Download 37274 COF (Rev A) - Commercial Wheelchair Lifts
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Service Manual for: UVL601C UVL603C UVL603C24 Under-Vehicle Lift® Series 04 www.braunability.com/international ISO 9001:2008 631 West 11th Street, Winamac, IN 46996, USA Phone: +1 574 946 6153 Fax: +1 574 946 4670 37274 Rev. A January 2012 Original Instructions Congratulations We at The Braun Corporation wish to express our fullest appreciation on your new purchase. With you in mind, our skilled craftsmen have designed and assembled the finest lift available. This manual provides maintenance and service-related material. Braun UVL Series™ lifts are built for dependability and will provide years of pleasure and independence as long as the lift is properly maintained and operated by an instructed person. Sincerely, THE BRAUN CORPORATION Ralph W. Braun Chief Executive Officer Warranty Consult your local Braun dealer regarding warranty policy. www.braunlift.com/international The Braun Corporation 1-800-THE LIFT® BRAUNLIFT.COM® MODEL NUMBER Model No. XXXXXXXXXX SERIAL NUMBER Serial No. XX-XXXXX MFG DATE DatHRI0DQXIDFWXUH XX/XX/XXXX 6DPSOH6HULDO1R6HULHV1R,GHQWLÀFDWLRQ7DJ Serial No. Model No. OWNER'S WARRANTY REGISTRATION XXXXXXXXXX XX-XXXXX PURCHASED FROM OWNER DATE INSTALLED NAME ADDRESS CITY TELEPHONE STATE ZIP TO VALIDATE WARRANTY REGISTRATION CARDS MUST BE RETURNED TO THE BRAUN CORPORATION. Sample Warranty/Registration Card Contents Service Safety Precautions .......................................... 2-3 /LIW6SHFLÀFDWLRQV............................................................. 4 Lift Terminology ............................................................... 5 Switch and Sensor Locations .......................................... 6 Switch LED Diagnostics .................................................. 7 Carriage Adjustments ...................................................... 7 Floor Level and Bridge Plate Adjustments.................. 8-11 Static and Dynamic Tests ......................................... 12-13 Maintenance and Lubrication ................................... 14-18 Troubleshooting Diagnosis Chart ............................. 19-22 UVL601C / UVL603C (12V) Lift Electrical Schematic ... 23 UVL603C24 (24V) Lift Electrical Schematic .................. 24 Hydraulics Parts List ...................................................... 26 Hydraulics Diagram ....................................................... 27 UVL601C / UVL603C (12V) Pump Module Parts List ... 28 UVL601C / UVL603C (12V) Pump Module Diagram ..... 29 UVL603C24 (24V) Pump Module Parts List .................. 30 UVL603C24 (24V) Pump Module Diagram ................... 31 UVL601C Repair Parts List ........................................... 32 UVL601C Housing Detail............................................... 33 UVL601C Carriage Detail .............................................. 34 UVL601C Platform Detail .............................................. 35 UVL603C / UVL603C24 Repair Parts List ..................... 36 UVL603C / UVL603C24 Housing Detail ....................... 37 UVL603C / UVL603C24 Carriage Detail ...................... 38 UVL603C / UVL603C24 Platform Detail ....................... 39 Declaration of Conformity - Machinery ..................... 40-41 Declaration of Noise Emission....................................... 42 Declaration of Conformity - EMC ................................... 