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
MATERIALSC11003-01 – Battery box rear side panel
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
Complete Scissors Lift Assembly 0000-000-000
PAGE 3
Fig. 1
Fig. 2
Fig. 3
Fig. 4
MATERIALSC11003-01 – Battery box rear side panel
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
PAGE 5
C1002602
C1002602
236054Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoid
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
Complete Scissors Lift Assembly 0000-000-000
PAGE 6
236054
C1002602
236054
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoid
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
Page | 8
C1002601
C1002602
C1002601C1002602
C1002601
C1002602
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit
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
Complete Scissors Lift Assembly 0000-000-000
Page | 9
C1002602
C1002601
C1002601
C1002602
C1002601
C1002602Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit
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
Complete Scissors Lift Assembly 0000-000-000
Page | 10
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
Page | 17
B1004223
B1004224
Grommet
B1004223
Fig. 1
Fig. 3
Fig. 2
MATERIALSB1004223 – Fuse block
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).
.
TOOLSFlat-head screwdriver
Complete Scissors Lift Assembly 0000-000-000
Page | 18
Top mounting hole
Make end even with brass plate
B1004223
B1004223
Grommet
B1004223
Fig. 1
Fig. 3
Fig. 2
MATERIALSB1004223 – Fuse block
1003455 – 4 AWG red wire (22½” length and 12” length)
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).
TOOLSAdjustable wrench
Flat-head screwdriver2 pieces of foam for vice
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
Page | 20
B1004223 B1004223
Fig. 2
C11003-03
Fig. 1
Fig. 3
MATERIALSB1004223 – Fuse block
1003455 – 4 AWG red wire (22½” length and 12” length)
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).
TOOLSFlat-head screwdriver
Complete Scissors Lift Assembly 0000-000-000
Page | 21
B1004223
B1004223Fig. 1
Fig. 2
MATERIALSC1002602 – 12 V relay solenoidC1002601 – Hydraulic power unit
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
Complete Scissors Lift Assembly 0000-000-000
Page | 22
C1002602
C1002602
C1002602
1003455Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoid
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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
Complete Scissors Lift Assembly 0000-000-000
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).
TOOLSAdjustable wrench
Complete Scissors Lift Assembly 0000-000-000
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).
TOOLSAdjustable wrench
Scissors Lift Pump Assembly 0000-000-000
PAGE 27
C1002598
C11003-01
C1002598
C1002598
Fig. 1
Fig. 3
Fig. 2
MATERIALSB1004223 – Fuse block
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
Scissors Lift Pump Assembly 0000-000-000
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
Page | 32
C1002601
C1002602
B106483 Fig. 1
Fig. 3
Fig. 2
MATERIALSC1002602 – 12 V relay solenoid
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
Page | 34
C1005342
C1003483
C1003483 C1005342
Fig. 1
Fig. 2Fig. 3
Fig. 4
MATERIALSC1002602 – 12 V relay solenoid
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
Scissors Lift Pump Assembly 0000-000-000
Page | 35
107086
C11003-03
107086
C1002602
1014004
Fig. 1
Fig. 3
Fig. 2
MATERIALSB1004223 – Fuse block
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
PROCEDURESConnecting the wires inside the battery box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 36
1070861075741003454 1014001Foam to
stabilize battery
1014004
1003455
Fig. 1
Fig. 2Fig. 3
Fig. 4
MATERIALSC1002602 – 12 V relay solenoid
C1002601 – Hydraulic power unitB106483 – Small ring terminal crimp connectors
107086 – Cable ties107574 – Tie anchors
PROCEDURESConnecting the wires inside the battery box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free clothCenter punch
Scissors Lift Pump Assembly 0000-000-000
Page | 38
C11003C11003C11003 Fig. 1
Fig. 3
Fig. 2
MATERIALSC11003 – Battery box assembly
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free clothUtility knife
Scissors Lift Pump Assembly 0000-000-000
Page | 39
C11003-09
C11003-09 Fig. 1
Fig. 3
Fig. 2
MATERIALSC11003 – Battery box assembly
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
Page | 41
C1003463
B1004207
C1003463
B1004207
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11003 – Battery box assembly
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
Scissors Lift Pump Assembly 0000-000-000
Page | 42
C110037195731B1004230
Fig. 2Fig. 3Fig. 4 Fig. 1
MATERIALSC11003 – Battery box assembly
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
Scissors Lift Pump Assembly 0000-000-000
Page | 43
B1004230
C1003463
B1004207
B1004207
C1003463
B1004230
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11003 – Battery box assembly
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).
