnect terminal to the end of the second red solenoid relay wire (Fig. 2).

Attach a male disconnect terminal to the open end of the brown wire (Fig. 3).

Connect the male disconnect terminal on the brown wire to the female end on the solenoid relay wire (Fig. 4).

TOOLSCrimping tool


Page | 34

C1005342

C1003483

C1003483 C1005342

Fig. 1

Fig. 2Fig. 3

Fig. 4


C1002601 – Hydraulic power unitB106483 – Small ring terminal crimp connectors

107086 – Cable tiesB1004262 – M5 nyloc hex nut

1014005 – 14 AWG blue wire (105” length)1014004 – 14 AWG red wire (105” length)

PROCEDURESConnecting the wires inside the battery box (continued)

Connect the crimped end of the blue wire to the center stud on the solenoid and tighten the 5 MM connection (Fig. 1).

Attach cable ties about every 4 to 6 inches along the length of the wires to hold them together (Fig. 2).

Feed the ring terminal end of the 105” red wire through the grommet in the divider panel (Fig. 3).

TOOLSRatchet

8 MM socket


Page | 35

107086

C11003-03

107086

C1002602

1014004

Fig. 1

Fig. 3

Fig. 2


1014001 – 14 AWG black wire (105” length)1003454 – 4 AWG black wire

1014004 – 14 AWG red wire (105” length)1003455 – 4 AWG red wire

107086 – Cable ties107574 – Tie anchors8 MM bolt (2 needed)8 MM nut (2 needed)

B1003408 – Red battery terminal coverB1003407 – Black battery terminal cover


Using a bolt and nut, connect the 105” red wire with the red 4 AWG from the fuse block and slide on the red terminal cover (Fig. 1).

Use cable ties to attach the red wire to the tie anchor holding the red wires together (Fig. 2).

Use a bolt and nut to connect 1 end of the (2) 105” sections of black wire to the grounded black 4 AWG and slide on the black terminal cover (Fig. 3).

Tack a small rectangular piece of neoprene foam tape onto the base panel near the fuse block to help level and stabilize the battery (Fig. 4).

TOOLSRatchet

13 MM socket4 MM Allen wrench

Wrench


Page | 36

1070861075741003454 1014001Foam to

stabilize battery

1014004

1003455

Fig. 1

Fig. 2Fig. 3

Fig. 4


C1002601 – Hydraulic power unitB106483 – Small ring terminal crimp connectors

107086 – Cable ties107574 – Tie anchors


Use cable ties to connect the 2 black wires to the 3 tie anchors inside the battery box (Fig. 1).

Feed the black wires through the grommet and into the solenoid side of the battery box (Fig. 2).

Add a cable tie to hold the black wires together (Fig. 3).

Roll the excess wire lengths and store them next to the hydraulic power unit for now (Fig. 4).

TOOLSRatchet

4 MM socketWrench


Page | 37

107086

107086

107574

Fig. 1

Fig. 2Fig. 3Fig. 4

MATERIALSC11003 – Battery box assembly

Foam backing

PROCEDURESAttaching the battery box top cover

Spray the edges of the battery box with alcohol and wipe clean with a lint-free cloth (Fig. 1).

Measure, cut, and apply lengths of foam backing to fit around the edges of the battery box (Fig. 2).

Use a center punch to make holes in the foam that match the tapped holes along the edge of the battery box (Fig. 3).


Soft lint-free clothCenter punch


Page | 38

C11003C11003C11003 Fig. 1

Fig. 3

Fig. 2


C11003-09 – Battery box top coverFoam backing

PROCEDURESAttaching the battery box top cover (continued)

Use a battery box template to cut out a section of foam to protect the hydraulic power unit section of the battery box (Fig. 1 and Fig. 2).

Spray the inside of the battery box lid with alcohol and wipe clean with a lint-free cloth (Fig. 3).


Soft lint-free clothUtility knife


Page | 39

C11003-09

C11003-09 Fig. 1

Fig. 3

Fig. 2


C11003-09 – Battery box top coverFoam backing

PROCEDURESAttaching the battery box top cover (continued)

Measure and mark the dimensions on the inside battery box top cover (Fig. 1).

Set the foam in place (Fig. 2).

Place the battery box top cover on the battery box (Fig. 2).

TOOLSMarker

Tape measureStraight edge


Page | 40

Fig. 1

Fig. 3

Fig. 2

MATERIALSC1003463 – Single jack chain (10 links)

B1004207 – Trolley stop pin

PROCEDURESAttaching the trolley stop pin

Count 10 links of single jack chain. Open link #11, slide off the 10 links, and close the eleventh link (Fig. 1).

Using a sanding disc, remove any burrs from the trolley stop pin (Fig. 2).

Open the end link on the chain, attach the chain to the trolley stop pin, and close the link. Once attached, make sure the pin pivots (Fig. 3)

TOOLSPower drill

Sanding discNeedle-nose pliers


Page | 41

C1003463

B1004207

C1003463

B1004207

Fig. 1

Fig. 3

Fig. 2


B1004230 – Stop pin clip7195731 – #6-32 x 0.625 Phillips head screw (2 needed)

Loctite 290

PROCEDURESAttaching the trolley stop pin (continued)

Drawing No. C11003

Place the stop pin clip in a vice and tap the hole to 6-32 (Fig. 1).

Tap the 2 holes on the corner of the battery box (Fig. 2).

Thread a screw into the stop pin clip. Add Loctite to the screw threads and attach the clip to the top tapped hole in the battery box (Fig. 3 and Fig. 4).

TOOLSDrill

6-32 tapPhillips head screwdriver

Drawing No. C11003


Page | 42

C110037195731B1004230

Fig. 2Fig. 3Fig. 4 Fig. 1


C1003463 – Single jack chain (10 links)B1004207 – Trolley stop pin

B1004230 – Stop pin clip7195731 – #6-32 x 0.625 Phillips head screw (2 needed)

Loctite 290

PROCEDURESAttaching the trolley stop pin (continued)

Use a center punch to widen the end link on the chain to fit the 6-32 screw (Fig. 1).

Slide the screw through the chain link, add Loctite, and thread it into the bottom tapped hole (Fig. 2).

Press the trolley stop pin into the stop pin clip (Fig. 3).

TOOLSHammer

Center punchPhillips head screwdriver

2 x 4 wooden board


Page | 43

B1004230

C1003463

B1004207

B1004207

C1003463

B1004230

Fig. 1

Fig. 3

Fig. 2


C11003-09 – Battery box top coverC11003-04 – Battery box mounting angle A

C11003-06 – Battery box cable cover1078562 – #8-32 x 0.3125 Phillips round head screw (2 needed)

B1004241 – M5-0.8 x 16 Phillips pan head screw (4 needed)1901051 – M5 flat washer (4 needed)

1000227 – Caution label

PROCEDURESAttaching the battery box top cover

Secure the battery box top cover with screws and washers (Fig. 1).

Using a utility knife, carefully measure, mark, and remove the protective film at the center of the battery box top cover and attach a caution label (Fig. 2).


Utility knifeTape measure

Marker


Page | 44

C11003-091078562

C11003-09

1000227

Fig. 1

Fig. 2

MATERIALSB1004227 – Auxiliary contact block

B1004229 – Auxiliary contacts106232 – Weld stud, #10-32 x ½ long

PROCEDURESAssembling the control box

Drawing No. C11008

Once the battery box is assembled and wired, you will assemble the control box (Fig. 1).

First you will need to weld 3 studs to the control box housing. Weld 2 studs on the inside face of the control box housing, which will support the battery charger mounting bracket, and 1 stud at the bottom inside corner of the housing (Fig. 2).

In addition, you will need to weld 1 stud and tack weld the control box rear mounting plate onto the inside of the control box rear plate. Refer to the drawings for the exact measurements and placement (Fig. 3).



Drawing No. C11008


Page | 45

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004227 – Auxiliary contact block

B1004229 – Auxiliary contacts

PROCEDURESAssembling the control box

As shown, the auxiliary contact block, which mounts inside the control box, has the center auxiliary contact missing (Fig. 1).

You will need to slide the auxiliary contact into the center slot before you can use it (Fig. 2 and Fig. 3).

TOOLS


Page | 46

B1004227

B1004227

B1004229

B1004227

B1004229

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004217 – Fused plug, 10A IEC 320 C14

B1004233 – Battery chargerB1004220 – Fuse cartridge, 20 MM, 2 AMP

PROCEDURESAssembling the control box (continued)

Open the latch on the back of the fused plug (Fig. 1).

Slide a fuse cartridge into the slot and close the latch (Fig. 2).

Stretch out the red and black wires on the battery charger, measure 10”, and cut off the excess wires (Fig. 3).

TOOLSTape measure

Wire cutter


Page | 47

B1004217

B1004217

B1004233

B1004220

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11008-02 – Control box housing

B1000624 – Control box weighing labelB1004228 – 3 position button selection knob


Clean the face of the control box housing with alcohol, peel off the control panel housing decal, and carefully attach it to the front of the housing (Fig. 1).

With the front label in place, insert the 3 position button selection knob into the bottom round hole (Fig. 2 and Fig. 3).




Page | 48

C11008-02B1000624

C11008-02 B1004228

B1004228

Fig. 1

Fig. 3

Fig. 2


B1004228 – 3 position button selection knobB1004227 – Auxiliary contact block


Thread a retainer onto the back of the selection knob to hold it in place (Fig. 1).

Using channel lock pliers, securely tighten the retainer (Fig. 2).

Push the auxiliary contact block onto the back of the 3 position button selection knob (Fig. 3).

TOOLSChannel lock pliers


Page | 49

B1004228

C11008-02

B1004228

B1004227

C11008-02

B1004228Fig. 1

Fig. 3

Fig. 2

MATERIALSB1003498 – Battery discharge gauge

C11008-02 – Control box housingB1004227 – Auxiliary contact block

Battery discharge gauge mounting bracketB1000624 – Control box weighing label


Slide the mounting bracket over the back of the battery discharge gauge (Fig. 1).

Push the back of the battery discharge gauge through its rectangular slot on the control box's front panel (Fig. 2).

Using a pair of screwdrivers, push in the tabs on both sides of the mounting bracket to lock the gauge in place (Fig. 3).

TOOLS2 flat-head screwdrivers


Page | 50

B1003498

Mounting bracket

B1003498

C11008-02

B1003498C11008-02

B1004227

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004225 – Green push buttonB1004226 – Red push buttonB1004229 – Auxiliary contacts

C11008-02 – Control box housingB1004228 – 3 position button selection knob

B1003498 – Battery discharge gauge


Both the red and green knobs use a mounting bracket with an auxiliary contact (Fig. 1).

The red and green knobs have a small arrow indicating its top (Fig. 2).

Insert the green push button into the RAISE hole with the arrow positioned up (Fig. 3).

TOOLS


Page | 51

B1004226

B1004225

B1004229Arrow

B1004225

B1004225

B1003498

B1004228C11008-02

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004225 – Green push buttonB1004226 – Red push buttonB1004229 – Auxiliary contacts

C11008-02 – Control box housingB1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block


Fit a mounting bracket and auxiliary contact onto the back of the green push button and tighten the locking screw (Fig. 1).

With the arrow on the red push button positioned up, push the knob through the LOWER hole (Fig. 2).

Tighten the screw to firmly secure the red push button (Fig. 3).



Page | 52

B1004229

B1003498B1004227 B1003498

B104226C11008-02

B1004225

C11008-02B1004229

B1003498

B1004227

C11008-02Fig. 1

Fig. 2

Fig. 3

MATERIALSC11008-01 – Battery charger mounting bracket

Foam backing


Before mounting the battery charger mounting bracket, you will first need to tap holes into the bracket (Fig. 1).

Once tapped, peel off the protective film and clean the inside of the bracket with alcohol (Fig. 2).

Measure inside the bracket, cut foam backing to size, and press it into the bracket (Fig. 3).

TOOLSPower drill8-30 tap

Measuring tape


Page | 53

C11008-01C11008-01

C11008-01

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11008-01 – Battery charger mounting bracket

B1004233 – Battery chargerB1004225 – Green push buttonB1004226 – Red push buttonB1004229 – Auxiliary contacts


#6-32 locknuts


Feed the red and black wires from the battery charger through the small hole on the side of the mounting bracket (Fig. 1).

Set the battery inside its mounting bracket noting the position of the indicator light (Fig. 2).

Mount the bracket onto the 2 weld studs in the control box housing with the 2 wires positioned on the top right. Secure the bracket with 2 locknuts and tighten (Fig. 3).

The indicator light on the battery charger should be visible through the small hole on the front of control box housing (Fig. 4).

TOOLS3/8” nut driver


Page | 54

Indicator light

C11008-01C11008-01

B1004233

B1004229

B1004227B1003498

C11008-01

C11008-02

Fig. 1Fig. 3Fig. 2

Indicator light

Fig. 4

MATERIALSC1005278 – Angled set power cord assembly


Strip and tin the ends of the black and red wires leading from the battery charger (Fig. 1).

Disassemble the angled set power cord assembly (Fig. 2).

Loosen the strain release bracket from the angled set power cord assembly (Fig. 3).

TOOLSWire stripperSolder ironWire solder

Phillips head screwdriver


Page | 55

C1005278

C1005278

Fig. 1

Fig. 3

Fig. 2


14 AWG white wire (11” section)14 AWG green wire (12” and 8¼” section)

1014001 – 14 AWG black wire (20”, 12”, and 10¼” section)1014004 – 14 AWG red wire (1¾”, 3 5/8”, 4”, 5½” and 6” sections)

C11008-02 – Control box housing


Cut an 11” section of white wire, a 12” and 8¼” section of green wire, a 20”, 12”, and 10¼” section of black wire, (2) sections of red wire measuring 1¾”, and a 3 5/8” section, 4” section, 5½” section, and 6” section of red wire. Strip and tin each end (Fig. 1).