43 Document Cross Reference Owner Manual #37275 Page 1 Service Safety Precautions Safety Symbols SAFETY FIRST! Know That.... The information contained in this manual and VXSSOHPHQWVLILQFOXGHG is provided for your use and safety. Familiarity with proper LQVWDOODWLRQRSHUDWLRQPDLQWHnance and service procedures LVQHFHVVDU\WRHQVXUHVDIH troublefree lift operation. Safety precautions are provided to LGHQWLI\SRWHQWLDOO\KD]DUGRXV situations and provide instruction on how to avoid them. A D NOTICE E 36513 B WARNING This symbol indicates important safety information regarding a potentially hazardous situation that could result in serious bodily injury and/or property damage. C CAUTION This symbol indicates important information regarding how to avoid a hazardous situation that could result in minor personal injury or property damage. $GGLWLRQDOLQIRUPDWLRQSURYLGHGWRKHOSFODULI\RUGHWDLODVSHFLÀFVXEMHFW This symbol indicates that there are dangerous high voltages present inside the HQFORVXUHRIWKLVSURGXFW7RUHGXFHWKHULVNRIÀUHRUHOHFWULFVKRFNGRQRWDWWHPSW to open the enclosure or gain access to areas where you are not instructed to do VR5HIHUVHUYLFLQJWRTXDOLÀHGVHUYLFHSHUVRQHORQO\ F This symbol indicates that a condition where damage to the equipment resulting injury could occur if operational procedures are not followed. To reduce the risk of GDPDJHRULQMXU\UHIHUWRDFFRPSDQ\LQJGRFXPHQWVIROORZDOOVWHSVRUSURFHGXUHV as instructed. G This symbol indicates an area to avoid bodily contact to prevent injury. 36514 H I This symbol indicates the presence of high pressure hydraulic hoses. Use appropriate personal protective equipment when working on hydraulic system. 7KLVV\PEROLQGLFDWHVWKHSUHVHQFHRIDÀUHKD]DUG$YRLGRSHQÁDPHVRUVSDUNV ZKHQZRUNLQJZLWKÁDPPDEOHPDWHULDOVWRSUHYHQWLQMXU\RUGDPDJH These symbols will appear throughout this manual as well as on the labels posted on your lift. Recognize the seriousness of this information. Page 2 Service Safety Precautions Service Safety Precautions WARNING If maintenance or repair procedures cannot be completed exactly as provided in this manual or if the instructions are not fully understood, contact The Braun Corporation immediately. Failure to do so may result in serious bodily injury and/ or property damage. WARNING 5HDGWKLVPDQXDOVXSSOHPHQWVDQGRSHUDWLQJLQVWUXFtions decals before performing operation or service procedures. WARNING Use appropriate personal protective equipment when servicing the lift. WARNING &KHFNIRUREVWUXFWLRQVVXFKDVJDVOLQHVZLUHVH[KDXVW etc. before drilling or cutting on vehicle. WARNING 5RXWHDOOFDEOHVFOHDURIH[KDXVWV\VWHPRWKHUKRWDUHDV PRYLQJSDUWVZHWDUHDVHWF WARNING 5LVNRIHOHFWULFDOVKRFNRUÀUH8VHH[WUDFDUHZKHQ making electrical connections. Connect and secure as outlined in Installation Instructions and Wiring Diagrams. WARNING $GMXVWYHKLFOHÁRRUOHYHOSRVLWLRQLQJRIEULGJHSODWHEHIRUHRSHUDWLQJOLIWZLWKSDVVHQJHU WARNING 0DLQWHQDQFHDQGUHSDLUVPXVWEHSHUIRUPHGRQO\E\DXWKRUL]HGVHUYLFHSHUVRQQHO WARNING 3HUIRUPPDLQWHQDQFHDQGOXEULFDWLRQSURFHGXUHVH[DFWO\DVRXWOLQHGLQWKH0DLQWHnance and Lubrication Schedule contained in this manual. WARNING Disconnect the power cable at the battery prior to servicing. WARNING Never modify (alter) a Braun Corporation lift. WARNING 5HSODFHPHQWSDUWVPXVWEH%UDXQDXWKRUL]HGUHSODFHPHQWV WARNING Never install screws or fasteners (other than factory equipped). WARNING :KHQHYHUUHSODFLQJDK\GUDXOLFF\OLQGHURUVHDOVORZHUSODWIRUPIXOO\ WARNING Failure to follow these safety precautions may result in serious bodily injury and/or property damage. Page 3 Lift Specifications 7KHOLIWPXVWEHLQVWDOOHGRSHUDWHGDQGPDLQWDLQHGDVGHWDLOHGLQDSSOLFDEOH manual. Any use of equipment other than instructed in this manual is prohibited. 7KH89/&DQG89/&KDYHFRPSOHWHGF\FOHVZLWKDNJOEORDGDQGDVWDWLF load test with a 1020 kg (2250 lb) load. Operating Temperature This equipment will operate in its intended ambient at a minimum between +5ºC and +40ºC. Relative Humidity 7KLVHTXLSPHQWZLOORSHUDWHFRUUHFWO\ZLWKLQDQHQYLURQPHQWDW5+DW& Altitude This equipment will operate correctly up to 1000m above mean sea level. Sound Pressure Level 7KHHPLVVLRQVRXQGSUHVVXUHOHYHODWWKHRSHUDWRUҋVSRVLWLRQLVH[SHFWHGQRWWRH[FHHGGE$ Transportation and Storage 7KLVHTXLSPHQWZLOOZLWKVWDQGRUKDVEHHQSURWHFWHGDJDLQVWWUDQVSRUWDWLRQDQGVWRUDJHWHPSHUDWXUHV RI&WR&DQGIRUVKRUWSHULRGVRIXSWR& 7KHOLIWKDVEHHQSDFNDJHGWRSUHYHQWGDPDJHIURPWKHHIIHFWVRIQRUPDOKXPLGLW\YLEUDWLRQDQGVKRFN Power Requirements 12 VDC -- UVL601C and UVL603C 24 VDC -- UVL603C24 Lift Weight (Installed) UVL601C -- 155 kg (341 lbs) UVL603C and UVL603C24 -- 166 kg (365 lbs) Lifting Capacity 0D[LPXPNJOEV 60 mm 8 3 mm 4 14 1C -5 60 3C 60 60 