TOOLSPhillips head screwdriver
Utility knifeTape measure
Marker
Scissors Lift Pump Assembly 0000-000-000
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Drawing No. C11008
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth
Scissors Lift Pump Assembly 0000-000-000
Page | 48
C11008-02B1000624
C11008-02 B1004228
B1004228
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11008-02 – Control box housing
B1004228 – 3 position button selection knobB1004227 – Auxiliary contact block
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
C11008-02 – Control box housingB1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block
#6-32 locknuts
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 55
C1005278
C1005278
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1005278 – Angled set power cord assembly
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 56
C1005278C1005278 C11008-02
C1005278
Fig. 1Fig. 3Fig. 2
Fig. 4
MATERIALSB106483 – Small ring terminal crimp connectors
B1004217 – Fused plug, 10A IEC 320 C14B1004218 – Rubber boot
Duct tape
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 57
B106483
B1004218B1004217
B1004218
B1004217
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1005278 – Angled set power cord assembly
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 58
B106483
B1004218
C1005279
C1005278
C1005278
B106483
C11008-02
C11008-01
B106483
C11008-01
C11008-02
Fig. 3
Fig. 2
Fig. 1
MATERIALSC1005278 – Angled set power cord assembly
C1005279 – Flag terminalB1004217 – Fused plug, 10A IEC 320 C14
C11008-01 – Battery charger mounting bracketC11008-02 – Control box housing
B1004218 – Rubber boot
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 59
C1005279
B1004217
C11008-02B1004217B1004217
C1005279
C11008-02
C11008-02
C1005278
Fig. 3
Fig. 1
Fig. 2
MATERIALSB1004217 – Fused plug, 10A IEC 320 C14
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
PROCEDURESAssembling the control box (continued)
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
Phillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
Page | 60
C11008-03
Spacer 1001765
1078456C11008-03
1001765
1078456
B1004242 C11008-04
B1004217
C11008-02Fig. 1
Fig. 2
Fig. 3
MATERIALSB1004217 – Fused plug, 10A IEC 320 C14
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
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
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
C11008-02 – Control box housingB1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block
1014004 – 14 AWG red wire (1¾” section — 2 needed)
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
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)
PROCEDURESAssembling the control box (continued)
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
Phillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
Page | 63
B1004227
B1004227
C1005342
B1003498
C11008-2
C1005342
Fig. 1
Fig. 3
Fig. 2
MATERIALSC1005342 – Female disconnect terminals
B1004229 – Auxiliary contactsC11008-02 – Control box housing
B1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block
B1004228 – 3 position button selection knob1014004 – 14 AWG red wire (5 ½”, 3 5/8”, and 1¾” section)
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
Page | 64
B1004227
C11008-02
C11008-02B1004229 B1003498
C1005342
B1004229C1005342 B1003498
B1004228
Jumper Fig. 3 Fig. 1
Fig. 2
MATERIALSC1005342 – Female disconnect terminals
B1004229 – Auxiliary contactsC11008-02 – Control box housing
B1003498 – Battery discharge gaugeB1004227 – Auxiliary contact block
B1004228 – 3 position button-selection knob1014004 – 14 AWG red wire (5 ½”, 3 5/8”, and 1¾” section)
107086 – Cable tie
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
Page | 65
B1004227
C11008-02
B1004227
B1004229B1004228
B1004227
B1004229
B1004228
B1004229C11008-04
B1004228
B1004227
Fig. 1Fig. 2
Fig. 3
Fig. 4
MATERIALSC1005278 – Angled set power cord assembly
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
PROCEDURESAssembling the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
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
MATERIALSB106483 – Small ring terminal crimp connectors
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 67
Fig. 3Fig. 1
B106483
B106483
B106483
B10648319610C11008-02
C11008-06
C11008-06C1005342
Fig. 2
Fig. 4
MATERIALSC1005342 – Female disconnect terminals
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
PROCEDURESAssembling the control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
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
Scissors Lift Pump Assembly 0000-000-000
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
C11008-02 – Control box housingC11008-06 – Control box rear plate
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
Scissors Lift Pump Assembly 0000-000-000
Page | 70
Template
C1001219C11008-07
Mounting plate template
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11008-07 – Display board mounting plateP13210 – M4-0.7 x 10 button head socket
C11008-02 – Control box housingC11008-06 – Control box rear plate
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).