With the strain release bracket positioned away from you, loosen the 3 screws and slide the 8¼” green wire into the slot closest to you, the 12” black wire in the center slot, and the 11” white wire in the slot closest to the bracket. Tighten each screw securely (Fig. 2).

Twist and feed each wire through the strain release bracket and wire holder and replace the screws on the strain release bracket (Fig. 3).

Replace the cover being careful not to pinch the wires (Fig. 4).

TOOLSWire cuttersWire stripperSoldering iron

Wire solderPhillips head screwdriver


Page | 56

C1005278C1005278 C11008-02

C1005278

Fig. 1Fig. 3Fig. 2

Fig. 4


B1004217 – Fused plug, 10A IEC 320 C14B1004218 – Rubber boot

Duct tape


Crimp a small ring terminal connector to the end of the green wire leading from the angled set power cord assembly (Fig. 1).

A rubber boot fits over the fused plug once it is attached to the control box. However, it only fits one way. For this reason, it is easier to fit the boot over the fused plug first and mark the bottom of the boot with duct tape (Fig. 2).

Once marked, remove the boot from the fused plug (Fig. 3).

TOOLSCrimping tool


Page | 57

B106483

B1004218B1004217

B1004218

B1004217

Fig. 1

Fig. 3

Fig. 2


B106483 – Small ring terminal crimp connectorsC1005279 – Flag terminal

C11008-01 – Battery charger mounting bracketC11008-02 – Control box housing

B1004218 – Rubber boot1078088 – #10-32 hex nut for weld stud


Feed the black and white wires from the angled set power cord assembly through the boot and crimp a flag terminal to each end. Also crimp a flag terminal to the 12” section of green wire. Add a small ring terminal connector to the open end of the 12” green wire (Fig. 1).

Attach the angled set power cord assembly to the left side of the battery charger and feed the green, white, and black wires extending from the boot through the slot on the side of the control box (Fig. 2).

Connect the small ring terminal connectors from the 2 green wires to the weld stud at the bottom of the control box. Hand tighten a hex nut over the stud to hold the wires in place (Fig. 3).

TOOLSCrimping tool


Page | 58

B106483

B1004218

C1005279

C1005278

C1005278

B106483

C11008-02

C11008-01

B106483

C11008-01

C11008-02

Fig. 3

Fig. 2

Fig. 1


C1005279 – Flag terminalB1004217 – Fused plug, 10A IEC 320 C14

C11008-01 – Battery charger mounting bracketC11008-02 – Control box housing

B1004218 – Rubber boot


Connect the flag connectors at the end of the green, white, and black wires extending from the boot to the back of the fused plug. Note the position of the wires; with the mounting hole on the left, fit the green wire on the single connector on top, followed by white, then black (Fig. 1).

Press the fused plug through the slot on the side of the control box (Fig. 2).

The 3 wires are now positioned on top inside the control box housing (Fig. 3).

TOOLS


Page | 59

C1005279

B1004217

C11008-02B1004217B1004217

C1005279

C11008-02

C11008-02

C1005278

Fig. 3

Fig. 1

Fig. 2


C11008-02 – Control box housingC11008-03 – IEC connector cover plate

C11008-04 – IEC connector C-plate bracketB1004242 – M3-0.5 x 8 Phillips flat head screw

1078456 – Cover plate lock screw with 1/4-20 x 0.63 L thread1001765 – ¼-20 push-on retainer

SpacerLoctite 290


Use a push-on retainer to secure the cover plate for the IEC connector to the lock screw. Place the cover plate over the screw and set a spacer under the plate. Set the push-on retainer over the screw threads. Place a ¼” tube over the push-on retainer and hammer it into place (Fig. 1 and Fig. 2).

To attach the C-plate bracket to the control box, apply Loctite to the screws, slide the screws through the bracket, and attach the bracket to the control box (Fig. 3).

TOOLSHammer¼” tube



Page | 60

C11008-03

Spacer 1001765

1078456C11008-03

1001765

1078456

B1004242 C11008-04

B1004217

C11008-02Fig. 1

Fig. 2

Fig. 3


C11008-02 – Control box housingC11008-03 – IEC connector cover plate

C11008-04 – IEC connector C-plate bracketB1004290 – Adhesive-backed neoprene pad

B1004242 – M3-0.5 x 8 Phillips flat head screw1078456 – Cover plate lock screw, 1/4-20 x 0.63 L thread

1001765 – ¼-20 push-on retainer1075130 – #8-32 acorn nut

SpacerLoctite 290


Apply Loctite to the threads of 2 flathead screws and secure the fused plug to the control box (Fig. 1).

Position the cover plate in the C-plate bracket, add Loctite to the screw, thread the screw through the bracket, and tighten with an acorn nut (Fig. 2).

Set the housing on its side, position the foam backing over the fused plug, and remove the backing (Fig. 3).

Close the cover plate, lock the thumb screw, and open the plate. The foam backing is now positioned on the plate (Fig. 4).



Page | 61

B1004217 B1004217B1004242

B1004217

C11008-04

C11008-021075130

C11008-02

C11008-04C11008-02

B1004290

B1004290

C11008-02

C11008-04

Fig. 1Fig. 2

Fig. 3

Fig. 4

MATERIALSB1004229 – Auxiliary contacts


1014004 – 14 AWG red wire (1¾” section — 2 needed)


Remove the auxiliary contact block from inside the control box housing (Fig. 1).

Bend the (2) 1¾” sections of red wire into a horseshoe shape to be used as a jumper (Fig. 2).

Attach the 2 jumper wires into the No. 4 terminal slots. Tighten only the center screw (Fig. 3).



Page | 62

B1004229

B1004227

B1003498

C11008-02

B1004227

B1004227

Fig. 3

Fig. 2

Fig. 1

MATERIALSC1005342 – Female disconnect terminals

B1004229 – Auxiliary contactsC11008-02 – Control box housing

B1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block

1014004 – 14 AWG red wire (5 ½” and 1¾” section)


With the jumpers positioned on your right, attach the 5½” red wire to the No. 4 jumper slot closest to you. Tighten the screw (Fig. 1).

Attach a female disconnect terminal to the end of the 5½” red wire (Fig. 2).

Connect the female disconnect from the 5½” red wire to the “P” terminal on the back of the battery discharge gauge (Fig. 3).

TOOLSCrimping tool



Page | 63

B1004227

B1004227

C1005342

B1003498

C11008-2

C1005342

Fig. 1

Fig. 3

Fig. 2




B1004228 – 3 position button selection knob1014004 – 14 AWG red wire (5 ½”, 3 5/8”, and 1¾” section)


Attach the 6” red wire to the center No. 3 terminal on the auxiliary contact block and tighten the screw to secure the wire. (Fig. 1).

Attach a female disconnect to the open end of the 6” red wire and connect it to the “KEY” terminal on the back of the battery discharge gauge (Fig. 2).

Using the 3 5/8” red wire as a jumper between the red (LOWER) and green (RAISE) push buttons, attach it to the No. 4 slots on the back of both push buttons. Tighten the screw on the right (red push button) slot only (Fig. 3).



Page | 64

B1004227

C11008-02

C11008-02B1004229 B1003498

C1005342

B1004229C1005342 B1003498

B1004228

Jumper Fig. 3 Fig. 1

Fig. 2




B1004228 – 3 position button-selection knob1014004 – 14 AWG red wire (5 ½”, 3 5/8”, and 1¾” section)

107086 – Cable tie


Attach the 4” red wire to the far left No. 3 slot on the auxiliary contact block and tighten the screw (Fig. 1).

Attach the other end of the 4” red wire to the No. 4 slot (next to the jumper) on the back of the green (RAISE) push button, which is closest to the battery charger. Tighten the screw (Fig. 2).

Attach the red wire leading from the battery charger to the far right No. 3 slot on the auxiliary contact block and tighten the screw. Push the auxiliary contact block onto the back of the 3 position button selection knob (Fig. 3).

Add a cable tie to keep the wires together (Fig. 4).



Page | 65

B1004227

C11008-02

B1004227

B1004229B1004228

B1004227

B1004229

B1004228

B1004229C11008-04

B1004228

B1004227

Fig. 1Fig. 2

Fig. 3

Fig. 4


B106483 – Small ring terminal crimp connectorsC11008-01 – Battery charger mounting bracket

C11008-02 – Control box housing1075207 – #8-32 x .25 Phillips pan head screw

C10008-10 – Power cord protective plateB1004218 – Rubber boot19610 – Grounding label


Slide the boot over fused plug positioning it so the taped bottom of the plug is down and remove the tape. To position the boot properly, it may be necessary to remove the fused plug from the housing (Fig. 1).

Attach the protective plate for the angled set power cord assembly. Adjust it so it covers the complete power cord assembly (Fig. 2).

Add grounding labels next to the weld stud inside the housing and the weld stud on the rear plate (Fig. 3).



Page | 66

C11008-04

C1005278

C11008-02

B106483

1075207

C11008-04

C11008-02

C10008-10

C11008-02

19610

B106483

Fig. 1

Fig. 3

Fig. 2


C11008-02 – Control box housingC11008-06 – Control box rear plate

19610 – Grounding label1014001 – 14 AWG black wire (20” section)

1078088 – #10-32 hex nut for weld stud


Add small ring terminal connectors to both ends of the 20” black wire (Fig. 1).

Attach 1 end of the 20” black wire to the weld stud inside the control box (Fig. 2).

Attach the open end of the 20” black wire to the weld stud on the rear cover plate for the control box. Add a lock washer and nut and tighten (Fig. 3).

Attach a small ring terminal connector to 1 end of the 12” black wire and attach a female disconnect terminal to the other end (Fig. 4).

TOOLSCrimping tool3/8” nut driver


Page | 67

Fig. 3Fig. 1

B106483

B106483

B106483

B10648319610C11008-02

C11008-06

C11008-06C1005342

Fig. 2

Fig. 4


B106483 – Small ring terminal crimp connectorsC11008-02 – Control box housing

C11008-08 – Control box rear plate B1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block

B1004228 – 3 position button selection knobB1004293 – Rubber grommet

1014001 – 14 AWG black wire (12” section)1078088 – #10-32 hex nut for weld stud

3M Lubricating spray


Connect the female disconnect end to the “N” terminal on the back of the battery discharge gauge (Fig. 1).

Connect the ring terminal connector end of the 12” black wire to the weld stud inside the control box (Fig. 2).

Lubricate and insert a grommet through the hole on the side of control box (Fig. 3).

Attach a male disconnect terminal to the end of the black wire leading from the battery charger and store it inside the control box housing (Fig. 4).

TOOLSCrimping tool3/8” nut driver


Page | 68

Fig. 4B106483 C11008-02

C11008-02

C11008-06

B1004293

B106483

C1003483

C11008-06

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11008-08 – Meter mounting plate

P13210 – M4-0.7 x 10 button head socketC11008-02 – Control box housing

C11008-06 – Control box rear plate

PROCEDURESAssembling the front panel for a non-weighing control box

For a non-weighing unit, you will need to attach a meter mounting plate to the front of the control box housing. Start by tapping the 4 holes on mounting plate (Fig. 1).

To expose the 4 holes on the face of the control box, poke through the label face and insert the screws. If necessary, use a center punch to enlarge the holes (Fig. 2).

Attach the mounting plate (Fig. 3).

TOOLSPower drill4 MM tap

2.5 MM Allen wrench


Page | 69

Fig. 2Fig. 3Fig. 1C11008-08

C11008-06 C11008-02

P13210

C11008-02

C11008-08

MATERIALSC11008-07 – Display board mounting plateP13210 – M4-0.7 x 10 button head socket


C1001219 – Standoff, pem #6-32 x 5/8” L

PROCEDURESAssembling the front panel for a weighing control box

Use a template to weld 4 standoffs to the back of the display board mounting plate (Fig. 1).

Lay the mounting plate face down on your work surface (Fig. 2).

Add 4 standoffs to the screws on the back of the template (Fig. 3).

TOOLSMounting plate template


Page | 70

Template

C1001219C11008-07

Mounting plate template

Fig. 1

Fig. 2

Fig. 3



C1001219 – Standoff, pem #6-32 x 5/8” L

PROCEDURESAssembling the front panel for a weighing control box (continued)

Tighten the screws on the face of the template to secure the standoffs (Fig. 1).

Position the template with standoffs to the back of the display board mounting plate (Fig. 2).

Add screws to the 4 corners to secure the 2 plates together (Fig. 3).



Page | 71

C11008-07

Template

C11008-07

Template

Template

Fig. 3

Fig. 1

Fig. 2



C1001219 – Standoff, pem #6-32 x 5/8” L


Verify that all 4 standoffs are straight. If necessary, gently tap the standoffs to straighten them (Fig. 1).

Tack weld around the base of the standoffs to secure them to the display board mounting plate (Fig. 2).

Remove the template and finish welding each standoff to the back of the mounting plate (Fig. 3).

TOOLSPhillips head screwdriverLeather welding gloves



Page | 72

C11008-07Template

C1001219

C1001219

Fig. 2

Welded standoffs

Fig. 1

Fig. 3

C11008-07

MATERIALSC11008-07 – Display board mounting plate

B1003456 – Display with membraneP13210 – M4-0.7 x 10 button head socket



With the standoffs mounted, attach the plate to the control box (Fig. 1).