1C -7 3C - 8 62 m 12 mm m 63 mm Dimension from top of housing. Page 4 WARN ING Push manuaT-hand and lly le lock out movein fully to Failurbefore engagplatfo and resulte to drivine rm deployin lock gplatfo in uninteplatfovehiclrm platfo ment. nded rm e. resultrm may Uninte platfo and/orin deploy seriou nded rm prope ment s may rty bodily damag injury Do not e. remo ve! 81823 = Center of Gravity Lift Terminology Lift Mounting Brackets (4) Chain Drive Motor Hydraulic Cylinder Hand-Held Pendant Control Bridge Plate Torque Tube Lift Housing Lifting Arms LIFT UP N LIFT DOW W STO LIFT R SE DOO CLO 81812 Ca rria ge Roll Stop Actuator WA RN ING Push manu T-han and ally dle lock out movein fully to Failubefor enga platfo and resulre to e drivin ge rm deplot in lock gplatfo in unint platfovehicrm platfoymen resul rm t. ende rm le. may and/ot in deploUnin d platfo tende serio ymen r prop rm us t d may erty bodil dama y injury Do ge. not rem ove ! 81823 Platform Pump Module Platform Cable-activated Manual Release System Inboard Left Right Rolling +RUL]RQWDO$UPV Roll Stop Outboard Page 5 Switch and Sensor Locations Lift Out Limit Switch 73950A Lift Out Cam 73774 Full Out Limit Switch 73950A Full Out Cam 73775 Below Stow Limit Switch 73950A Floor Level Limit Switch 73950A Floor Level Cam 73712 Below Stow Cam 73712 Roll Stop Limit Switch 73950A LIFT UP LIFT DOWN STOW LIFT E DOOR CLOS 81812 WARN ING Push manuaT-hand and lly le lock out movein fully to before Failure engagplatforand result to driving e platfor m in deployin lock uninteplatfor vehiclem platfor ment. nded m . result m may Uninte platfor and/orin deploy seriou nded m proper ment s may ty bodily damag injury Do not e. remo ve! Pressure Switch 87052 81823 Pressure Switch 73960A Inboard Left Page 6 Right Outboard Switch LED Diagnostics Lift Out Switch: The Lift Out Switch stops inward travel of the carriage/platform during Stow function (activated by the housing-mounted Lift Out Cam). Move cam in to increase inward travel. Move cam out to decrease inward travel. Diagnostic LED “LIFT OUT” will be illuminated when the switch is not contacting the cam. Full Out Switch: The Full Out Switch stops outward travel of the carriage/platform during Deploy (Up/Down) functions (activated by the housing-mounted Full Out Cam). Move cam in to decrease outward travel. Move cam out to increase outward travel. Carriage rollers must be inside housing a minimum 1.3 cm (1/2"). The platform will not raise or lower until this switch is activated. Diagnostic LED “FULL OUT” will be illuminated when the switch is contacting the cam. Floor Level Switch: Diagnostic LED “FL LVL” will be illuminated when the switch is contacting the cam. Detailed on page 8. Below Stow (Stow Start) Switch: The Below Stow Switch controls the height of the carriage/ platform before it moves inward during the Stow function (activated by the torque tube-mounted Stow Start Cam). Rotate the cam in to decrease platform height. Rotate the cam out to increase platform height. Adjust cam so bottom of platIRUPLVÁXVKZLWKWKHKRUL]RQWDODUPVZKHQ switch is activated. Diagnostic LED “BELOW” will be illuminated when platform is at stow start height or below. Carriage Adjustments 36514 Carriage Ride Height Adjustment Drive Chain Adjustment 7KHFDUULDJHKRUL]RQWDODUPVPRYHUROOLQDQG out of the housing tracks on roller bearings. )ROORZLQJLQVWDOODWLRQRUH[WHQVLYHOLIWRSHUDWLRQ FOHDUDQFHEHWZHHQKRUL]RQWDODUPVDQGWUDFNV may diminish. The eccentric shaft mounting plate allows height adjustment. In event the drive chain sags 1.3 cm (1/2") or PRUHDGMXVWWHQVLRQDVGHWDLOHG7LJKWHQWR eliminate visible sag but do not overtighten. Remove eccentric plate mounting screw. UsLQJVFUHZGULYHURUVPDOOURGURWDWHWKHVKDIW clockwise to increase carriage height. Rotate the shaft counterclockwise to decrease carriage height. Reinstall mounting screw in nearest retainer hole. Adjust left and right side eccentric shafts (screw positions may vary from side to VLGH$GMXVWKHLJKWVXFKWKDWKRUL]RQWDODUPVGR not contact top or bottom of tracks (align center). 