TOOLSPhillips head screwdriver
Scissors Lift Pump Assembly 0000-000-000
Page | 71
C11008-07
Template
C11008-07
Template
Template
Fig. 3
Fig. 1
Fig. 2
MATERIALSC11008-07 – Display board mounting plateP13210 – M4-0.7 x 10 button head socket
C11008-02 – Control box housingC11008-06 – Control box rear plate
C1001219 – Standoff, pem #6-32 x 5/8” L
PROCEDURESAssembling the front panel for a weighing control box (continued)
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
Welding helmetWelding equipment
Scissors Lift Pump Assembly 0000-000-000
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
C11008-02 – Control box housingC11008-06 – Control box rear plate
PROCEDURESAssembling the front panel for a weighing control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 73
C11008-07
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11008-07 – Display board mounting plate
B1003456 – Display with membrane
PROCEDURESAssembling the front panel for a weighing control box (continued)
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
Scissors Lift Pump Assembly 0000-000-000
Page | 74
C11008-07B1003456
B1003456
B1003456
Display
Membrane
Fig. 3
Fig. 2
Fig. 3
MATERIALSC11008-07 – Display board mounting plate
B1003456 – Display with membraneP13210 – M4-0.7 x 10 button head socket
C11008-02 – Control box housingC11008-06 – Control box rear plate
PROCEDURESAssembling the front panel for a weighing control box (continued)
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).
TOOLSPhillips head screwdriver
2.5 MM Allen wrench
Scissors Lift Pump Assembly 0000-000-000
Page | 75
C11008--02
B1003456
B1003456
B1003456
Fig. 2
Fig. 3
Fig. 1
MATERIALSFoam backing
C11008-02 – Control box housingC11008-06 – Control box rear plate
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
Scissors Lift Pump Assembly 0000-000-000
Page | 76
C11008-06C11008-02Fig. 3
C11008-06
C11008-02
Fig. 2C11008-02 Fig. 1C11008-02
Fig. 4
MATERIALSC11008-02 – Control box housing
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).
TOOLSPhillips head screwdriver
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
Scissor Lift Table Assembly 0000-000-000
PAGE 78
C11002-05
C11002-03
Angle
Fig. 3
C11002-03C11002-05
Fig. 1
Fig. 2
C11002-03
C11002-05
MATERIALSC11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right
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)
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsSquare
Drawing No. C11002
Scissor Lift Table Assembly 0000-000-000
PAGE 79
C11002-02C11002-02
C11002-02
Fig. 2Fig. 3
C11002-03
C11002-05
C11002-05
C11002-03C11002-05
Fig. 1
MATERIALSC11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right
C11002-05 – Handle frame base (2 needed)C11002-04 – Handle frame support
TOOLSMarker
Tape measureClampsSquare
Drawing No. C11002
Scissor Lift Table Assembly 0000-000-000
PAGE 80
C11002-04
C11002-03
C11002-05
C11002-02
C11002-05
C11002-04Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Rubber-tipped hammerBar clamp
ClampsSquare
Drawing No. C11002
Scissor Lift Table Assembly 0000-000-000
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
C11002-04 – Handle frame supportC11002-05 – Handle frame base (2 needed)
TOOLSLeather welding gloves
Welding helmetWelding equipment
Clamps Drawing C11002
Scissor Lift Table Assembly 0000-000-000
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
MATERIALSC11002-01 – Round handle section
C11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right
C11002-04 – Handle frame supportC11002-05 – Handle frame base (2 needed)
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Square Rubber-tipped hammerDrawing No. C11002
Scissor Lift Table Assembly 0000-000-000
PAGE 83
C11002-02
C11002-04
C11002-01
C11002-01
C11002-04C11002-03
C11002-01
C11002-03
C11002-04Fig. 1
Fig. 3
Fig. 2
MATERIALSC11002-01 – Round handle section
C11002-02 – Handle frame upright – left C11002-03 – Handle frame upright – right
C11002-04 – Handle frame support C11002-05 – Handle frame base (2 needed)
TOOLSClamps
Portable power jackSquare
Drawing C11002
Scissor Lift Table Assembly 0000-000-000
Page 84
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
Scissor Lift Table Assembly 0000-000-000
Page 85
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsSquare
Bar clampTape measure
Drawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page 86
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
Scissor Lift Table Assembly 0000-000-000
Page 87
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
B1004280 – Handle outer pivot bracket (2 needed)
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
Scissor Lift Table Assembly 0000-000-000
Page 88
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
B1004280 – Handle outer pivot bracket (2 needed)
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Clamps(4) 1/8” shims
Rubber-tipped hammerTape measure
Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 89
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
Scissor Lift Table Assembly 0000-000-000
Page 90
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
Scissor Lift Table Assembly 0000-000-000
Page 91
Fig. 3
C11002 C11006-01
C11006-02C11002
C11002
C11006-01
C11006-03
C11006-02
Fig. 1
Fig. 2
Fig. 4
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