Using a marker, trace around the mounting area on the plate. This will show you where to place the display membrane (Fig. 2).

Remove the plate from the control box (Fig. 3).

TOOLS2.5 MM Allen wrench

Marker


Page | 73

C11008-07

Fig. 1

Fig. 3

Fig. 2


B1003456 – Display with membrane


Remove the display and membrane from the protective packaging (Fig. 1 and Fig. 2).

Peel the double-sided tape off the back of the membrane and attach it to the marked area on the display board mounting plate. Make sure the membrane is straight (Fig. 3).

TOOLS


Page | 74

C11008-07B1003456

B1003456

B1003456

Display

Membrane

Fig. 3

Fig. 2

Fig. 3


B1003456 – Display with membraneP13210 – M4-0.7 x 10 button head socket



With the mounting plate face down, line up the holes on the display with the standoffs on the mounting plate and attach the 4 screws (Fig. 1).

Plug the membrane ribbon into its matching slots on the back of the display panel (Fig. 2).

Attach the mounting plate to the control box and secure it with 4 screws (Fig. 3).


2.5 MM Allen wrench


Page | 75

C11008--02

B1003456

B1003456

B1003456

Fig. 2

Fig. 3

Fig. 1

MATERIALSFoam backing


C11008-03 – IEC connector cover plate

PROCEDURESAttaching the rear plate to the control box

Apply alcohol to a soft lint-free cloth and wipe down the edges of the control box. Measure, cut, and apply foam backing to 3 sides of the control box (Fig. 1).

Poke through the foam to expose the mounting holes (Fig. 2).

Using a burr bit, you will need to elongate the top hole above the IEC connector cover plate (Fig. 3).

Use a file to smooth out any rough edges left by the burr bit (Fig. 4).

TOOLSPencil drill

Burr bitFile

Center punch


Page | 76

C11008-06C11008-02Fig. 3

C11008-06

C11008-02

Fig. 2C11008-02 Fig. 1C11008-02

Fig. 4


C11008-06 – Control box rear plate B1004239 – M5-0.8 x 10 Phillips pan head screw

1000227 – Caution label

PROCEDURESAttaching the rear plate to the control box (continued)

Loosely attach the rear plate to the control box (Fig. 1).

Clean the plate with alcohol and measure to find its center (Fig. 2).

Attach a Caution label (Fig. 3).


Tape measureMarker

Isopropyl alcohol in a spray bottleSoft lint-free cloth

Scissor Lift Table Assembly 0000-000-000

PAGE 77

1000227C11008-06

C11008-06

C11008-06B1004239

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right

C11002-05 – Handle frame base (2 needed)

TOOLSPower drill

Sanding disc ClampsSquare

Drawing No. C11002


PAGE 78

C11002-05

C11002-03

Angle

Fig. 3

C11002-03C11002-05

Fig. 1

Fig. 2

C11002-03

C11002-05


C11002-05 – Handle frame base (2 needed)

PROCEDURES

Assembling the pivot handle (continued)Drawing No. C11002

Tack weld the handle to its base at its four corner contact points to hold the parts in place (Fig. 1).

Remove the clamps and weld around the joint where the two parts meet (Fig. 2).

Rotate the assembly to weld each side. When finished weld the second handle frame to its base (Fig. 3)



ClampsSquare

Drawing No. C11002


PAGE 79

C11002-02C11002-02

C11002-02

Fig. 2Fig. 3

C11002-03

C11002-05

C11002-05

C11002-03C11002-05

Fig. 1


C11002-05 – Handle frame base (2 needed)C11002-04 – Handle frame support

TOOLSMarker

Tape measureClampsSquare

Drawing No. C11002


PAGE 80

C11002-04

C11002-03

C11002-05

C11002-02

C11002-05

C11002-04Fig. 1

Fig. 2

Fig. 3


C11002-04 – Handle frame supportC11002-05 – Handle frame base (2 needed)

PROCEDURES

Assembling the handle (continued)Drawing No. C11002

Gently tap the parts with a rubber-tipped hammer to square the assembly (Fig. 1).

If necessary, attach a bar clamp to pull the pieces in slightly and check again that the assembly is square (Fig. 2).

Once square, tack weld the corners of the handle frame support to the handle frame base and check again for square (Fig. 2).



Rubber-tipped hammerBar clamp

ClampsSquare

Drawing No. C11002


PAGE 81

C11002-02 C11002-03C11002-03C11002-04C11002-04

C11002-05

C11002-04Fig. 1

Fig. 1

Fig. 1

MATERIALSC11002-01 – Round handle section

C11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right




Clamps Drawing C11002


PAGE 82

C11002-01

C11002-04

C11002-03C11002-02

C11002-01

C11002-04

C11002-03

C11002-01

C11002-02C11002-03

C11002-04Fig. 1

Fig. 3

Fig. 2




PROCEDURESAssembling the handle (continued)

Drawing No. C11002

Check that the handle assembly is square. If not, adjust it using a rubber-tipped hammer (Fig. 1 and Fig. 2).

With the assembly square, weld the round handle section and the handle frame support to the handle frame base (Fig. 3).



Square Rubber-tipped hammerDrawing No. C11002


PAGE 83

C11002-02

C11002-04

C11002-01

C11002-01

C11002-04C11002-03

C11002-01

C11002-03

C11002-04Fig. 1

Fig. 3

Fig. 2



C11002-04 – Handle frame support C11002-05 – Handle frame base (2 needed)

TOOLSClamps

Portable power jackSquare

Drawing C11002


C11002-01

C11002-04

C11002-04

C11002-02

C11002-01

C11002-01

C11002-03

C11002-04

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11006-03 – Cross member (2 needed) C11006-05 – Vertical member “B” – left

C11006-06 – Vertical member “A” – right

TOOLSClampsSquare

Bar clampRubber-tipped hammerDrawing No. C11006


Fig. 1

Fig. 2Fig. 4

Weep hole

C11006-03

C11006-06C11006-05

C11006-03

C11006-03C11006-05

MATERIALSC11006-03 – Cross member (2 needed) C11006-05 – Vertical member “B” – left

C11006-06 – Vertical member “A” – right

PROCEDURESAssembling the base frame

Drawing No. C11006

Using the drawings, measure and mark the location for the second cross member and clamp it between the vertical members on the top section of the assembly. During welding, the second cross member will also act as a spacer. Check for square at the corners and further secure the two vertical members to the cross members with a bar clamp (Fig. 1).

Once square, tack weld the closest cross member to the vertical member at the 4 corners on each side and check for square (Fig. 2).

Remove the clamps, flip, and rotate the assembly making certain that the left vertical member with the large hole on the inside is closest to you and on your right (Fig. 3).



ClampsSquare

Bar clampTape measure

Drawing No. C11006


Position large hole closest to you on right

C11006-05

C11006-06

C11006-03

Fig. 3

C11006-03

C11006-06 C11006-05

Fig. 1

Fig. 2

MATERIALSC11006-03 – Cross member (2 needed)C11006-05 – Vertical member “B” – left

C11006-06 – Vertical member “A” – rightB1004281 – Right handle inner pivot bracketB1004289 – Left handle inner pivot bracket

B1004280 – Handle outer pivot bracket (2 needed)

PROCEDURES

Installing the pivot bracketsDrawing No. C11006

Butt a shim against the vertical members, both on the inside and outside, near the cross member junction (Fig 1).

Position the inner pivot plate with the machined side against the vertical member and the open slit facing you. Position the outer pivot plate with its machined side against the outside of the vertical member (Fig. 2).

Clamp the 2 pivot plates against the vertical member. Attach the other pivot plates the same way (Fig. 3).

TOOLSClampsSquare

Drawing No. C11006


B1004289

C11006-05

C11006-03

C11006-05

C11006-03

B1004280

B1004289

B1004280

C11006-05Shims

C11006-03

Fig. 1

Fig. 1

Fig. 1

MATERIALSC11006-03 – Cross member (2 needed)C11006-05 – Vertical member “B” – left

C11006-06 – Vertical member “A” – rightB1004281 – Right handle inner pivot bracketB1004289 – Left handle inner pivot bracket


PROCEDURES

Installing the pivot brackets (continued)Drawing No. C11006

Using a rubber-tipped hammer, gently tap the inner and outer pivot bracket to align them flush with the vertical member (Fig. 1 and Fig. 2).

Tack weld the brackets to the vertical members (Fig. 3).

TOOLSClampsSquare

Drawing No. C11006


B1004280

B1004289

C11006-06

C11006-03

C11006-03

C11006-05

B1004280

B1004289C11006-06

Flush

B1004280

C11006-03

Fig. 1

Fig. 1

Fig. 1

MATERIALSC11006-03 – Cross member (2 needed) C11006-05 – Vertical member “B” – rightC11006-06 – Vertical member “A” – left

B1004281 – Right handle inner pivot bracketB1004289 – Left handle inner pivot bracket


PROCEDURESInstalling the pivot brackets (continued)

Drawing No. C11006

Remove the clamps and flip the assembly so the pivot brackets point down. Using a tape measure, check the outside square on both sides of the assembly from corner to corner. If square, the measurements will be the same on both sides (Fig. 1).

Once square, weld each cross member to the vertical members and weld the inner and outer brackets to the vertical members (Fig. 2 and Fig. 3).



Clamps(4) 1/8” shims

Rubber-tipped hammerTape measure

Drawing C11006


C11006-05

B1004280

C11006-06

C11006-06

C11006-05

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11006-01 – Frame length – bottom member “A” – left

C11006-02 – Frame length – bottom member “B” – right C11006-14 – End caps (2 needed)

TOOLSClampSquare

Drawing C11006


C11006-14

5/8”11/16”

Threaded holes

Fig. 3

Fig. 2

Fig. 1

MATERIALSC11002 – Pivot handle assembly

C11006-03 – Cross member C11006-01 – Frame length – bottom member “A” – left C11006-02 – Frame length – bottom member “B” – rightC11006-04 – Cross member with caster mounting holes

C11006-12 – Load cell mounting member (2 needed)C11006-07 – End cross member

PROCEDURESWelding the bottom member assembly

Drawing No. C11006

Position the pivot handle assembly on the edge of your work surface. If it does not fit flush, grind down the weld on the bottom so it sits flush (Fig. 1).

Clamp the pivot handle assembly to your work surface (Fig. 2).

Position the left and right bottom members with the holes facing up (Fig. 3).

Using L-shaped brackets securely clamp the bottom members to the pivot handle assembly and check that it is square (Fig. 4).

TOOLSGrinding tool

ClampsSquare

L-shaped bracketsDrawing C11006


Fig. 3

C11002 C11006-01

C11006-02C11002

C11002

C11006-01

C11006-03

C11006-02

Fig. 1

Fig. 2

Fig. 4




TOOLSClamps

Bar clampSquare

Rubber-head hammerDrawing C11006


C11006-12

C11006-01

C11006-03C11006-01

Mounting holes

Fig. 1

Fig. 1

Fig. 1



C11006-12 – Load cell mounting memberC11006-07 – End cross member



ClampBar clamp

SquareDrawing C11006


Fig. 2

C11006-02

C11006-12

C11006-12

C11006-01

C11006-03

Fig. 1

C11006-02

C11006-03

Fig. 3

MATERIALSC11006-03 – Cross member

C11006-01 – Frame length – bottom member “A” – left C11006-02 – Frame length – bottom member “B” – rightC11006-04 – Cross member with caster mounting holes


TOOLSWire brush

Leather welding glovesWelding helmet

Welding equipmentClampSquare

Drawing C11006


C11006-02C11006-07

C11006-03C11006-01

C11006-02

C11006-07Fig. 1

C11006-01

C11006-03

Fig. 1

Fig. 1




PROCEDURESBuilding the bottom member assembly (continued) Drawing No. C11006

Turn the bottom frame assembly on its side and slide a 1/8” to ¼” spacer, depending on thickness of length members, under the frame for back bending. Then clamp down the frame (Fig. 1).

With the frame on its side, weld front to back, starting on the inside weld. Turn the frame over and weld the other side the same way (Fig. 2).

Once complete, set a straight edge on the top of the frame to check for pull (Fig. 3).



ClampSquare

1/8” to ¼” spacer (depending on thickness of length members)Drawing C11006


Fig. 11/8” spacer

Straight edge

Fig. 3

Fig. 2




PROCEDURESBuilding the bottom member assembly (continued) Drawing No. C11006

Using a tape measure, check the bottom assembly for square. Measure from corner to corner on both sides. The measurements should match (Fig. 1).

If the measurements do not match, use a bar clamp and tighten from corner to corner and check again for square (Fig. 2).

TOOLSTape measure

Bar clampSquare

Drawing C11006


Fig. 2Fig. 1

MATERIALSB1004203 – Lower slide rail



TOOLSTape measure

MarkerSquare

Drawing C11006


Fig. 1

Long slot, position near vertical member

Short slot, position near center of frame

Marking

Fig. 1

Fig. 1




PROCEDURESInstalling the lower slide rail (continued)

Drawing No. C11006

Position 1 bottom frame length off your work surface and clamp on (8) ¼” plates to hold the rail in position. Make sure the hole on the left is centered over the hole in the rail. This is the where you attach the stop pin sleeve (Fig. 1).

Tack weld the shorter slot toward the center of the frame first, then tack weld the long slot (Fig. 2).

Tack weld all 5 slots in the rail and all the closed holes. Rotate the frame and tack weld the second lower slide rail to the frame (Fig. 3).



ClampSide spacers



Fig. 1

Tack weldAlign stop pin sleeve hole

Side spacer

Fig. 1

Fig. 1





Drawing No. C11006

With both lower slide rails tack welded to the frame, you will need to back bend the frame before you complete welding. This helps prevent pulling. Set the frame onto your work surface and slide a 5/8” spacer under the center of each bottom frame member and clamp it to your work surface (Fig. 1).