1. Unlock and pull the manual release cable and lock in released position. 0DQXDOO\H[WHQGSODWIRUPFDUULDJHIXOORXW 3. Remove adjustment bolt (tensioner) access cover. 4. Use deep well socket (long key sleeve) to loosen outside jam nut. Tighten inside jam nut to eliminate visible chain sag but do not overtighten. 5. Lock jam nuts together. Unlock and push the manual cable in fully. Lock release cable. Move the platform in and out until platform chain release assembly engages chain. Access Cover Jam Nuts Figure A Tensioner WAR NING Pu sh ma T-h andnuallyandle loc out mo in full ve Faik bef to eng pla y and ore reslure to driage tform depult in loc vingplatfo in k rm pla loymeuninteplatfovehicle restform nt. nde rm . andult in dep Uninted pla may /or ser loyme ndetform pro iou nt d per s bod ma ty y dam ily inju Do age ry no . t rem ove! 81823 Manual Release Cable Page 7 Floor Level and Bridge Plate Adjustments 36514 $FKLHYLQJSURSHUÁRRUOHYHO positioning of the platform and bridge plate requires a combination of Floor Level switch adjustment and bridge plate adjustPHQW%RWKDUHIDFWRU\VHWEXW ÁRRUOHYHOSRVLWLRQLQJPXVWEH inspected during installation procedures (will vary per vehicle application). Floor Level Requirements: When the lift is positioned at ÁRRUOHYHOUDLVHGIXOO\WKH bottom of the platform must be DERYHÁRRUOHYHODQGWKHEULGJH plate must rest solidly on vehicle ÁRRUZLWKDPLQLPXPRIFP (1.5") of overlap. Ensure the lift is positioned and VHFXUHGDVVSHFLÀHGLQWKHLQstructions supplied with the lift. Adjust the Floor Level switch ÀUVW (detailed below). If the bridge plate does not rest solLGO\RQYHKLFOHÁRRUDGMXVWWKH bridge plate cam as detailed in Cam Adjustment (adjust cam only if necessary). CAUTION Do not adjust bridge plate linkage rod. Linkage rod adjustment may result in lift damage. Do not adjust the bridge plate linkage rod (see Photo J on page 11). The linkage rod should be adjusted to increase usable platform length only (following all other procedures). Floor Level Switch Adjustment The Floor Level switch stops upward travel of the platform during the Up function (activated by the torque tube-mounted Floor Level cam). Hydraulic pressure may affect platform height slightly. Fine tuning adjustment (tweaking) of the Floor Level switch (cam) may be required. OPEN OPEN Hand Pump OSE CL 2. Loosen the clamp securing the torque tubemounted Floor Level cam. See Photo A. Rotate the cam until the Floor Level switch is activated (cam depresses switch). Tighten the clamp securing the cam. OSE CL 1. Position the bottom of the lift platform FPDERYHÁRRUOHYHOXVLQJWKH manual hand pump. See Figure B. Manual Hand Pump VALVE VALVE Pump Handle OPEN CLOSE Figure B Floor Level Cam Valve Floor Level Switch A 8VLQJWKHFRQWUROSHQGDQW FKHFNÁRRUOHYHO position by lowering the platform to stow level and then pressing the UP button until the platform raises fully (stops). If the bridge plate rests solidly on vehicle ÁRRU and has a minimum of 3.8 cm (1.5") RIYHKLFOHÁRRURYHUODS move to page 10 and check the usable platform length as outlined. 4. If the bridge plate does not rest on the veKLFOHÁRRUKRYHUVDERYHÁRRUDGMXVWWKH cam as detailed in the following section. Page 8 Torque Tube Cam depressing switch. Floor Level and Bridge Plate Adjustments Bridge Plate Cam Adjustment $GMXVWWKH)ORRU/HYHOVZLWFKÀUVW (detailed in previous section). If the Floor Level Requirements (at right) are not met - adjust the bridge plate cam as detailed in the following procedures (lift in photos is not a UVL601C/ UVL603C). 1. Position the lift platform below stow level. See Photo B. Lowering the platform will allow access to the cam bolt securement nut. See Photo D. Floor Level Requirements: When the lift is poVLWLRQHGDWÁRRUOHYHOUDLVHGIXOO\WKHERWWRP RIWKHSODWIRUPPXVWEHDERYHÁRRUOHYHODQG the bridge plate must rest solidly on vehicle ÁRRUDQGKDYHDPLQLPXPRIFPRI YHKLFOHÁRRURYHUODS. Stow Level Platform below Stow Level 2. Remove the 1/4"VHUUDWHGÁDQJHQXWVHcuring the lifting arm cam bolt. See Photos C and D. Do not remove the bolt. Stow Level 8VLQJWKHFRQWUROSHQGDQW press the UP button until the platform raises fully (stops). 