TOOLSClamps
Bar clampSquare
Rubber-head hammerDrawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 92
C11006-12
C11006-01
C11006-03C11006-01
Mounting holes
Fig. 1
Fig. 1
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 memberC11006-07 – End cross member
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampBar clamp
SquareDrawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 93
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
C11006-12 – Load cell mounting memberC11006-07 – End cross member
TOOLSWire brush
Leather welding glovesWelding helmet
Welding equipmentClampSquare
Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 94
C11006-02C11006-07
C11006-03C11006-01
C11006-02
C11006-07Fig. 1
C11006-01
C11006-03
Fig. 1
Fig. 1
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
C11006-12 – Load cell mounting memberC11006-07 – End cross member
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampSquare
1/8” to ¼” spacer (depending on thickness of length members)Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 95
Fig. 11/8” spacer
Straight edge
Fig. 3
Fig. 2
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
C11006-12 – Load cell mounting memberC11006-07 – End cross member
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
Scissor Lift Table Assembly 0000-000-000
Page 96
Fig. 2Fig. 1
MATERIALSB1004203 – Lower slide rail
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 memberC11006-07 – End cross member
TOOLSTape measure
MarkerSquare
Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 97
Fig. 1
Long slot, position near vertical member
Short slot, position near center of frame
Marking
Fig. 1
Fig. 1
MATERIALSB1004203 – Lower slide rail
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 memberC11006-07 – End cross member
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampSide spacers
SquareDrawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 98
Fig. 1
Tack weldAlign stop pin sleeve hole
Side spacer
Fig. 1
Fig. 1
MATERIALSB1004203 – Lower slide rail
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 memberC11006-07 – End cross member
PROCEDURESInstalling the lower slide rail (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page 99
Hold-down barFig. 1
5/8” spacerWedge
Fig. 2
Fig. 3
MATERIALSB1004203 – Lower slide rail
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 memberC11006-07 – End cross member
PROCEDURESInstalling the lower slide rail (continued)
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampHold-down bar
5/8” spacerWooden wedge
Spacer Square
Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 100
Fig. 1
Fig. 2
Fig. 3
MATERIALSB1004282 – Base frame pivot bracket (4 needed)
C11006-03 – Cross memberB1004203 – Lower slide rail
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 memberC11006-07 – End cross member
TOOLSTape measure
Marker Drawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 101
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)
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
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
TOOLSLeather welding gloves
Welding helmetWelding equipment
SquareDrawing C11006
Scissor Lift Table Assembly 0000-000-000
Page 102
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
Scissor Lift Table Assembly 0000-000-000
Page 103
Hold-down barC11002Fig. 1
Fig. 3
Fig. 2
MATERIALSC11002 – Pivot handle assemblyC11006 – Base frame assembly
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
Welding helmetWelding equipment
Compressed airDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page 104
Spacer
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11006 – Base frame assembly
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
Scissor Lift Table Assembly 0000-000-000
Page 105
Spacer
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11002 – Pivot handle assemblyC11006 – Base frame assembly
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
Scissor Lift Table Assembly 0000-000-000
Page 106
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
Welding helmetWelding equipment
Center punchDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page 107
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Drawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page 108
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
Welding helmetWelding equipment
1/32” metal shimDrawing No. C11007
Scissor Lift Table Assembly 0000-000-000
Page 109
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
Leather welding glovesWelding helmet
Welding equipmentFixture
Drawing No. C11007
Scissor Lift Table Assembly 0000-000-000
Page 110
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
Welding helmetWelding equipment
Fixture Drawing No. C11007
Scissor Lift Table Assembly 0000-000-000
Page 111
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
Leather welding glovesWelding helmet
Welding equipmentDrawing No. C11005
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 113
C11005-01
C11005-01
Short end
Long end
C11005-01 Fig. 1
Fig. 2
Fig. 3
MATERIALSC11005-01 – Length member (2 needed)
C11005-02 – Pivot piece (2 needed)C11005-04 – Short cross member
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
Welding helmetWelding equipment
Drawing No. C11005