Slide a wooden wedge under each bottom frame member (Fig. 2).

Using clamps and a spacer, secure a hold-down bar across the spacers (Fig. 3).

TOOLSClamps

Hold-down bar5/8” spacer

Wooden wedgeSpacer Square

Drawing C11006


Hold-down barFig. 1

5/8” spacerWedge

Fig. 2

Fig. 3





Drawing No. C11006

Weld the ends of both lower slide rails to the bottom frame lengths (Fig. 1 and Fig. 2).

Weld all tacked areas where the slots meet the frame. Do not weld any open holes (Fig. 3).



ClampHold-down bar

5/8” spacerWooden wedge

Spacer Square

Drawing C11006


Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004282 – Base frame pivot bracket (4 needed)

C11006-03 – Cross memberB1004203 – Lower slide rail



TOOLSTape measure

Marker Drawing C11006


Fig. 2

B1004282

C11006-07 Fig. 1

Fig. 3

MATERIALSB1004282 – Base frame pivot bracket (4 needed)

C11006-03 – Cross memberB1004203 – Lower slide rail (2 needed)



PROCEDURESInstalling the pivot brackets

Drawing No. C11006

Once in position, check that the pivot brackets are square (Fig. 1).

Tack weld each bracket to the cross member and check for square. Make any adjustments using a rubber-tipped hammer (Fig. 2).

Weld the 4 brackets to the end cross member and verify they are square (Fig. 3





B1004282

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11002 – Pivot handle assemblyC11006 – Base frame assembly

PROCEDURESAttaching the pivot handle assembly to the base frame assembly

Drawing No. C11006

Securely clamp the pivot handle assembly, with the pivot brackets facing you, to your work surface and verify that it is square (Fig. 1).

Butt the base frame assembly, with the slide rails closest to you, up against the pivot handle assembly, and secure it with L-shaped brackets and clamps. Verify the assemblies are square (Fig. 2).

Clamp a hold-down bar to the pivot bracket end of the lower frame assembly (Fig. 3).

TOOLSClampsSquare

L-shaped bracketsHold-down bar

Drawing No. C11006


Hold-down barC11002Fig. 1

Fig. 3

Fig. 2


PROCEDURESAttaching the pivot handle assembly to the base frame assembly (continued)

Drawing No. C11006

Tack weld the pivot handle assembly to the base frame assembly and check for square (Fig. 1).

Turn the assembly over and place a spacer bar under the frame (Fig. 2).

Tack weld the bottom of the frame and check for square. If square, weld the bottom of the frame. Turn it over and weld the top and sides. Once the pivot handle assembly is attached, finish welding the non-welded side of the load cell mounting member. Using compressed air quickly cools a hot weld (Fig. 3).

TOOLSBrass spacers

Clamps Square

Spacer barLeather welding gloves


Compressed airDrawing No. C11006


Spacer

Fig. 1

Fig. 2

Fig. 3


C11006-08 – Lower hydraulic bracket weldment “B” – rightC11006-09 – Lower hydraulic bracket weldment “B” – left

PROCEDURESAttaching the lower hydraulic bracket weldment

Drawing No. C11006

The lower hydraulic brackets each have a spacer that you will need to weld to each bracket. Position the spacer so the holes line up. Notice that with the holes aligned, the spacer is on an angle. Weld the spacer to the bracket. (Fig. 1).

Turn the base frame assembly upside down so the top with the slide rails are facing down (Fig. 2).

Measure and mark to find the center placement on both cross members for the right and left lower hydraulic bracket (Fig. 3).

TOOLSTape measure

MarkerSquare

Drawing No. C11006


Spacer

Fig. 1

Fig. 3

Fig. 2


C11006-08 – Lower hydraulic bracket weldment “B” – rightC11006-09 – Lower hydraulic bracket weldment “B” – left

PROCEDURESAttaching the lower hydraulic bracket weldment (continued)

Drawing No. C11006

If necessary, remove any burrs or sharp edges from the lower hydraulic brackets (Fig. 1).

Using L-shaped brackets and clamps, secure both lower hydraulic brackets to the cross members. Make sure you position the hydraulic brackets with the bolt hole ends resting on the cross member with caster mounting holes and the spacers on the inside (Fig. 2).

Once square, tack weld them in place, check square again Weld each piece to the bottom of the frame and check for square. Then flip the assembly so the slide rails are up (Fig. 3).

TOOLSPower drill

Sanding discGrinding tool

L-shaped bracketsClamps Spacers

Drawing No. C11006


Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004206 – Stop pin sleeve

113068 – Anti-seize compoundC11002 – Pivot handle assemblyC11006 – Base frame assembly

PROCEDURESInstalling the stop pin sleeve

Drawing No. C11006

Grind two flat spots to both sides of the head on a stop pin sleeve. This way it will fit into the channel on the lower slide rail. Verify that the head fits through the slide rail (Fig. 1).

Brush anti-seize onto the stop pin sleeve and insert the sleeve into the hole on the left slide rail, which is closest to the cross member with caster holes (Fig. 2).

Using a center punch, hammer the sleeve into the hole until the top of the sleeve is flush with the base frame assembly (Fig. 3).

TOOLSHammer

Grinding toolLeather welding gloves


Center punchDrawing No. C11006


Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004206 – Stop pin sleeve

C11002 – Pivot handle assemblyC11006 – Base frame assembly

PROCEDURESInstalling the sleeve stop pin (continued)

Drawing No. C11006

Flip the frame again. The sleeve should be protruding from the hole at the bottom of the frame (Fig 1).

Weld around the bottom of the sleeve (Fig. 2 and Fig. 3).



Drawing No. C11006


B1004206B1004206Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004285 – Lower side rail pivot plate weldment (2 needed) C11007-01 – Scissor frame ”A” length member (2 needed)

B1004285-01 – Lower slide rail plate (2 needed)5/16” metal rod (2 needed)

PROCEDURESAssembling the lower slide rail pivot plate tube guides (continued)

Drawing No. C11007

The lower slide rail pivot plate does not have a pin attached. To attach the pin, you will need to measure and cut (2) 1 5/16” sections of a 5/16” metal rod to make 2 pins (Fig. 1).

Measure and mark the center of the rail plates and the center of the pins (Fig. 2).

Set the plate on a 1/32” metal shim, and weld the plate and pin together (Fig. 3).

TOOLSGrinding tool Tape measure

Marker Leather welding gloves


1/32” metal shimDrawing No. C11007


Fig. 2B1004285

B1004285-015/16” metal rod

Fig. 3

Fig. 1

Fig. 1

MATERIALSB1004285-01 – Lower slide rail plate (2 needed)

C11007-01 – Scissor frame ”A” length member (2 needed)

PROCEDURESAssembling the lower slide rail plate to the scissor frame “A” length members

Drawing No. C11007

Clamp the scissor frame length members onto your work surface with the holes on your left and away from you and the single hole on your right. The pivot plate fits in the end opposite the hole (Fig. 1).

Welding the pivot plate to the scissor frame length members is easier when using a fixture that will hold the plate at the angle needed (Fig. 2).

A fixture is 3 metal pieces welded together with a slot to hold the plate at the proper angle during welding (Fig. 3).

TOOLSClamps


Welding equipmentFixture

Drawing No. C11007


Fixture

Fixture

B1004285-01C11007-01

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004285-01 – Lower slide rail plate (2 needed)

C11007-01 – Scissor frame ”A” length member (2 needed)

PROCEDURESAssembling the lower slide rail plate to the scissor frame “A” length members

Drawing No. C11007

With the fixture inserted into the bottom of the scissor frame length members, insert the rail plate (Fig. 1).

Tack weld the rail plate in place then remove the fixture and finish welding the rail plate (Fig. 2).

Use a sanding disc to remove any burrs and to smooth the weld (Fig. 3).

TOOLSPower drill

Sanding discLeather welding gloves


Fixture Drawing No. C11007


B1004285-01Fixture

Fixture

B1004285-01

Fig. 2

Fig. 1

Fig. 3

MATERIALSC11005-02 – Pivot piece (2 needed).

C11005-04 – Short cross member

PROCEDURESAttaching the short cross member to the pivot pieces

Drawing No. C11005

Using the drawings, measure and mark the areas where the short cross member attaches to the pivot pieces. Lay the pivot pieces on your work space and slide the short cross member in place according to your markings (Fig. 1).

Clamp the assembly to your work surface and check that it is square (Fig. 2).

Tack weld the short cross member to the pivot pieces at the 4 corners (Fig. 3).

TOOLSClampsSquare


Welding equipmentDrawing No. C11005


Page | 112

C11005-04

C11005-02 Fig. 1

Fig. 2

Fig. 2

MATERIALSC11005-01 – Length member (2 needed)

C11005-02 – Pivot piece (2 needed)C11005-04 – Short cross member

PROCEDURESAttaching the pivot pieces and long cross members to the length members

Drawing No. C11005

Lay the top frame length members on your work surface with the holes up. There is a short end and a long end. Measure to the center of the hole on both ends to find the short end and the long end. The short end attaches to the pivot piece assembly (Fig. 1).

Using the drawings as a guide, measure and mark the areas on the length members where the pivot piece assembly attaches and where the cross members attach (Fig. 2 and Fig. 3).

TOOLSTape measure

MarkerSquareClamps

Drawing No. C11005


Page | 113

C11005-01

C11005-01

Short end

Long end

C11005-01 Fig. 1

Fig. 2

Fig. 3



C11005-03 – Long cross member (3 needed)

PROCEDURESAttaching the pivot pieces and long cross members to the length members (continued)

Drawing No. C11005

Clamp the length members and long cross members together with the pivot assembly on the inside. Make sure all weep holes on the cross members are positioned down (Fig. 1).

Use additional bar clamps to firmly hold the pieces together, check for square, and make any necessary adjustments using a rubber-tipped hammer (Fig. 2).

Tack weld the long cross members to the length members and check for square. When welding, establish a starting point at one end and work your way around the assembly, up one side and down the other. Flip the assembly and weld the bottom, hot weld to cold (Fig. 3).

TOOLSBar clamps

ClampsSquare

Rubber-tipped hammerLeather welding gloves


Drawing No. C11005


Page | 114

C11005-01C11005-02

C11005-04

C11005-03

Fig. 1

Fig. 2

Fig. 3



C11005-03 – Long cross member (3 needed)

PROCEDURESAttaching the pivot pieces and long cross members to the length members (continued)

Drawing No. C11005

Clamp the assembly on its side (Fig. 1).

Weld from front to back starting on the inside weld. Flip the assembly and weld the other side (Fig. 2).

When complete, check the assembly for square. If it is not square after welding, use a portable power jack to stretch the frame slightly to square it (Fig. 3).

TOOLSClamps


Welding equipmentSquare

Portable power jackBlocks of wood

Drawing No. C11005


Page | 115

Fig. 1

C11005-01

C11005-02C11005-04

C11005-03

Fig. 2

Fig. 3



C11005-03 – Long cross member (3 needed)C11005-05 – Hydraulic support weldment – left

C11005-06 – Hydraulic support weldment – right

PROCEDURESAttaching the welded hydraulic support to the cross members

Drawing No. C11005

If not already done, weld the left and right hydraulic support weldment together. Once welded, pivot the frame assembly so only the pivot piece section rests on your work surface. Set the welded hydraulic support on the 2 inner long cross members and measure and mark to center the hydraulic support (Fig. 1).

Use clamps to hold the hydraulic support secure. If needed, clamp a ¼” plate to the front of the hydraulic support to hold it in position (Fig. 2).

Tack weld the hydraulic support to both cross members and check for square (Fig. 3).

TOOLSClamps

Tape measureMarker


Welding equipmentDrawing No. C11005


Page | 116

Fig. 2C11005-03¼” plate

C11005- 05 and C11005-06 Fig. 1

Fig. 3

MATERIALSC11005 – Scissor frame “B” assembly

B1004210 – Upper slide rail pin

PROCEDURESAttaching the upper slide rail pins

Drawing No. C11004

To attach the upper slide rail pins to the length members, position the scissor frame “B” assembly slightly off your work surface with the hydraulic support weldment positioned up. Mount the pins 1 1/8” from the edge of the length members. Mark the location on the length members (Fig. 1).

Clamp a 1” by 4” metal bar to the assembly to use as a brace (Fig. 2).

Butt the pin housing up against the metal bar and ¼” spacer secured by a clamp. Make sure the pin housing is flush with the spacer and metal bar then add additional clamps to hold the pins secure (Fig. 3).

Weld the pins to the frame (Fig. 4).

TOOLSClampsMarker

Tape measureLeather welding gloves


1” x 4” metal bar¼” spacer

Drawing C11004


Page | 117

B1004210

C11005-01B1004210

C11005-01C11005-031” x 4” bar

Fig. 2

Fig. 1

Fig. 3

Fig. 4

MATERIALSC11004-01 – Top frame length member (2 needed)

C11004-03 – Top frame pivot end cross member (2 needed)

PROCEDURESAssembling the top frame

Drawing No. C11004

Clamp the top frame length members side by side on your work surface with the holes on top. Line up the holes and check that they are even (Fig. 1).

Measure from the ends of the length members to the center of the holes. If the measurements are different, rotate 1 length member and measure again. Position the 2 length member with the closest measurements side by side, with the holes on top (Fig. 2).

With the measurement verified, turn each length member so the holes are on the side. Clamp the 2 pivot end cross members between both ends of the length members and check for square (Fig. 3).