4. Remove the cam securement bolt (lift bridge plate to relieve pressure on bolt). $OORZWKHEULGJHSODWHWRUHVWRQWKHÁRRU B Continued Cam Bolt C 1/4" Serrated Flange Nut D Page 9 Floor Level and Bridge Plate Adjustments Bridge Plate Cam Adjustment 5. Rotate the cam so the cam follower bearing engages the cam notch (saddle). See Photos E and F. Cam Notch (Saddle) Rota Slider Block te Cam 6. Reinstall the cam securement bolt in one of the three lifting arm holes that aligns best with one of the nine cam holes. See Photos E and F. 5HSRVLWLRQWKHFDPEROWÁDQJHORFN nut. Tighten securely. 7. Use the control pendant to lower lift platform to stow level and then UDLVHSODWIRUPIXOO\WRÁRRUOHYHO (stops). Verify Floor Level Requirements (see previous page). 1RWH$FKLHYLQJSURSHUÁRRUOHYHO positioning of the platform and bridge plate requires a combination RIÁRRUOHYHOVZLWFKDGMXVWPHQWDQG bridge plate cam adjustment. Adjust as needed to meet Floor Level Requirements. Rocker E Lifting Arm (3 available holes) Cam (9 available holes) Cam Notch (Saddle) Engaging Cam Follower Bearing Rota te Cam F Page 10 Floor Level and Bridge Plate Adjustments Usable Platform Length CAUTION Improper bridge plate linkage rod adjustment may result in lift damage. Do not adjust the bridge plate linkage rod unless H[WUD usable platform length is needed. See Photo I. Linkage rod adjustment affects angle of bridge plate (vertical position). If the angle of the bridge plate (when in the vertical position) restricts the usable platform OHQJWKIRUWKHZKHHOFKDLUSDVVHQJHUDGMXVWment of the linkage rod will change the angle. Adjust the bridge plate as detailed in the previRXVSURFHGXUHV7KHQDGMXVWWKHOLQNDJHURG as detailed (only if necessary). If the linkage URGLVRYHUDGMXVWHGWRRORQJRUWRRVKRUWLW ZLOOH[FHHGWKHWUDYHORIWKHVOLGHUEORFNUHVXOWLQJLQGDPDJHWRWKHFDPIROORZHUEHDULQJWKH cam and/or other components. I Linkage Rod Adjustment Bridge Plate 1. Position the lift platform below stow level. 2. Loosen the jam nuts at each end of the linkage rod. Adjust rod length as QHHGHG0LQLPL]HDGMXVWPHQW 3. Carefully check the bridge plate angle and operation using the hand pump. Ensure the linkage rod has not been over adjusted resulting in pressure on components (damage will result). 4. Tighten the linkage rod jam nuts. J Linkage Rod Page 11 Static and Dynamic Tests Compatibility between the lift and the vehicle 7KHLQVWDOOHUVKDOOFRQÀUPWKHFRPSDWLELOLW\EHWZHHQWKHOLIWDQGWKHYHKLFOH Static Test Deformation 7KHXQODGHQSODWIRUPLVSRVLWLRQHGPLGZD\EHWZHHQJURXQGOHYHODQGYHKLFOHÁRRUOHYHODQG PHDVXUHPHQWVDUHWDNHQRIWKHKHLJKWRIWKHSODWIRUPDQGLWVDQJXODUDWWLWXGHUHODWLYHWRWKHYHKLFOHÁRRU A load of 425k is applied to the platform and subsequently removed. %\UHSHDWLQJPHDVXUHPHQWVRIWKHKHLJKWDQGDWWLWXGHRIWKHSODWIRUPYHULI\WKDWQRSHUPDQHQW deformation has occurred in any part of the lift or its attachment to the vehicle which could affect the function of the lift. Drift $ORDGRINJLVDSSOLHGWRWKHSODWIRUPSRVLWLRQHGDWÁRRUOHYHO0HDVXUHPHQWVDUHWDNHQRIWKH KHLJKWRIWKHSODWIRUPDQGLWVDQJXODUDWWLWXGHUHODWLYHWRWKHYHKLFOHÁRRU7KHVHPHDVXUHPHQWVDUH repeated after a 15 minute test period. 9HULI\WKDWWKHYHUWLFDOGULIWRIWKHSODWIRUPEHWZHHQWKHWZRPHDVXUHPHQWVKDVQRWH[FHHGHGPP 9HULI\WKDWWKHDQJXODUGULIWRIWKHSODWIRUPEHWZHHQWKHWZRPHDVXUHPHQWVKDVQRWH[FHHGHG If lift does drift: 1. Deploy lift to ground level. 2. Press circuit board manual override buttons L-UP and L-DN for 20 seconds. 3. Open manual down valve 1 turn and press “UP” on hand pendant for 20 seconds. Close valve. Test to Verify that the Lift Cannot Lift Excessive Load $ORDGRINJLVDSSOLHGWRWKHSODWIRUPSRVLWLRQHGDWJURXQGOHYHO$FWXDWHWKH´83µFRQWURODQG verify that the platform does not lift (tilt is permissible). 1. Lower platform to the ground. 2. Place 425kg at center of platform. 