Scissor Lift Table Assembly 0000-000-000
Page | 114
C11005-01C11005-02
C11005-04
C11005-03
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11005-01 – Length member (2 needed)
C11005-02 – Pivot piece (2 needed)C11005-04 – Short cross member
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
Leather welding glovesWelding helmet
Welding equipmentSquare
Portable power jackBlocks of wood
Drawing No. C11005
Scissor Lift Table Assembly 0000-000-000
Page | 115
Fig. 1
C11005-01
C11005-02C11005-04
C11005-03
Fig. 2
Fig. 3
MATERIALSC11005-01 – Length member (2 needed)
C11005-02 – Pivot piece (2 needed)C11005-04 – Short cross member
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
Leather welding glovesWelding helmet
Welding equipmentDrawing No. C11005
Scissor Lift Table Assembly 0000-000-000
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
Welding helmetWelding equipment
1” x 4” metal bar¼” spacer
Drawing C11004
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 118
C11004-01
C11004-03
C11004-01
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11004-01 – Top frame length member (2 needed)
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
Scissor Lift Table Assembly 0000-000-000
Page | 119
Tap hole C11004-03C11004-03
C11004-01
C11004-03
C11004-04
C11004-01
Fig. 2Fig. 3 Fig. 1
MATERIALSC11004-01 – Top frame length member (2 needed)
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 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
Scissor Lift Table Assembly 0000-000-000
Page | 120
C11004-04 has tap hole
C11004-01 C11004-02
C11004-02 has weep hole
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004-01 – Top frame length member (2 needed)
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
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
Welding helmetWelding equipment
5/8” spacerDrawing C11004
Scissor Lift Table Assembly 0000-000-000
Page | 121
C11004-04C11004-02
C11004-03C11004-01
C11004-04
Fig. 1
Fig. 2Fig. 3
MATERIALSC11004-01 – Top frame length member (2 needed)
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Clamps¼” plate
Drawing C11004
Scissor Lift Table Assembly 0000-000-000
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
Clamps Drawing C11004
Scissor Lift Table Assembly 0000-000-000
Page | 123
C11004-03C11004-07
C11004-03Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
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
Scissor Lift Table Assembly 0000-000-000
Page | 124
C11004-06
C11004-06
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11004 – Top frame assembly
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
Scissor Lift Table Assembly 0000-000-000
Page | 125
Fig. 2
C11004-06Fig. 1
Hold-down bar
C11004-06
Tack weldBrass spacer
Fig. 3
MATERIALSC11004 – Top frame assembly
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsHammer
Wooden wedgeDrawing No. C11004
Scissor Lift Table Assembly 0000-000-000
Page | 126
Wedge
C11004-06
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11004 – Top frame assembly
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsTape measure
Marker ¼” plate
Drawing No. C 11004
Scissor Lift Table Assembly 0000-000-000
Page | 127
Measure 13/64” from edge
B1004284 Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
B1004284 – Top frame outer pivot bracketB1004286 – Top frame inner pivot bracket
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsTape measure
Marker ¼” plate
Drawing No. C 11004
Scissor Lift Table Assembly 0000-000-000
Page | 128
B1004284
B1004286
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsTape measure
MarkerPower drill
Sanding discDrawing No. C11004
Scissor Lift Table Assembly 0000-000-000
Page | 129
C11004-09Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
B1004284 – Top frame outer pivot bracketB1004286 – Top frame inner pivot bracket
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsGrounding cable2 blocks of wood
Drawing No. C11004
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 131
C11004-05C11004-05
Fig. 1
Long side
Short side
C11004-05
Fig. 3
Fig. 2
MATERIALSC11004-05 – Top frame support angle (2 needed)
C11004 – Top frame assembly
PROCEDURESAttaching the top frame support angle
(continued) Drawing No. C11004
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
Scissor Lift Table Assembly 0000-000-000
Page | 132
C11004-03
C11004-03
C11004-05
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004-05 – Top frame support angle (2 needed)
C11004 – Top frame assembly
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsSpacers¾” bar
18 or 20 gauge shimDrawing No. C11004
Scissor Lift Table Assembly 0000-000-000
Page | 133
18 or 20 gauge shim
¾” barFig. 1
Fig. 3
Fig. 2
MATERIALSC11004-05 – Top frame support angle (2 needed)
C11004 – Top frame assembly
PROCEDURESAttaching the top frame support angle
(continued) Drawing No. C11004
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsSpacers¾” bar
18 or 20 gauge shimDrawing No. C11004
Scissor Lift Table Assembly 0000-000-000
Page | 134
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004-05 – Top frame support angle (2 needed)
C11004 – Top frame assembly
PROCEDURESAttaching the top frame support angle
(continued) Drawing No. C11004
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).