TOOLSClamps

Tape measureMarker

Drawing C11004


Page | 118

C11004-01

C11004-03

C11004-01

Fig. 1

Fig. 2

Fig. 3


C11004-03 – Top frame pivot end cross member (2 needed)C11004-02 – Top frame cross member]

C11004-04 – Top frame pivot cross member (3 needed)

PROCEDURESAssembling the top frame (continued)

Drawing No. C11004

Make sure you position both pivot end cross members with the tap hole closest to the right and facing out (Fig. 1).

Tack weld the cross members to the length members and verify that the assembly is square. If not, use a bar clamp between 2 corners to square (Fig. 2).

Measure, mark, and clamp the remaining cross members inside the frame (Fig. 3).

TOOLSBar clamp

Tape measureMarker Clamps

Spacer barsHold-down barsDrawing C11004


Page | 119

Tap hole C11004-03C11004-03

C11004-01

C11004-03

C11004-04

C11004-01

Fig. 2Fig. 3 Fig. 1


C11004-03 – Top frame pivot end cross member (2 needed)C11004-02 – Top frame cross member



Drawing No. C11004

Make sure that all the cross members are properly positioned. Working from front to back, the second cross member has a weep hole, which you place down against your work surface (Fig. 2).

The remaining 3 pivot cross members have tapped holes on both ends, which are positioned up when mounted to the frame (Fig. 3).

With each cross member properly positioned and clamped to your work surface, check that the assembly is square (Fig. 3).

TOOLSSquare Clamps

Drawing C11004


Page | 120

C11004-04 has tap hole

C11004-01 C11004-02

C11004-02 has weep hole

Fig. 1

Fig. 3

Fig. 2


C11004-03 – Top frame pivot end cross member (2 needed)C11004-02 – Top frame cross member



Drawing No. C11004

If needed, use additional bar clamps to square the frame assembly (Fig. 1).

Tack weld the cross members to the frame lengths and check for square. Once square, establish a start point and work your way around the frame. Finish by flipping the assembly to weld the bottom, and then weld both sides (Fig. 2).

When welding the sides remember to back bend the frame using a 5/8” spacer (Fig. 3).

TOOLSClamps

Bar clampsLeather welding gloves


5/8” spacerDrawing C11004


Page | 121

C11004-04C11004-02

C11004-03C11004-01

C11004-04

Fig. 1

Fig. 2Fig. 3


C11004-08 – Body Tray Width Adjusting Bracket (4 needed)B1004205 – Body Tray Adjusting Shaft (4 needed)

PROCEDURESAttaching the width adjusting brackets

Drawing No. C11004

To attach the body tray width adjusting brackets, position the top of the frame assembly (with tapped holes showing on the 3 pivot cross members) so it is slightly off your work surface. Clamp a ¼” plate underneath one of the large holes in the length member and align the bracket with the hole. Slide the body tray adjusting shaft through the both holes to hold the bracket in place (Fig. 1).

Securely clamp the bracket to the frame (Fig. 2).

Tack weld the bracket, remove the clamps, and weld the bracket in place. Follow this same procedure for the remaining 3 brackets (Fig. 3).



Clamps¼” plate

Drawing C11004


Page | 122

Tapped hole

C11004-01

¼” plate

C11004-08

B1004205

Fig. 3Fig. 1

Fig. 2

MATERIALSC11004 – Top frame assembly

C11004-07 – Top tray clamp location bracket (2 needed)

PROCEDURESInstalling the top tray clamp location brackets

Drawing No. C11004

To attach a top tray clamp location bracket position the top of the frame with one end slightly off your work surface. Using the drawings as a guide, mark the location of the bracket and slide it on a pivot end cross member (Fig 1).

Clamp the bracket in position (Fig. 1).

Tack weld to support the bracket, remove the clamps, and weld the bracket to the pivot end cross member. Weld the second bracket to the other pivot end cross member (Fig. 3).



Clamps Drawing C11004


Page | 123

C11004-03C11004-07

C11004-03Fig. 1

Fig. 3

Fig. 2


C11004-06 – Upper slide rail (2 needed)

PROCEDURESAssembling the upper slide rails

Drawing No. C11004

The upper slide rails mount to the bottom of the frame. Turn the frame over so the tapped holes in the 3 cross members is against your work surface and slide the frame slightly off the surface. Mark tack weld areas along the length of the slide rails staggered about every 6” to 8” (Fig. 1).

Using the drawings as your guide, measure, mark, and set the frame in position (Fig. 2).

Clamp the upper slide rail to the length member using spacers to hold it in place (Fig. 1).

TOOLSClamps

Spacers Drawing No. C11004


Page | 124

C11004-06

C11004-06

Fig. 1

Fig. 2

Fig. 3


C11004-06 – Upper slide rail (2 needed).

PROCEDURESAssembling the upper slide rails (continued)

Drawing No. C11004

Check for square and tack weld along the length of the upper slide rail using your marks as a guide. Mount and tack weld the second upper slide rail (Fig. 1).

Slide a brass spacer under each side of the frame assembly where the upper slide rails end (Fig. 2).

Clamp 2 hold-down bars to the frame to hold it secure. Position 1 bar near the end of the assembly and position the other bar over the upper slide rail. Use spacers under the bar when clamping to the hold-down bars (Fig. 3).

TOOLSClamps

Brass spacerHold-down bar

Drawing No. C11004


Page | 125

Fig. 2

C11004-06Fig. 1

Hold-down bar

C11004-06

Tack weldBrass spacer

Fig. 3


C11004-06 – Upper slide rail (2 needed)Duct tape

PROCEDURESAssembling the upper slide rails (continued)

Drawing No. 11004

To aid with back bending, hammer a wooden wedge under the assembly (Fig. 1).

Weld all the tacked areas (Fig. 2).

When you finish welding both upper slide rails to the top frame assembly, cover each slide rail with 2 layers of duct tape to prevent scratches (Fig. 3).



ClampsHammer

Wooden wedgeDrawing No. C11004


Page | 126

Wedge

C11004-06

Fig. 1

Fig. 2

Fig. 3


B1004284 – Top frame outer pivot bracketB1004286 – Top frame inner pivot bracket

PROCEDURESAttaching the pivot brackets

Drawing No. C11004

Position the end of the top frame without the slide rail off your work surface, clamp a ¼” plate to the bottom corners of the frame. Measure and mark 13/64” from the edge of the length member and pivot end cross member intersection and line up and clamp an outer pivot bracket to the side of a length member (Fig. 1).

Tack weld the outer pivot bracket to the length member and check for square (Fig. 2 and Fig. 3).



ClampsTape measure

Marker ¼” plate

Drawing No. C 11004


Page | 127

Measure 13/64” from edge

B1004284 Fig. 1

Fig. 3

Fig. 2



PROCEDURESAttaching the pivot brackets

(continued) Drawing No. C11004

Measure and mark 1¾” from the machined surface of the outer bracket (Fig. 1).

Remove the clamps and set an inner pivot bracket on the marked area (Fig. 2).

Tack weld the inner pivot bracket to the pivot end cross member, check for square, and weld only the inner pivot bracket at this time. Mount pivot brackets to the other side of the pivot end cross member (Fig. 3).



ClampsTape measure

Marker ¼” plate

Drawing No. C 11004


Page | 128

B1004284

B1004286

Fig. 1

Fig. 3

Fig. 2


C11004-09 – Weight actuator strike plate (2 needed)

PROCEDURESAttaching the weight actuator strike plates

Drawing No. C11004

Using the drawings as a guide, measure and mark the areas to mount the weight actuator strike plates. One covers the weep hole on the cross member. The second mounts to the pivot end cross member between the rails (Fig. 1).

Remove any burrs or sharp edges from the strike plates (Fig. 2).

Tack weld the 4 corners, make sure it is square, then weld the strike plates to the cross members (Fig. 3).



ClampsTape measure

MarkerPower drill

Sanding discDrawing No. C11004


Page | 129

C11004-09Fig. 1

Fig. 3

Fig. 2



PROCEDURESWelding the pivot brackets

Turn the assembly over so the taped upper slide rails rest on your work surface. Slide 2 blocks of wood under the assembly to level it (Fig. 1).

To prevent electrical shock while welding, always use a grounding cable whenever there is a barrier, such as tape or a block of wood, blocking the metal to metal contact (Fig. 2).

With the assembly right-side up, weld the outer pivot brackets. When welding the outer bracket, weld from the base of the bracket and up its sides, otherwise the bracket may pull in too much during welding (Fig. 3).



ClampsGrounding cable2 blocks of wood

Drawing No. C11004


Page | 130

Grounding cable

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11004-05 – Top frame support angle (2 needed)

C11004 – Top frame assembly

TOOLSPower drill

Sanding discDrawing No. C11004


Page | 131

C11004-05C11004-05

Fig. 1

Long side

Short side

C11004-05

Fig. 3

Fig. 2



PROCEDURESAttaching the top frame support angle


Measure the width of the long side (Fig. 1).

Mark the width of the support angle’s long side along the inside surface of the pivot end cross member (Fig. 2).

Clamp 4 spacers across the top of the pivot end cross member (Fig. 2).

TOOLSSquareMarker

SpacersClamps

Drawing No. C11004


Page | 132

C11004-03

C11004-03

C11004-05

Fig. 1

Fig. 3

Fig. 2





ClampsSpacers¾” bar

18 or 20 gauge shimDrawing No. C11004


Page | 133

18 or 20 gauge shim

¾” barFig. 1

Fig. 3

Fig. 2





Mark the 3 tack weld areas spaced evenly across the cross member (Fig. 1).

Starting at the corners, tack weld all the marked areas (Fig. 2).

Remove the clamps and spacers (Fig. 3).






Page | 134

Fig. 1

Fig. 3

Fig. 2





Weld all the tack welded areas. When complete, repeat this process on the opposite end (Fig. 1).

Flip the unit over so the top faces you and weld the top of the support angle on both ends (Fig. 2 and Fig. 3).






Page | 135

C11004-05Fig. 1

Fig. 3

Fig. 2

MATERIALSC11006 – Base frame assembly

B1004231 – Caster swivel 125mm x 30mm with direction lockB1004232 – Caster swivel 125 mm x 30 mm

B1004287 – Wheel assembly mounting spacerB1004263 – M12 nyloc nut

B1004269 – M12 flat washerB1004246 – SHCS, M12-1.75 x 80

PROCEDURESAssembling the scissors lift sub-assemblies

Drawing No. C11006

Using a crane, set the base frame assembly upside down on your work surface (Fig. 1).

Disassemble the caster and wheel assembly by removing the screw and nut (Fig. 2).

Set each screw, nut, and wheel aside for now (Fig. 3).

TOOLSRatchet

13 MM socketDrawing No. C11006


Page | 136

C11006

Fig. 1

Fig. 3

Fig. 2





TOOLSDrawing No. C11006


Page | 137

Directional lock

No directional lock

Fig. 1

Fig. 3

Fig. 2





113068 – Anti-seize compound

PROCEDURESAttaching the casters


Place a wheel assembly mounting spacer over the caster mounting hole and insert the caster screw through the spacer and hole (Fig. 1).

Apply an anti-seize compound to the screw threads (Fig. 2).

Attach a flat washer and nut (Fig. 3).



Page | 138

B1004263 and B1004269

B1004287

B1004287

Fig. 1

Fig. 3

Fig. 2





TOOLSRatchet

13 MM socket10 MM Allen wrench

Steel tube to grip Allen wrenchDrawing No. C11006


Page | 139

Fig. 1

Fig. 2

Fig. 2






(continued) Drawing No. 11006

Each caster has a foot lock (Fig. 1) that when engaged will lock the wheels (Fig. 2) or allow steering (Fig. 3). There are 4 brake locks; 2 at the back, near the handle, and 2 in the center. The 2 steer locks are in the front.



Page | 140

Foot lockFig. 1

Fig. 2

Fig. 3





3M Silicone Lubricant



Add the wheels to each caster. When assembling, position the Brake or Steer foot lock at the rear. Attach the screws from the outside to the inside. The washer and nut fit on the inside. Make sure the wheels spin freely and each foot lock works properly (Fig. 1).

With the wheels mounted, lubricate the caster bearings (Fig. 2 and Fig. 3).



Page | 141

B1004231Fig. 3

Foot lock

Washer and nut on inside

Fig. 3

Fig. 2

MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly

PROCEDURESSecuring the battery box

Drawing No. C11000

With the battery box upside down and the flow control facing the lower hydraulic brackets, align the battery box’s mounting angles over the holes at the bottom of the base frame assembly (Fig. 1).

With the holes aligned (Fig. 2) clamp the mounting angles to the bottom of the frame (Fig 3).

TOOLSClamps

Drawing No. C11000


Page | 142

Mounting angle

Base frame

Mounting holes aligned

Hydraulic brackets

Flow control valve

Mounting angles

Fig. 1

Fig. 3

Fig. 2


B100424254 – Hex head bolt, M10-1.5 x 751078958 – #10 flat washer112106 – #10-32 nyloc nut

PROCEDURESSecuring the battery box (continued) Drawing No. C11000

Working from the bottom up, insert 6 screws and add and tighten the nyloc nuts and flat washers (Fig. 1).

With the battery box mounted, use a crane to turn the base frame assembly upright, so it rests on its wheels (Fig. 2 and Fig. 3).