3. Press up switch and verify platform does not lift (tilt is permissible). ,ISODWIRUPGRHVQRWOLIWSURFHHGWR'\QDPLF7HVW,ISODWIRUPGRHVOLIWSURFHHGWRVWHSSXPSUHOLHI valve adjustment is necessary. $FFHVVUHOLHIYDOYHWKURXJKFLUFXLWERDUGPRXQWLQJSODWHDFFHVVKROH/RRVHQKH[QXWRQWKH UHOLHIYDOYHDGMXVWPHQWVFUHZGRQRWUHPRYHKH[QXW 6. Turn adjustment screw counterclockwise1/8 turn. 7. Press up switch and verify platform does not lift (tilt is permissible). ,ISODWIRUPGRHVQRWOLIWWLJKWHQKH[QXWGRQRWWXUQUHOLHIYDOYHDGMXVWPHQWVFUHZZKLOH WLJKWHQLQJKH[QXW,ISODWIRUPGRHVOLIWUHSHDWVWHSVWKURXJK Page 12 Static and Dynamic Tests Dynamic Test :LWKNJDSSOLHGWRWKHSODWIRUPYHULI\WKDWWKHOLIWLVDEOHWRRSHUDWHWKURXJKRXWLWVIXOOUDQJHRI normal lifting and lowering. 1. Lower platform to the ground. 2. Place 340kg at center of platform. 3. Press up switch and verify that the lift is able to operate throughout its full range of normal lifting and lowering movements. ,ISODWIRUPLVDEOHWRRSHUDWHWKURXJKRXWLWVIXOOUDQJHRIQRUPDOOLIWLQJDQGORZHULQJPRYHPHQWVQR DGMXVWPHQWLVQHFHVVDU\,ISODWIRUPGRHVQRWOLIWSURFHHGWRVWHSSXPSUHOLHIYDOYHDGMXVWPHQWLV necessary. $FFHVVUHOLHIYDOYHWKURXJKFLUFXLWERDUGPRXQWLQJSODWHDFFHVVKROH/RRVHQKH[QXWRQWKH UHOLHIYDOYHDGMXVWPHQWVFUHZGRQRWUHPRYHKH[QXW 6. Turn adjustment screw clockwise 1/8 turn. 7. Press up switch and verify lift is able to operate throughout its full range of normal lifting and lowering movement. ,IOLIWGRHVQRWRSHUDWHWKURXJKRXWLWVIXOOUDQJHUHSHDWVWHSVWKURXJK,IOLIWGRHVRSHUDWH WKURXJKRXWLWVIXOOUDQJHWLJKWHQKH[QXWGRQRWWXUQUHOLHIYDOYHDGMXVWPHQWVFUHZZKLOH WLJKWHQLQJKH[QXW Test of Operations and Safety Functions $OOIXQFWLRQVRIWKHOLIWDQGRSHUDWLRQVRIDOOVDIHW\GHYLFHVDUHYHULÀHGDIWHUWKHVWDWLFDQGG\QDPLFWHVWV have been completed. These tests do not apply to pipe break valves nor non-resettable safety devices such as electrical fuses (These items are the subject of a manufacturer’s type test). Relief Valve Adjustment Screw 9/16" +H[1XW Page 13 Maintenance and Lubrication 36513 36514 3URSHUPDLQWHQDQFHLVQHFHVVDU\WRHQVXUHVDIH trouble-free lift operation. Inspecting the lift for DQ\ZHDUGDPDJHRURWKHUDEQRUPDOFRQGLWLRQV should be a part of the transit agency daily service program. Simple inspections can detect potential problems. 3DUNYHKLFOHRQDOHYHOVXUIDFHFOHDURIWUDIÀFDQG bystanders. Place vehicle transmission in “Park” and engage parking brake. Deploy lift to ground level. Provide adequate work space around fullyGHSOR\HGOLIW3HUIRUPVSHFLÀHGPDLQWHQDQFHDQG lubrication procedures (position lift as required). 3XPS0RGXOH:KHQFOHDQLQJWKHH[WHULRURI WKHSXPSPRGXOHÀUVWGLVFRQQHFWWKHXQLWIURP LWVSRZHUVRXUFH'RQRWXVHOLTXLGFOHDQHUV DHURVROVDEUDVLYHSDGVVFRXULQJSRZGHUVRU VROYHQWVVXFKDVEHQ]LQHRUDOFRKRO8VHD soft cloth lightly moistened with a mild detergent solution. Ensure the surface cleaned is fully dry before reconnecting power. Other Components: Clean components and the surrounding area before applying lubricants. Clean only with mild detergent and water. Do not clean with solvents. Allow the lift to dry thoroughly DQGDSSO\OXEULFDQWVDVVSHFLÀHGDIWHUHYHU\ cleaning. LPS2 General Purpose Penetrating Oil is recommended where Light Oil is called out. Use of improper lubricants can attract dirt or other contaminants which could result in wear or damage to Page 14 components. Platform components H[SRVHGWRFRQWDPLnants when lowered to the ground may UHTXLUHH[WUDDWWHQtion. WARNING Maintenance and lubrication procedures must be performed as VSHFLÀHGE\DQ authorized service technician. Failure to do so may result in serious bodily injury and/or property damage. Perform maintenance and lubrication procedures at the scheduled intervals according to the number of cycles. When servicing the OLIWDWWKHUHFRPPHQGHGLQWHUYDOVLQVSHFWLRQDQG OXEULFDWLRQSURFHGXUHVVSHFLÀHGLQWKHSUHYLRXV sections should be repeated. These intervals are a general guideline for scheduling maintenance procedures and will vary acFRUGLQJWROLIWXVHDQGFRQGLWLRQV/LIWVH[SRVHGWR VHYHUHFRQGLWLRQVZHDWKHUHQYLURQPHQWFRQWDPLQDWLRQKHDY\XVDJHHWFPD\UHTXLUHLQVSHFWLRQ and maintenance procedures to be performed PRUHRIWHQWKDQVSHFLÀHG Records of maintainence and service procedures should be maintained. Discontinue lift use if maintenance and lubrication SURFHGXUHVDUHQRWSURSHUO\SHUIRUPHGRULIWKHUH