TOOLSLeather welding gloves
Welding helmetWelding equipment
ClampsSpacers¾” bar
18 or 20 gauge shimDrawing No. C11004
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 136
C11006
Fig. 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
TOOLSDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page | 137
Directional lock
No directional lock
Fig. 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
113068 – Anti-seize compound
PROCEDURESAttaching the casters
(continued) Drawing No. C11006
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).
TOOLSDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page | 138
B1004263 and B1004269
B1004287
B1004287
Fig. 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
TOOLSRatchet
13 MM socket10 MM Allen wrench
Steel tube to grip Allen wrenchDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page | 139
Fig. 1
Fig. 2
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
PROCEDURESAttaching the casters
(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.
TOOLSDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
Page | 140
Foot lockFig. 1
Fig. 2
Fig. 3
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
3M Silicone Lubricant
PROCEDURESAttaching the casters
(continued) Drawing No. C11006
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).
TOOLSDrawing No. C11006
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 142
Mounting angle
Base frame
Mounting holes aligned
Hydraulic brackets
Flow control valve
Mounting angles
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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).
TOOLSPhillips head screwdriver
Drawing No. C11000
Scissor Lift Table Assembly 0000-000-000
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
TOOLSDrawing No. C11000
Scissor Lift Table Assembly 0000-000-000
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)
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
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
Scissor Lift Table Assembly 0000-000-000
Page | 145
C11006-15
C1003580 and C1003219
C11006-15
C11006-15
3 3/16” measurement
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assembly
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)
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)C11017 – Load cell spacer (2 needed)
TOOLSDrawing No. C11001
Scissor Lift Table Assembly 0000-000-000
Page | 146
C11017
Position with arrow up
C1003287
C1003287
Fig. 1
Fig. 2
Fig. 2
MATERIALSC11006 – Base frame assembly
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)
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)C11017 – Load cell spacer (2 needed)
113068 – Anti-seize compound
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
19 MM socketDrawing No. C11001
Scissor Lift Table Assembly 0000-000-000
Page | 147
C1003580 and C1003219
C1003287
C1003287
B1004253
C1003287B1004300 and B1004263
Fig. 1
Fig. 2
Fig. 2
MATERIALSC11006 – Base frame assembly
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)
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)C11017 – Load cell spacer (2 needed)
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
Scissor Lift Table Assembly 0000-000-000
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
17 MM socketDrawing No. C11000
Scissor Lift Table Assembly 0000-000-000
Page | 149
B1004202
B1004201Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyB1004201 – Hydraulic cylinder
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
Scissor Lift Table Assembly 0000-000-000
Page | 150
B1004201 Brass washerB1004202
B1004201
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyB1004201 – Hydraulic cylinder
B1004202 – Hydraulic hose assemblyB1004251 – Hex head bolt, M12-1.75 x 90B1004300 – M12 flat washer (2 needed)
B1004263 – M12 nyloc nutBrass washer (2 needed)
TOOLS
2 Ratchets(2) 19 MM sockets
Drawing No.C11000
Scissor Lift Table Assembly 0000-000-000
Page | 151
Brass washer B1004300
B1004201 B1004263Brass washer
B1004201
B1004202
B1004251B1004201
Brass washer
B1004251
B1004300
B1004202
Fig. 3 Fig. 1
Fig. 2
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
C1002599 – Directional flow control valveB1004201 – Hydraulic cylinder
B1004202 – Hydraulic hose assemblyB1004251 – Hex head bolt, M12-1.75 x 90B1004300 – M12 flat washer (2 needed)
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
Scissor Lift Table Assembly 0000-000-000
Page | 152
C11003
B1004202
C11003
C1002599B1004202
S shape
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
C1002601 – Hydraulic power unitB1004201 – Hydraulic cylinder assembly
1000219 – Hydraulic fluid, ISO Grade 68 Visc. 335
PROCEDURESInstalling the hydraulic cylinder (continued) Drawing No. C11000
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
Scissor Lift Table Assembly 0000-000-000
Page | 153
C1002601
1000219
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
C1002601 – Hydraulic power unit1000219 – Hydraulic fluid, ISO Grade 68 Visc. 335
PROCEDURESInstalling the hydraulic cylinder (continued) Drawing No. C11000
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
Scissor Lift Table Assembly 0000-000-000
Page | 154
1000219
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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
Scissor Lift Table Assembly 0000-000-000
Page | 155
Work wire puller through hole
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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
Scissor Lift Table Assembly 0000-000-000
Page | 156
Push wires through hole
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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)
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
Scissor Lift Table Assembly 0000-000-000
Page | 157
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assemblyB1004293 – Rubber grommet
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 158
B1004293
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
1014005 – 14 AWG blue wire (105” length)1014007 – 14 AWG brown wire (105” length)
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 159