Drawing No. C11000


Page | 143

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11006 – Base frame assemblyC11006-15 – Stop (2 needed)

B1004253 – Hex head bolt, M12-1.75 x 100 (4 needed)B1004263 – Nyloc nut, M12 (4 needed)B1004300 – M12 flat washer (4 needed)

C1003580 – Hex head bolt, M12-1.75 x 70 (2 needed)C1003219 – Jam nut, M12 (2 needed)

C11006-12 – Load cell mounting member (2 needed)113068 – Anti-seize compound



Page | 144

Load cell or stop mounting holes

C11006-12 C11006-15

C1003580 and C1003219

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11006 – Base frame assemblyC11006-15 – Stop (2 needed)

B1004253 – Hex head bolt, M12-1.75 x 100 (4 needed)B1004263 – Nyloc nut, M12 (4 needed)B1004300 – M12 flat washer (4 needed)


C11006-12 – Load cell mounting member (2 needed)113068 – Anti-seize compound

PROCEDURESMounting a stop to a non-weighing unit (continued) Drawing No. C11000

Thread the bolt and jam nut into the single hole at the end of the stop (Fig. 1).

Apply anti-seize to the 2 longer bolts, slide them through the stop and load cell member, attach flat washers, and thread on 2 nyloc nuts. Tighten using a pair of ratchets (Fig 2).

With the stop secure, measure from the bottom of the block to the top of the jam nut bolt. You want a 3 3/16” measurement. If needed, adjust the bolt to that measurement then tighten the jam nut to lock the bolt. Adjust the second stop the same way (Fig. 3).

TOOLS2 ratchets

(2) 19 MM socketsSquare

Drawing No. C11000


Page | 145

C11006-15

C1003580 and C1003219

C11006-15

C11006-15

3 3/16” measurement

Fig. 1

Fig. 2

Fig. 3


C1003287 – Load cell (2 needed)B1004253 – Hex head bolt, M12-1.75 x 100 (4 needed)

B1004263 – Nyloc nut, M12 (4 needed)B1004300 – M12 flat washer (4 needed)


C11006-12 – Load cell mounting member (2 needed)C11017 – Load cell spacer (2 needed)



Page | 146

C11017

Position with arrow up

C1003287

C1003287

Fig. 1

Fig. 2

Fig. 2







PROCEDURESMounting a load cell to a weighing unit (continued)

Drawing No. C11001

Apply anti-seize to the shorter bolt and attach a jam nut. Thread the bolt into the single hole on the load cell (Fig. 1).

After applying anti-seize to the 2 longer bolts, slide them through the load cell, spacer, and load cell mounting member (Fig. 2).

Attach flat washers and nyloc nuts and tighten with a pair of ratchets (Fig. 3).

TOOLSRatchet



Page | 147

C1003580 and C1003219

C1003287

C1003287

B1004253

C1003287B1004300 and B1004263

Fig. 1

Fig. 2

Fig. 2






PROCEDURESMounting a load cell to a weighing unit (continued) Drawing No. 11001

Use a sanding disc to smooth the head of the jam nut bolt (Fig. 1).

Adjust the bolt until it measures 3 3/16” (Fig. 2).

Once adjusted, tighten the jam nut to lock the bolt in place (Fig. 3).

TOOLSPower drill

Sanding discSquareRatchet

19 MM socketAdjustable wrench

Drawing No. C11001


Page | 148

C1003580 and C1003219

3 3/16” measurement

Fig. 1

Fig. 2

Fig. 2

MATERIALSC11006 – Base frame assemblyB1004201 – Hydraulic cylinder

B1004202 – Hydraulic hose assembly

PROCEDURESInstalling the hydraulic cylinder

Drawing No. C11000

Remove the red plug from the cylinder (Fig. 1).

Thread the hollow bolt and brass washer from the hydraulic hose assembly through the open end of the hydraulic hose. Add a second brass washer on top. Lubricate a rubber gasket and slide it over the bolt (Fig. 2).

Thread the hydraulic hose into the open cylinder hole and tighten the bolt (Fig. 3).

TOOLSRatchet



Page | 149

B1004202

B1004201Fig. 1

Fig. 2

Fig. 3


B1004202 – Hydraulic hose assemblyB1004251 – Hex head bolt, M12-1.75 x 90B1004300 – M12 flat washer (2 needed)

B1004263 – M12 nyloc nutBrass washer (2 needed)

PROCEDURESInstalling the hydraulic cylinder (continued)

Drawing No. C11000

Position the cylinder between the hydraulic brackets with the hose toward the battery box (Fig. 1).

Slide a spacer bar through the hole in the cylinder shaft to hold it in position on top of the hydraulic brackets (Fig. 2).

Slide a bolt with washer through the mounting hole at the base of the hydraulic cylinder. Slide a brass washer over the bolt inside the bracket (Fig. 3).

TOOLSSpacer bar

Drawing C11000


Page | 150

B1004201 Brass washerB1004202

B1004201

Fig. 1

Fig. 2

Fig. 3



B1004263 – M12 nyloc nutBrass washer (2 needed)

TOOLS

2 Ratchets(2) 19 MM sockets

Drawing No.C11000


Page | 151

Brass washer B1004300

B1004201 B1004263Brass washer

B1004201

B1004202

B1004251B1004201

Brass washer

B1004251

B1004300

B1004202

Fig. 3 Fig. 1

Fig. 2


C1002599 – Directional flow control valveB1004201 – Hydraulic cylinder


B1004263 – M12 nyloc nut Brass washer (2 needed)

PROCEDURESInstalling the hydraulic cylinder (continued) Drawing No. C11000

Remove the protective cap from the flow control valve and thread the hydraulic hose end over the fitting (Fig. 1).

To prevent the hose from kinking, bend the hose into an S-shape (Fig. 2).

Using a pair of open-end wrenches, tighten the hose connection to the flow control (Fig. 3).

TOOLS(2) 11/16” crescent wrenches

Drawing No. C11000


Page | 152

C11003

B1004202

C11003

C1002599B1004202

S shape

Fig. 1

Fig. 2

Fig. 3


C1002601 – Hydraulic power unitB1004201 – Hydraulic cylinder assembly

1000219 – Hydraulic fluid, ISO Grade 68 Visc. 335


Remove the top cover from the battery box and set the stored wires aside (Fig. 1).

Remove the breather cap from the hydraulic power unit (Fig. 2).

Fill a half liter bottle with heavy/medium hydraulic fluid (Fig. 3).

TOOLSFunnel

Hydraulic fluid .5 liter bottleDrawing No. C11000


Page | 153

C1002601

1000219

Fig. 1

Fig. 2

Fig. 3


C1002601 – Hydraulic power unit1000219 – Hydraulic fluid, ISO Grade 68 Visc. 335


Set a funnel in the hydraulic pump hole. Put a cloth around the hole of the pump so as not to spill oil onto the pump (Fig. 1).

Slowly squeeze the contents of the bottle into the pump. When the bottle is empty fill it again and repeat the process. The hydraulic pump takes 2 bottles, or 1 liter of hydraulic fluid (Fig. 2).

When finished, replace the breather cap and tighten it with a ratchet wrench (Fig. 3).

TOOLSRatchet

19 MM socketFunnel

Hydraulic fluid .5 liter bottleCloth

Drawing No. C11000


Page | 154

1000219

Fig. 1

Fig. 2

Fig. 3


PROCEDURESWiring the battery box to the control box

Feed a wire puller through the bottom vertical member. Use the open hole at the bottom of the pivot handle assembly (Fig. 1).

Continue feeding the wire puller to the last open hole in the left lower slide rail, next to the battery box (Fig. 2).

Push the end of the wire puller back through the top hole and work it until it comes out of the hole on the side of the bottom member (Fig. 3).

TOOLSWire puller


Page | 155

Work wire puller through hole

Fig. 1

Fig. 2

Fig. 3


1014004 – 14 AWG red wire (105” length)1014001 – 14 AWG black wire (105” length — 2 needed)

PROCEDURESWiring the battery box to the control box (continued)

Feed 1 red and 2 black wire through the grommet in the battery box and attach the wires to the end of the wire puller (Fig. 1).

Continue pulling the red and black wires through the grommet until all the slack in gone inside the box (Fig. 2).

Push the 3 wires and wire puller through the hole on the side of the left bottom member next to the battery box. Make sure you feed the complete taped section of wire into the bottom member to lessen the chance of the wires becoming detached from the wire puller (Fig. 3).

TOOLSWire puller

Tape


Page | 156

Push wires through hole

Fig. 1

Fig. 2

Fig. 3




Gently pull the 3 attached wires through the bottom member (Fig. 1 and Fig. 2).

Feed the 3 wires up through the left vertical member in the handle assembly (Fig. 3).

TOOLSWire puller


Page | 157

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11006 – Base frame assemblyC11003 – Battery box assemblyB1004293 – Rubber grommet


Pull the wires through the large hole in the left vertical member (Fig. 1).

Keep pulling until the 3 wires coming from the battery box and into the left bottom member are relatively straight, without any extra slack (Fig. 2).

Remove the 3 wires from the wire puller (Fig. 3).

TOOLSWire puller


Page | 158

B1004293

Fig. 1

Fig. 2

Fig. 3




Feed the wire puller back into the bottom vertical member and out through the hole (Fig. 1).

Push the blue and brown wires through the grommet, removing any slack inside the battery box (Fig. 2).

Pull the blue and brown wires through the bottom vertical member (Fig. 3).

TOOLSWire puller


Page | 159

Fig. 1

Fig. 2

Fig. 3




107086 – Cable tiesB1004293 – Rubber grommet


Feed the wires up and out through the pivot handle assembly. Continuing pulling to remove excess slack in the wires and remove the wire puller (Fig. 1).

Use cable ties to keep the wires inside the battery box together and neat (Fig. 2).

Add another cable tie to the wires exiting the battery box (Fig. 3).

TOOLSWire puller


Page | 160

B1004293Fig. 1

Fig. 3

Fig. 2


C11003-06 – Battery box cable coverB1004293 – Rubber grommet



1078562 – Phillips #8-32 x 0.3125 round head screw (2 needed)


Cut a section from the side of a rubber grommet (Fig. 1).

Place the grommet around the 5 wires and work it into the hole on the side of the bottom member. The grommet will help protect the wires (Fig. 2).

Slide the battery box cable cover over the wires lining up the 2 screw holes, add the screws and tighten (Fig. 3).

TOOLSWire cutters



Page | 161

B1004293

B1004293

C11003-06

1078562

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing

C11008-05 – Control box rear panel


Remove the rear panel from the control box (Fig. 1).

Disconnect the ground wire from inside the panel (Fig. 2).

Clamp 2 L-shaped brackets and spacers to the sides of the handle assembly, right below the control box mounting holes (Fig. 3).

TOOLS3/8” nut driver

Phillips head screwdriverClamps

L-shaped brackets Spacer


Page | 162

C11008-05

C11008-05

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panelB1004293 – Rubber grommet




Set the control box on the brackets and slide the 5 wires through a rubber grommet. It may be easier to remove the grommet from the control box (Fig. 1).

Work the grommet into the hole on the side of the control box as you continue to pull the wires through the grommet (Fig. 2 and Fig. 3).

TOOLSClamps

L-shaped brackets Spacers


Page | 163

C11008-02

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panel1001745 – M6-1.0 x 16 SHCS (4 needed)

Lock washer


If needed, adjust the brackets and spacers slightly for the control box to line up with the mounting holes (Fig. 1).

Attach the screws and lock washers to secure the box (Fig. 2).

Once the control box is mounted and secure, remove the brackets (Fig. 3).

TOOLSClamps

L-shaped brackets Spacers



Page | 164

1001745 Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panel1014005 – 14 AWG blue wire (105” length)


1014001 – 14 AWG black wire (105” length — 2 needed)


Pull 1 black wire to the weld stud in the control box for a rough measurement and cut off the excess wire (Fig. 1).

Roughly measure the second black wire to the back of the 3 position selection knob and cut off the excess (Fig. 2).

Give the brown wire enough slack to go around all the switches and end at the back of the red (LOWER) button. Cut off the excess (Fig. 3).

TOOLSWire cutters


Page | 165

Fig. 1

Fig. 2

Fig. 3




1014001 – 14 AWG black wire (105” length — 2 needed)


Measure enough of the blue wire to loop around the red (LOWER) and green (RAISE) buttons and to the bottom of the battery discharge gauge and cut off the excess (Fig. 1).

The red wire should be able to reach the 3 position selection knob. Cut off the excess (Fig. 2).

Strip and tin the ends of each of the 5 wires (Fig. 3).

TOOLSWire cutters

Wire strippersSoldering iron

Solder


Page | 166

Fig. 1

Fig. 3

Fig. 2




1014001 – 14 AWG black wire (105” length — 2 needed)B1004227 – Auxiliary contact block


Attach the red wire leading from the battery box to the No. 4 slot on the auxiliary contact block attached to the back of the 3 position selection knob. Tighten the screw to secure the wire (Fig 1 and Fig. 2).

Feed the brown wire around the bottom of the switches and loop it around the back of the green (RAISE) button and attach it to the auxiliary contact’s No. 3 slot on the back of the red (LOWER) button. Tighten the screw to secure (Fig. 3).



Page | 167

B1004227

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panelB106483 – Small ring terminal crimp connectors



C1003483 – Male disconnect terminalsC1005342 – Female disconnect terminals

107086 – Cable ties


Loop the blue wire around the bottom switches and insert it into the auxiliary contact’s No. 3 slot on the back of the green (RAISE) button. Tighten the screw (Fig. 1).

Crimp a small ring terminal connector to the end of the longer black wire and attach it to the weld stud inside the control box (Fig. 2).

Attach a female terminal to the shorter black wire and connect it to the male terminal black wire inside the control box. If the unit is a weighing model additional steps are needed, please continue to the next section (Fig. 3).