LVDQ\VLJQRIZHDUGDPDJHRULPSURSHURSHUDWLRQ&RQWDFW\RXUDXWKRUL]HGUHSUHVHQWDWLYH Maintenance and Lubrication Lubrication Diagram Drive Chain Release Latch SG Drive Chain and Rollers LO Hydraulic Cylinder Pivot Points LO Carriage Rollers (bearings) LO Torque Tube Pivot Points LO Eccentric Shaft Rollers (bearings) LO Torque Tube Pivot Points LO Lifting Arm Pivot Points and Rollers (bearings) LO 5ROOLQJ+RUL]RQWDO Carriage Tube Slot Area DE Carriage Rollers (bearings) LO Roll Stop Detent Pin LO WA RN ING Push manu T-han and ally dle lock out movein fully to Failubefor enga platfo and resulre to e drivin ge rm deplot in lock gplatfo in unint platfovehicrm platfoymen resul rm t. ende rm le. may and/ot in deploUnin d platfo tende serio ymen r prop rm us t d may erty bodil dama y injur Do ge. y not rem ove ! 81823 Platform Cable-activated Manual Release System Bridge Plate Latch LO Lifting Arm Pivot Points and Rollers (bearings) LO Bridge Plate Linkage Pivot Points LO Bridge plate Hinge Pivot Points LO Roll Stop and Lower Closure Pivot Points LO See the Maintenance/Lubrication Schedule for recommended applications per number of cycles. Lubricant Type 6SHFLÀHGUHFRPPHQGHG Lubricant /LJKW3HQHWUDWLQJ2LO /36*HQHUDO3XUSRVH (30 weight or equivalent) Penetrating Oil 6WDLQOHVV6WLFN 'RRU(DVH DE - Door-Ease Style (tube) Stick (tube) 6\QWKHWLF*UHDVH 0RELOWHPS6+& SG - Synthetic Grease (Multipurpose) LO - Light Oil $YDLODEOH Amount R] Aerosol Can R] R] Tube %UDXQ Part No. 15807 15806 28598 Page 15 Maintenance and Lubrication 750 Cycles Page 16 Roll stop and lower closure pivot points (2) Apply Light Oil - See Lubrication Diagram Roll stop detent pin pivot points (2) Apply Light Oil - See Lubrication Diagram Bridge Plate hinge pivot points Apply Light Oil - See Lubrication Diagram Bridge plate linkage pivot points Apply Light Oil - See Lubrication Diagram Lifting arm pivot points and rollers (bearings) Apply Light Oil - See Lubrication Diagram Inspect roll stop and lower closure for proper operation Correct or replace damaged parts. Inspect roll stop seal and lower closure gasket 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG Inspect roll stop detent pin hairpin cotter Ensure hairpin cotter is present and can be UHPRYHGDQGLQVHUWHGHDVLO\5HVHFXUH replace or correct as needed. ,QVSHFWOLIWIRUZHDUGDPDJHRUDQ\ abnormal condition Correct as needed. Inspect lift for rattles Correct as needed. Check drive chain tension. Pull out and lock manual release cable. Adjust chain tension as needed. See Drive Chain Adjustment. Inspect bridge plate and linkage for: 3URSHURSHUDWLRQ 3RVLWLYHVHFXUHPHQW :HDURUGDPDJH 3URSHUDGMXVWPHQW 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG See Floor Level Switch and Bridge Plate Adjustment Instructions. Check carriage ride height in housing Adjust as needed. See Carriage Ride Height Adjustment. Check stow height/lifting arm alignment /LIWLQJDUPVVKRXOGEHKRUL]RQWDODOLJQHG with each other and aligned with carriage. Adjust as needed. See LED Diagnostics for Below Stow (Stow Start) switch adjustment. Inspect wiring harnesses for VHFXUHPHQWZHDURURWKHUGDPDJH 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG Check lower pan securement 5HVHFXUHUHSODFHGDPDJHGSDUWVRU correct as needed. Torque tube pivot bearings (4 places) Apply Light Oil - See Lubrication Diagram Maintenance and Lubrication 1500 Cycles Carriage rollers (bearings) Apply Light Oil - See Lubrication Diagram Eccentric shaft rollers (bearings) Apply Light Oil - See Lubrication Diagram 5ROOLQJKRUL]RQWDOFDUULDJHDUPVORWDUHD Apply Door Ease - See Lubrication Diagram. Apply to the surface area DURXQGERWKVORWVDQGZLSHRIIH[FHVV Hydraulic cylinder pivot points (4 per cylinder) Apply Light Oil - See Lubrication Diagram Drive chain and chain rollers Apply Light Oil - See Lubrication Diagram Drive chain release latch mechanism Apply Synthetic Grease - See Lubrication Diagram 'HSOR\OLIWUHPRYHORZHUSDQDQGEORZ out housing and platform. Clean housing tracks. 