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
1014005 – 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)
107086 – Cable tiesB1004293 – Rubber grommet
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 160
B1004293Fig. 1
Fig. 3
Fig. 2
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
C11003-06 – Battery box cable coverB1004293 – Rubber grommet
1014005 – 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)
1078562 – Phillips #8-32 x 0.3125 round head screw (2 needed)
PROCEDURESWiring the battery box to the control box (continued)
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
Phillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
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
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 162
C11008-05
C11008-05
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-02 – Control box housing
C11008-05 – Control box rear panelB1004293 – Rubber grommet
1014005 – 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)
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 163
C11008-02
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel1001745 – M6-1.0 x 16 SHCS (4 needed)
Lock washer
PROCEDURESWiring the battery box to the control box (continued)
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
Phillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
Page | 164
1001745 Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel1014005 – 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)
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 165
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel1014005 – 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)
PROCEDURESWiring the battery box to the control box (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 166
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel1014005 – 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)B1004227 – Auxiliary contact block
PROCEDURESWiring the battery box to the control box (continued)
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).
TOOLSPhillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
Page | 167
B1004227
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panelB106483 – Small ring terminal crimp connectors
1014005 – 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)
C1003483 – Male disconnect terminalsC1005342 – Female disconnect terminals
107086 – Cable ties
PROCEDURESWiring the battery box to the control box (continued)
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).
TOOLSPhillips head screwdriver
Crimping tool
Scissor Lift Table Assembly 0000-000-000
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
Scissor Lift Table Assembly 0000-000-000
Page | 169
Frame length holeTape
C1003287B1004293
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panelC1003287 – Load cell
B1004293 – Rubber grommet
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
Scissor Lift Table Assembly 0000-000-000
Page | 170
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panelC1003287 – Load cell
B1004293 – Rubber grommet
PROCEDURESWiring the load cells to the control box for weighing units (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 171
B1004293
B1004293
C11008-2
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panelB106483 – Small ring terminal crimp connectors
1014001 – 14 AWG black wire (20” section)1014004 – 14 AWG red wire (5” section)
B1003456 – Display with membrane
PROCEDURESWiring the load cells to the control box for weighing units (continued)
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
Phillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
Page | 172
Fig. 2B106483
10140041014001
Fig. 1
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panelB106483 – Small ring terminal crimp connectors
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)
PROCEDURESWiring the load cells to the control box for weighing units (continued)
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).
TOOLSPhillips head screwdriver
3/8” nut driver
Scissor Lift Table Assembly 0000-000-000
Page | 173
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel
PROCEDURESWiring the load cells to the control box for weighing units (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 174
Twist to single strand
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
C11008-05 – Control box rear panel1014001 – Black 14 AWG (1” section)1014004 – Red 14 AWG (!” section)
PROCEDURESWiring the load cells to the control box for weighing units (continued)
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
Scissor Lift Table Assembly 0000-000-000
Page | 175
1014001
1014004
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
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
PROCEDURESWiring the battery box to the control box (continued)
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
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Page | 176
Fig. 3C1005342 and C1005343
C11008-05
Fig. 1
Fig. 2
MATERIALSC11002 – Pivot handle assemblyC11008-2 – Control box housing
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
113068 – Anti-seize compound
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
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C11002
C11002
B1004269 and B1004263
C11002
B1004294
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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
Scissor Lift Table Assembly 0000-000-000
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B1002757
B1002757
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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
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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
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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
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Fig. 1
Fig. 2
Fig. 3
MATERIALSC11006 – Base frame assemblyC11003 – Battery box assembly
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).
TOOLSPhillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
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Amber light shows charging; green light shows changed C11003-06
C11003-06
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11005 – Scissor frame “B” assembly
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
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C11005
C11005
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11005 – Scissor frame “B” assembly
C11006 – Base frame assemblyB1004251 – Hex head bolt, M12-1.75 x 90
B1004299 – #10 flat washerB1004262 – M10 nyloc nut
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
MATERIALSC11005 – Scissor frame “B” assembly
C11006 – Base frame assemblyB1004201 – Hydraulic cylinder
B1004251 – Hex head bolt, M12-1.75 x 90B1004299 – #10 flat washerB1004262 – M10 nyloc nut
Brass washer113068 – Anti-seize compound
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
Scissor Lift Table Assembly 0000-000-000
Page | 185
B1004201
Brass washer
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11005 – Scissor frame “B” assembly
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
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C11018
C11018C1003483
C11019C11005C11005
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11005 – Scissor frame “B” assembly
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth4 sections of cardboard
Phillips head screwdriverRatchet
13 MM socket
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C11005
C11005
C11005
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11005 – Scissor frame “B” assembly
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
MATERIALSC11004 – Top frame assembly
C11005 – Scissor frame “B” assemblyC11006 – Base frame assembly
C11007 – Scissor tie piece weldment (2 needed)B1004254 – Hex head bolt, M10-1.5 x 75
B1004299 – #10 flat washerB1004262 – M10 nyloc nut
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
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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
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Page | 190
C11005
C11004
C11005
C11004 C11004-06
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
C11005 – Scissor frame “B” assemblyC11006 – Base frame assembly
C11007 – Scissor tie piece weldment (2 needed)B1004254 – Hex head bolt, M10-1.5 x 75
B1004299 – #10 flat washerB1004262 – M10 nyloc nut
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
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Fig. 2
Fig. 3
C11004C11004
C11004
C11007
B1004254 B1004299
Fig. 1
MATERIALSC11004 – Top frame assembly
C11005 – Scissor frame “B” assemblyC11006 – Base frame assembly
C11007 – Scissor tie piece weldment (2 needed)B1004254 – Hex head bolt, M10-1.5 x 75
B1004299 – #10 flat washerB1004262 – M10 nyloc nut
Brass washer113068 – Anti-seize compound
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
Scissor Lift Table Assembly 0000-000-000
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
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C11006-14
C11006-14
C11006-14
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11006 – Base frame assembly
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
Scissor Lift Table Assembly 0000-000-000
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).
TOOLSPhillips head screwdriver
Ratchet2.5 M socket
Scissor Lift Table Assembly 0000-000-000
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
PROCEDURESInstalling the body tray adjusting shaft
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
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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
PROCEDURESInstalling the body tray adjusting shaft
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
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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
PROCEDURESInstalling the body tray adjusting shaft
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).
TOOLSPhillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
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).
TOOLSPhillips head screwdriver
Wire cutter
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B1004204
10547
Fig. 3
Fig. 2
Fig. 1
MATERIALSC11015 – Body tray securing peg
236042 – Phillips #8-32 x 0.5 pan head screw796036 – #6 flat washer
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
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10547
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11015 – Body tray securing peg
236042 – Phillips #8-32 x 0.5 pan head screw796036 – #6 flat washer
C1003463 – Stainless steel loop chainLoctite 290
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).
TOOLSPhillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
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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
PROCEDURESAttaching the body tray securing peg (continued)
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
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Page | 202
C11004236042
C11004
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11015 – Body tray securing peg
236042 – Phillips #8-32 x 0.5 pan head screw796036 – #6 flat washer
C1003463 – Stainless steel loop chainLoctite 290
PROCEDURESAttaching the body tray securing peg (continued)
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
Phillips head screwdriver
Scissor Lift Table Assembly 0000-000-000
Page | 203
C11015
C11015
C1003463
Fig. 3
Fig. 1
Fig. 2
MATERIALSC11004 – Top frame assembly
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth
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C11016
C11016
B1004215
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11004 – Top frame assembly
C11016 – Ball unit top panelB1004215 – Ball transfer roller
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
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B1004215
C11004
B1004215
Roller retaining clamp
Pipe
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
C11016 – Ball unit top panelB1004215 – Ball transfer roller
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
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Roller retaining clamp
Chrome tape
B1004215B1004204
B1004205
Fig. 1
Fig. 2
Fig. 3
MATERIALSC11004 – Top frame assembly
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
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11016
Fig. 1
Fig. 3
Fig. 2
MATERIALSC11004 – Top frame assembly
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).
TOOLSPhillips head screwdriver
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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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth
Scissor Lift Table Assembly 0000-000-000
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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
Scissor Lift Table Assembly 0000-000-000
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).
TOOLSIsopropyl alcohol in a spray bottle
Soft lint-free cloth
Scissor Lift Table Assembly 0000-000-000
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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
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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.
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Fig. 1
Fig. 2
Fig. 3
Top Related