Crimping tool


Page | 168

Fig. 3

Fig. 1

Fig. 2

MATERIALSC11006 – Base frame assemblyC11002 – Pivot handle assemblyC11008-2 – Control box housing

C11008-05 – Control box rear panelC1003287 – Load cell

B1004293 – Rubber grommet

TOOLSWire cutter

Tape


Page | 169

Frame length holeTape

C1003287B1004293

Fig. 1

Fig. 2

Fig. 3




PROCEDURESWiring the load cells to the control box for weighing units (continued)

Feed a wire puller through the left frame length and out the hole near the load cell and attach the cut end of the load cell wire to the wire puller (Fig. 1).

Pull the wire through the fame length (Fig. 2).

Fit the grommet into the hole (Fig. 3).

TOOLSWire puller

Tape


Page | 170

Fig. 1

Fig. 2

Fig. 3





Roughly measure the length of cable from the front load cell to the control box, cut off any excess, attach a grommet, feed the wire puller through the hole, and attach the load cell wire (Fig. 1).

Pull the wire through the hole and attach a grommet (Fig. 2).

Attach both the front and rear load cell wires to the wire puller and feed them up through the left handle and into the control box. Continue pulling the wires to remove any slack (Fig. 3).

TOOLSWire puller

Tape


Page | 171

B1004293

B1004293

C11008-2

Fig. 1

Fig. 2

Fig. 3



1014001 – 14 AWG black wire (20” section)1014004 – 14 AWG red wire (5” section)

B1003456 – Display with membrane


Once inside the control box, tape the rear wire closer to its access point inside the control box and cut off any extra wire (Fig. 1).

Cut, strip, and tin a 15” and 1” section of black wire and a 5” and 1” section of red wire. The 1” sections will be used as jumpers. Add a small ring terminal connector to 1 end of the black wire (Fig. 2).

Remove the small green terminal connector from the back of the display and add 1 end of the red wire to the left or positive slot and tighten the connection (Fig. 3).

TOOLSWire cutter

Wire stripperTape

Soldering ironSolder



Page | 172

Fig. 2B106483

10140041014001

Fig. 1

Fig. 3



C11008-2 – Control box housingC11008-05 – Control box rear panel

B106483 – Small ring terminal crimp connectors1014001 – 14 AWG black wire (20” section)

1014004 – 14 AWG red wire (5” section)


Add the tinned end of the black wire to the negative side on the terminal connector and plug the connector into the display board (Fig. 1).

Remove the auxiliary contact from the back of the red (LOWER) button and attach the open end of the red wire to No. 4 connector. Tighten the screw and replace the connector (Fig. 2).

Attach a ring terminal on the black wire to the weld stud and tighten the nut (Fig. 3).


3/8” nut driver


Page | 173

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panel


Roughly measure and cut both load cell cables to the same length of about 12”. Using a utility knife, carefully cut off about 2” of the protective sleeve to expose the silver stranded wires, which are wrapped around the other wires (Fig. 1 and Fig. 2).

Remove the clear plastic covering and carefully unwind the stranded wires and twist them into a single strand. Be very careful not to break off strands while wrapping or cutting. Repeat this for the other load cell cable (Fig. 3).

TOOLSWire cutterUtility knife


Page | 174

Twist to single strand

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panel1014001 – Black 14 AWG (1” section)1014004 – Red 14 AWG (!” section)


Strip both sets of wires, twist the 2 sets of load cell wires together, each matching their colors, and tin the ends of the twisted wires (Fig. 1).

Remove the long green terminal connector from the back of the display and add the red and black jumpers. Working from left to right, the red jumper goes into the second and fourth slots and the black jumper goes into the third and fifth slots. Tighten the screws to secure the jumpers (Fig. 2).

With the jumpers attached, connect the twisted silver wires to slot #1, the red to slot #4, the black to slot #5, the white to slot #6, and green to slot #7. Remember to tighten the screws to secure the wires and plug it into the control board at the back of the display (Fig. 3).

TOOLSWire stripperSoldering iron

Solder


Page | 175

1014001

1014004

Fig. 1

Fig. 2

Fig. 3


C11008-05 – Control box rear panel107086 – Cable ties

B1004239 – Phillips pan head screw, M5-0.8 x 10111137 – Kep nut, #10 x 32

C1005343 – Male disconnect terminalC1005342 – Female disconnect terminal


Tuck all wires neatly inside the control box (Fig. 1).

Attach cable ties about every 4” to 6” to keep the wires neat and together (Fig. 2).

Reattach the ground wire to the inside of the control box rear panel and replace the rear panel (Fig. 3).

TOOLSPhillips screwdriver

7/16” nut driver


Page | 176

Fig. 3C1005342 and C1005343

C11008-05

Fig. 1

Fig. 2


C11008-05 – Control box rear panelB1004294 – Knob star M8 x 25mm stud

B1004246 – SHCS, M12-1.75 x 80B1004269 – M12 flat washerB1004263 – M12 nyloc nut


PROCEDURESInstalling the pivot handle assembly

Work the pivot handle inside its brackets. Make sure it seats all the way to the bottom of the slot (Fig. 1).

Slide a bolt and lock washer through the slot and handle assembly on both sides of the handle, apply anti-seize to the threads, and attach a lock washer and nyloc nut. Tighten with a pair of wrenches (Fig. 2).

Adjust the handle to the upright position, and attach the knob star studs (Fig. 3).

TOOLSRatchet

19 MM socket


Page | 177

C11002

C11002

B1004269 and B1004263

C11002

B1004294

Fig. 1

Fig. 2

Fig. 3


B1002757 – Sealed 12V 80 AH batteryB1003408 – Red battery terminal cover

B1003407 – Black battery terminal cover

PROCEDURESConnecting the terminals to the battery

Using 2 hands set the battery inside the battery box angle brace (Fig. 1).

When placing the battery, be careful not to pinch the red and black terminal wires with the weight of the battery (Fig. 2).

Remove the screws from the black and red terminal holes (Fig. 3).

TOOLS


Page | 178

B1002757

B1002757

Fig. 1

Fig. 2

Fig. 3


B1002757 – Sealed 12V 80 AH batteryB1003408 – Red battery terminal cover

B1003407 – Black battery terminal cover

PROCEDURESConnecting the terminals to the battery (continued)

Attach the wires to the red terminal side and tighten the bolt (Fig 1).

Fit the red terminal cover over the connection (Fig. 2).

Attach the black terminal connectors and cover (Fig. 3).

TOOLSRatchet

13 MM socket


Page | 179

B1003408 Fig. 1

Fig. 2

Fig. 3

MATERIALSC11008-02 – Control box housingC11006 – Base frame assembly

1000542 – Scissors lift power cord

PROCEDURESChecking the circuitry

With the battery connected, you should test the circuitry of the system using a ground board tester and voltage tester (Fig. 1).

Clip the grounding cables from the testers to metal areas on the scissors lift (Fig. 2).

Attach the charging cable to the side of the control box (Fig. 3).

TOOLSPower supply

AC/DC withstand voltage testerGround bond tested


Page | 180

1000542 Fig. 1

Fig. 2

Fig. 3

MATERIALSC11008-02 – Control box housing1000542 – Scissors lift power cord

PROCEDURESChecking the circuitry (continued)

Plug the unit’s charging cable into the tester and run the test (Fig. 1).

Both testers should show Pass. If they do not, disconnect the tester, check the electrical system for a potential short, and retest (Fig. 2).

With the circuitry tested plug the charging cable into a power outlet and turn the selector knob to CHARGE. A red light will run across the center of the battery status indicator showing that the unit is charging (Fig. 3).

TOOLSPower supply

AC/DC withstand voltage testerGround bond tested


Page | 181

Fig. 1

Fig. 2

Fig. 3


C11003-06 – Battery box top cover1075501 – Phillips pan head screw, 10-32 x 0.5

112106 – #10-32 nyloc nut1078958 – #10 flat washer

PROCEDURESReplacing the battery box top cover

During charge, the battery charge indicator light will glow amber. Once the unit is fully charged, the amber light changes to green (Fig. 1).

With the unit charging, set the top cover on the battery box. You should be able to read the writing on the cover standing in front of the control box (Fig. 2).

Replace and tighten the screws to secure the top cover (Fig. 3).



Page | 182

Amber light shows charging; green light shows changed C11003-06

C11003-06

Fig. 1

Fig. 2

Fig. 3


C11006 – Base frame assemblyB1004251 – Hex head bolt, M12-1.75 x 90

B1004299 – #10 flat washerB1004262 – M10 nyloc nut

Brass washer113068 – Anti-seize compound

PROCEDURESAttaching the scissors frame “B” assembly to the bottom section

Using a crane, angle the scissors frame “B” assembly, over the bottom section (Fig. 1).

With the scissors frame held securely with the crane, fit the pivot pieces inside the pivot brackets and secure 1 side with a long bolt or round shaft. Attach the hardware to the other side first (Fig. 2).

Apply anti-seize to the threaded end of the bolt used with the pivot pieces (Fig. 3).

TOOLSCrane

Round shaft


Page | 183

C11005

C11005

Fig. 1

Fig. 2

Fig. 3


C11006 – Base frame assemblyB1004251 – Hex head bolt, M12-1.75 x 90


Brass washer

PROCEDURESAttaching the scissors frame “B” assembly to the bottom section (continued)

Add a lock washer to the bolt and working from outside the frame to the inside, slide the bolt and lock washer through the first bracket, a brass washer, the length member, a second brass washer, and the second bracket. Add a second lock washer and thread on a nyloc nut. It is important to fit brass washers between the brackets and the length member on both sides; otherwise the unit may not operate smoothly (Fig. 1 and Fig. 2).

Using a pair of ratchets tighten the bolts securely (Fig. 3).

TOOLS2 ratchets

(2) 19 MM sockets


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C11005C11005

B1004251

Brass washer

B1004251 and B1004299

B1004262 and B1004299

Fig. 1

Fig. 2

Fig. 3


C11006 – Base frame assemblyB1004201 – Hydraulic cylinder

B1004251 – Hex head bolt, M12-1.75 x 90B1004299 – #10 flat washerB1004262 – M10 nyloc nut


PROCEDURESAttaching the hydraulic cylinder

With the middle assembly still at an angle, remove the spacer bar and fit the top of the hydraulic cylinder inside the hydraulic supports, lining up the holes (Fig. 1).

Add a lock washer to the bolt and slide it through the hole in the hydraulic support. Fit a brass washer between the hydraulic support and cylinder shaft and continue sliding the bolt through the shaft. Add a second brass washer and slide the bolt through the other end of the hydraulic support. Again, in order to have a smooth operation, you must sandwich the cylinder between 2 brass washers (Fig. 2).

With the bolt through the other side, apply anti-seize to the threads and attach a lock washer and nyloc nut (Fig. 3).

TOOLSCrane


Page | 185

B1004201

Brass washer

Fig. 1

Fig. 2

Fig. 3


C11006 – Base frame assemblyB1004210 – Upper slide rail pin (2 needed)

C11018 – Long spacer (2 needed)C11019 – Short spacer (2 needed)

C1003483 – Ball bearing (2 needed)

PROCEDURESAttaching spacers and ball bearing to upper slide rail pins

Tighten the bolt and nut with a pair of wrenches (Fig. 1).

Slide the long spacer, ball bearing, and short spacer onto the upper slide rail pins (Fig. 2 and Fig. 3).

TOOLS2 ratchets

(2) 19 MM sockets


Page | 186

C11018

C11018C1003483

C11019C11005C11005

Fig. 1

Fig. 3

Fig. 2


C11006 – Base frame assemblyC11003 – Battery box assembly

C11003-06 – Battery box cable cover

PROCEDURESAttaching scissors frame “B” assembly

If needed, tighten the 6 screws and nuts supporting the battery box to the bottom frame. The screws are inside the slots in the lower rails (Fig. 1).

Spray inside the lower rails with isopropyl alcohol and wipe the rails clean with a soft lint-free cloth (Fig. 2).

Place sections of cardboard at the 4 corners of the base frame assembly and lower the scissors frame “B” assembly (Fig. 3).


Soft lint-free cloth4 sections of cardboard

Phillips head screwdriverRatchet

13 MM socket


Page | 187

C11005

C11005

C11005

Fig. 1

Fig. 3

Fig. 2


C11006 – Base frame assemblyC11007 – Scissor tie piece weldment (2 needed)

B1004285 – Lower slide rail pivot plate weldment (2 needed)Brass rollers (4 needed)

PROCEDURESAttaching rail pins to the lower slide rails

Slide brass rollers over the ends of the lower slide rail pivot plate weldments, which are attached to the scissor tie pieces (Fig. 1).

Use a sanding disc to smooth the rollers and remove any burrs (Fig. 2).

Working from a slight angle, slide the pins with rollers into the lower slide rails (Fig. 3 and Fig. 4).

TOOLSCrane

Power drillSanding disc


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Fig. 3Fig. 2Fig. 1

B1004285

B1004203

B1004285C11007

Fig. 3


C11005 – Scissor frame “B” assemblyC11006 – Base frame assembly

C11007 – Scissor tie piece weldment (2 needed)B1004254 – Hex head bolt, M10-1.5 x 75


Brass washer

PROCEDURESAttaching the scissor tie piece to the scissors frame “B” assembly

Insert a bolt and washer through the center hole in a scissors tie piece and slide on a brass washer (Fig. 1).

Use the crane to raise the scissors frame “B” assembly. Lift the scissor tie piece, align the bolt and brass washer with the center hole in the scissors frame, and insert the bolt through the frame (Fig. 2).

With the bolt through both pieces, lower the assembly, apply anti-seize to the bolt threads, attach a flat washer and nyloc nut, and tighten with a pair of wrenches. Repeat this process to attach the second scissors tie piece (Fig. 3).

TOOLS2 ratchets

(2) 17 MM sockets


Page | 189

B1004254 and B1004299

Brass washer

C11007

C11007

C11005 B1004254 and B1004299

Brass washer

Brass washer

C11005

C11007

B1004262 and B1004299

Fig. 1

Fig. 2

Fig. 3

MATERIALSC11004 – Top frame assemblyC11004-06 – Upper slide rail

C11006 – Base frame assemblyC11005 – Scissor frame “B” assembly

PROCEDURESAttaching the slide rail pins into the upper slide rails

Lift the slide rail pin area on the scissors frame “B” assembly and slide a 2” x 4” under the pin area so it rests on an angle (Fig. 1).

Using the crane, slowly lower the top frame assembly in place (Fig. 2).

Using the crane, glide the slide rail pins into the upper slide rails (Fig. 3).

TOOLSCrane

2” X 4” wood


Page | 190

C11005

C11004

C11005

C11004 C11004-06

Fig. 1

Fig. 3

Fig. 2





Brass washer

PROCEDURESAttaching the scissors tie pieces to the top frame assembly

Use a wooden board to help align the mounting brackets with the holes in the 2 scissor tie piece weldments (Fig. 1).

Working from the inside of the frame, slide the bolt with lock washer through the single hole in the mounting bracket and add a brass washer. Lift the scissor tie piece into the bracket and work the bolt through the tie piece (Fig. 2).

Work a second brass washer over the bolt between the tie piece and bracket (Fig. 3).

TOOLSWooden board


Page | 191

Fig. 2

Fig. 3

C11004C11004

C11004

C11007

B1004254 B1004299

Fig. 1






PROCEDURESAttaching the scissors tie pieces to the top frame assembly (continued)

Continue to work the bolt through the scissor tie piece, brass washer, and the first hole in the outer bracket (Fig. 1).

Apply anti-seize to the bolt threads and add a lock washer and nyloc nut. Tighten the bolt with a pair of wrenches (Fig. 1).

Attach the second scissor tie piece the same way, working from inside the frame to the outside. Once tightened, the bolt heads from both sets of length members and those from the top frame assembly should face one another (Fig. 3).

TOOLS2 ratchets

(2) 17 MM sockets


Page | 192

C11004

Brass washer

B1004254 and B1004299

C11004C11007

C11006

Fig. 1

Fig. 3

Fig. 2

MATERIALSC11006-14 – End cap

PROCEDURESInstalling the end caps

Before installing the end caps, use a sanding disc to remove any burrs or excess flux (Fig. 1).

Cut the bottom of the end caps into 4 flexible feet. This makes inserting them easier (Fig. 2 and Fig 3).

TOOLSPower drill

Sanding discWire cutters


Page | 193

C11006-14

C11006-14

C11006-14

Fig. 1

Fig. 3

Fig. 2


C11006-14 – End cap105941 – Corner bumper guard

112198 – Phillips round head screw, #10-32 x 1.0

PROCEDURESInstalling end caps and corner bumper

Slide the end caps into each open end of the frame (Fig. 1)

To evenly seat the end cap you may need to use a block of wood and a rubber-tipped hammer (Fig. 1).

With the end caps mounted, attach the 2 corner bumper guards with 4 Phillips head screws (Fig. 2).

TOOLSRubber-tipped hammer

Phillips head screwdriverBlock of wood


Page | 194

C11006-14

105941

Fig. 1

Fig. 3

Fig. 2

MATERIALSB10054205 – Body tray adjusting shaft

C11004-08 – Body tray width adjusting bracket112198 – Phillips round head screw, 10-32 x1.0

1078958 – #10 flat washer 112106 – Nut stop, #10-32

PROCEDURESInstalling the body tray adjusting shaft

Lock the body tray adjusting shaft in a vice with the hole with the largest gap on top (Fig. 1).

Slide a screw and flat washer through the top hole and thread on a nyloc nut.

Tighten with a Phillips head screwdriver and ratchet (Fig 3).


Ratchet2.5 M socket


Page | 195

B10054205

B10054205

112106112198 and 1078958

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1004204 – Body tray guide block

B1004208 – Pin with chainB1004244 – Button head socket, M5-0.8 x 55

B1004205 – Body tray adjusting shaftLoctite 290


Working from the inside to the outside, slide the adjusting shaft through the frame and bracket (Fig. 1).

Hammer the tapped grommets into the holes on the body tray guide blocks (Fig. 2).

Align the block with the last hole in the shaft and thread in a screw (Fig. 3).

TOOLSBall hammer


Page | 196

B1004205B1004204B1004205

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004208 – Pin with chain

B1004204 – Body tray guide blockB1004244 – Button head socket, M5-0.8 x 55

1002291 – 5M hex nutLoctite 290


Securely tighten the screw with an Allen wrench. Remember to add a screw to both sides of the block (Fig. 1).

Set the block in place over the adjusting bracket and top frame assembly. Attach the remaining 3 blocks (Fig. 2).

Slide the pin with chain into the side of the block (Fig. 3).

TOOLS8 M Allen wrench


Page | 197

B1004204

B1004204

B1004208

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1004208 – Pin with chain

B1004204 – Body tray guide block236031 – Phillips #6-32 x 0.5 pan head screw

Loctite 290


Attach a screw to the open end of the chain (Fig. 1).

Add Loctite to the screw threads (Fig. 2).

Thread the screw and chain assembly into the single hole on the side of the block (Fig. 3).



Page | 198

236031B1004208

B1004208

Fig. 1

Fig. 2

Fig. 3

MATERIALS105247 – Chain

B1004208 – Pin with chainB1004204 – Body tray guide block

236031 – Phillips #6-32 x 0.5 pan head screw796036 – #6 flat washer

PROCEDURESAdding screws to optional cover holes

There are 2 holes beside each block that are used to install an optional canopy for the scissors lift (Fig. 1).

Add 2 screws, 2 lock washers, and 2 flat washers to the holes (Fig. 2).

Cut 2 sections of chain each measuring 15 links (Fig. 3).


Wire cutter


Page | 199

B1004204

10547

Fig. 3

Fig. 2

Fig. 1

MATERIALSC11015 – Body tray securing peg


C1003463 – Stainless steel loop chainLoctite 290

PROCEDURESInstalling the body tray securing peg (continued)

Use pliers to separate the end link of the chain (Fig. 1).

Using a center punch, hammer, and block of wood, widen the end link on the opposite side of the chain (Fig. 2 and Fig. 3).

TOOLSPliers

Ball hammerCenter punchBlock of wood


Page | 200

10547

Fig. 1

Fig. 3

Fig. 2




PROCEDURESAttaching the body tray securing peg (continued)

Slide a screw through the open link halves (Fig. 1).

Attach the screw and chain assembly to the body tray securing peg (Fig. 2).

Apply Loctite to the screw threads (Fig. 2).



Page | 201

Fig. 1

C11015 236042 and 796036C1003463

C11015

C11015

Fig. 3

Fig. 2

MATERIALSC11004-07 – Top tray clamp location bracket236042 – Phillips #8-32 x 0.5 pan head screw

Loctite 290


Using a Phillips head screwdriver, secure the chain to the peg (Fig. 1).

Once tightened, the screw will be protruding through the back of the peg (Fig. 2).

Use a sanding disc to grind down the threads so the bottom of the peg is smooth (Fig. 2).

TOOLSPower drill

Sanding discPhillips head screwdriver


Page | 202

C11004236042

C11004

Fig. 1

Fig. 3

Fig. 2





Make sure you grind the bottom of the peg to a smooth finish; otherwise the top panel may not fit (Fig. 1).

Slide the peg with chain attached into the clamp bracket (Fig. 2).

Using Loctite on the screw threads, attach the screw to the open end of the chain and attach it to the single hole next to the clamp bracket. Remove the duct tape from the upper slide rail (Fig. 3).

TOOLSGrinding tool



Page | 203

C11015

C11015

C1003463

Fig. 3

Fig. 1

Fig. 2


C11016 – Ball unit top panelB1004215 – Ball transfer roller

PROCEDURESAssembling the ball unit top panel

Peel the protective film from the sides, around the holes, and around the screw slots in the ball unit top panel (Fig. 1).

The top panel holds 18 ball transfer rollers. Wipe each roller down with isopropyl alcohol and a soft cloth (Fig. 2).

Lay the top panel face down on a hard surface (Fig. 3).




Page | 204

C11016

C11016

B1004215

Fig. 1

Fig. 2

Fig. 3



Roller retaining clampChrome tape

PROCEDURESAssembling the ball unit top panel (continued)

Lift the top panel slightly and insert each roller, bottom up, into a hole (Fig. 1).

Set a retaining clamp over the bottom end of each roller (Fig. 2).

Using either a section of pipe or your fingers, push the retaining clamp down so it seats evenly onto the back of the roller (Fig. 3).

TOOLSSection of pipe


Page | 205

B1004215

C11004

B1004215

Roller retaining clamp

Pipe

Fig. 1

Fig. 3

Fig. 2



Roller retaining clampChrome tape

B1004204 – Body tray guide blockB1004205 – Body tray adjusting shaft

PROCEDURESAttaching the ball unit top panel

Wrap precut sections of chrome tape around the roller’s retaining clamp (Fig 1).

Pull the 4 body tray guide blocks out fully (Fig. 2).

Lay 2 wood planks across the scissors lift assembly (Fig. 3).

TOOLSWood planks


Page | 206

Roller retaining clamp

Chrome tape

B1004215B1004204

B1004205

Fig. 1

Fig. 2

Fig. 3


C11016 – Ball unit top panel231130 – Neoprene double-sided tape

PROCEDURESAttaching the ball unit top panel (continued)

Slide the top panel onto the wood setting on top of the frame (Fig. 1).

Add double-sided tape to decal backing (Fig. 2).

Cut 6 small sections of double-sided tape (Fig. 3).

TOOLSWood planksUtility knife


Page | 207

11016

Fig. 1

Fig. 3

Fig. 2


C11016 – Ball unit top panelB1004240 – Phillips pan head screw, M5-0.8 x 12

1901951 – M5 flat washer

PROCEDURESAttaching the ball unit top panel (continued)

Evenly space the sections of tape onto the inside edges of the frame, where the top panel rests, on both sides of the assembly (Fig. 1).

Peel off the tape backing, remove the boards, and gently set the top panel into its frame (Fig. 2).

Add screws and flat washers to hold the top panel in place (Fig. 3).



Page | 208

C11016

C11016

C11016

Fig. 1

Fig. 3

Fig. 2

MATERIALSScissors lift assembly

C11003 – Battery box assemblyB1004207 – Trolley stop pin

PROCEDURESVerifying operation of the scissors lift

Raise and lower the scissors lift a few times to verify it is operating smoothly. If the scissors lift lowers too quickly, you may need to adjust the setting on the flow control. Remember, the higher the setting, the faster the lift will lower (Fig. 1).

With the scissors lift raised, insert the trolley stop pin into its sleeve (Fig.2).

Remove the protective film form the battery cover and wipe it with isopropyl alcohol and a soft cloth (Fig. 3).




Page | 209

B1004207

C11003

Fig. 1

Fig. 3

Fig. 2

MATERIALS3M Silicone Lubricant

500 pounds of weighted materials

PROCEDURESLubricating and weight testing the unit

With the scissors in a raised position, lubricate the bottom and top rails (Fig. 1).

Remove the trolley stop pin and attach it to its clip. Lower the scissors lift (Fig. 2).

The scissors lift is designed to hold a maximum weight of 500 pounds. To verify it can operate under the maximum weight, evenly distribute 500 pounds of weight on the scissors lift and raise and lower the lift several times. Remember, you must weight-test every lift (Fig. 3).

TOOLS


Page | 210

B1004207

Fig. 1

Fig. 3

Fig. 2

MATERIALS1001247 – Pinch point label

Warning decal

PROCEDURESAdding final decals to the assembly

The scissors lift contains 8 pinch points. You will need to add a Pinch Point Warning decal to each area. Before adding any decals, wipe the area down with isopropyl alcohol and a soft cloth, otherwise the decals may not stick (Fig. 1).

Add 3 decals to each scissors tie piece, 1 to the bottom cross member, and 1 to the handle above the control box (Fig. 2).

Add a warning decal to the handle above the control box and 3 to the top frame assembly (Fig. 3).




Page | 211

Warning decal placement

Pinch point decal areas

1001247

Fig. 1

Fig. 2

Fig. 3

MATERIALS110/240 decal

Frame Locking Pin Operation decalMax weight decal

Danger decal

PROCEDURESAdding final decals to the assembly (continued)

Other decals to add include a 110/240V. Add this to the side of the control box, below the IEC connector (Fig. 1).

Add a Frame Locking Pin Operation decal to the base frame directly below the locking pin slot (Fig. 2).

Add a Max weight and Danger decal to the front cross member on the top frame assembly (Fig. 3).

TOOLS


Page | 212

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1000624 – Scale Calibration Procedures

PROCEDURESCalibrating the weighing model

To calibrate, start by turning the selector switch to On. A single red light will show in the battery indicator gauge (Fig. 1).

To reach the calibration mode, raise the unit then lower it and hold the lower button in for 10 seconds (Fig. 2).

Once in the calibration mode, refer to the Scale Calibration Procedures to complete the calibration process (Fig. 3).

TOOLSAccurate weight units totaling 200 lbs.


Page | 213

Fig. 1

Fig. 2

Fig. 3

Scissors lift and pump assembly

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