8VHFRPSUHVVRUDQGQR]]OHWRUHPRYH all debris from housing. Use clean cloth and solvent to clean tracks. Clean lower SDQVORWDQGDSSO\DQWLVHL]HWRVORWEHIRUH reinstalling pan. &KHFNGULYHFKDLQWHQVLRQHUMDPQXWVDQG connecting link for securement and/or misalignment. Correct or replace damaged parts and/or relubricate. See Drive Chain Adjustment. Inspect drive chain release latch PHFKDQLVPIRUSURSHURSHUDWLRQSRVLWLYH VHFXUHPHQWZHDURURWKHUGDPDJH Correct or replace damaged parts and/or relubricate. Inspect platform cable-activated manual release system (T-handle/cable assembly and carriage movement) Ensure T-handle release and cable assembly operate properly. Ensure FDUULDJHFDQEHPDQXDOO\H[WHQGHGDQG retracted freely. Inspect limit switches and cams for securement and proper adjustment 5HVHFXUHUHSODFHRUDGMXVWDVQHHGHG See LED Switch Adjustments. ,QVSHFWFDUULDJHOLIWLQJDUPDQGHFFHQWULF shaft rollers (bearings) for wear or GDPDJHSRVLWLYHVHFXUHPHQWDQGSURSHU operation &RUUHFWUHSODFHGDPDJHGSDUWVDQGRU relubricate. ,QVSHFWH[WHUQDOVQDSULQJVHFOLSV &DUULDJHUROOHUEHDULQJV /RZHUOLIWLQJDUPSLQV (FFHQWULFVKDIWWUDFNUROOHUEHDULQJ 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG Inspect lower lifting arm pins for wear or GDPDJHSRVLWLYHVHFXUHPHQWDQGSURSHU adjustment 5HVHFXUHUHSODFHGDPDJHGSDUWV lubricate or correct as needed. Page 17 Maintenance and Lubrication 1500 Cycles 4500 Cycles ,QVSHFWHFFHQWULFVKDIWSLQVEHDULQJ PRXQWLQJVFUHZZDVKHUVDQGVHFXUHPHQW KDUGZDUHIRUZHDURUGDPDJHSRVLWLYH securement and proper operation 5HVHFXUHUHSODFHGDPDJHGSDUWV lubricate or correct as needed. See Carriage Ride Height Adjustment. ,QVSHFWWRUTXHWXEHFDPVIRUVHFXUHPHQW wear or damage 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG Inspect housing cam brackets for VHFXUHPHQWZHDURUGDPDJH 5HVHFXUHUHSODFHRUFRUUHFWDVQHHGHG ,QVSHFWF\OLQGHUVKRVHVÀWWLQJVDQG K\GUDXOLFFRQQHFWLRQVIRUZHDUGDPDJH or leaks 7LJKWHQUHSDLURUUHSODFHLIQHHGHG Inspect power cable 5HVHFXUHUHSDLURUUHSODFHLIQHHGHG Hydraulic Fluid (Pump) - Check level. Note: Fluid should be changed if there is visible contamination. Inspect the K\GUDXOLFV\VWHPF\OLQGHUKRVHVÀWWLQJV VHDOVHWFIRUOHDNVLIÁXLGOHYHOLVORZ 8VHDYLDWLRQÁXLGRQO\SDUW5 'RQRWPL[ZLWK'H[WURQ,,,RURWKHU K\GUDXOLFÁXLGV&KHFNÁXLGOHYHOZLWK SODWIRUPORZHUHGIXOO\)LOOWRPD[LPXP ÁXLGOHYHOLQGLFDWHGRQUHVHUYLRUVSHFLÀHG RQGHFDO'RQRWRYHUÀOO,IÁXLGOHYHO decal is not present - measure 22 mm (7/8")IURPWKHERWWRPRIWKHÀOOWXEHWR ORFDWHÁXLGOHYHO Inspect lifting arm bushings and pivot pins for visible wear or damage Replace if needed. Inspect roll stop pivot pin mounting bolts (2) Tighten or replace if needed Mounting Check to see that the lift is securely anchored to the vehicle and there are QRORRVHEROWVEURNHQZHOGVRUVWUHVV fractures. Decals and Antiskid 5HSODFHGHFDOVLIZRUQPLVVLQJRULOOHJLEOH Replace antiskid if worn or missing. Consecutive 750 Cycle Intervals 5HSHDWDOOSUHYLRXVO\OLVWHGLQVSHFWLRQ OXEULFDWLRQDQGPDLQWHQDQFHSURFHGXUHV at 750 cycle intervals. Lift Disposal Procedure 5HWXUQOLIWWRDQDXWKRUL]HGGHDOHUIRUGUDLQLQJRIWKHK\GUDXOLFV\VWHP Page 18 2. Transport lift to a recycling center for recycling. Troubleshooting Diagnosis Chart 36513 36514 WARNING Troubleshooting and repair procedures must be performed DVVSHFLÀHGE\DXthorized service personnel only. Failure to do so may result in serious bodily injury and/or property damage. FUNCTION 1.00 NO OPERATION 2.00 PUMP RUNS BUT WILL NOT LIFT PLATFORM If a problem occurs with your OLIWGLVFRQWLQXHRSHUDWLRQLPPHGLDWHO\'RQRWDWWHPSWUHSDLUV yourself. Contact your sales representative. The cause of the problem can be determined by locating the lift function and related symptom in the Troubleshooting Diagnosis Charts. The VSHFLÀFFDXVHDQGUHPHG\FDQ then be determined by process of elimination. A Electrical Schematic and Hydraulic Diagram are provided to aid in troubleshooting. $5HSDLU3DUWVVHFWLRQZLWKH[ploded views and corresponding parts lists is also provided. Correct the problem if possible. If the SUREOHPFRQWLQXHVFRQWDFW\RXU sales representative. POSSIBLE CAUSE REMEDY 1.11 Low Battery Vehicle engine must be running during lift operation. Check condition of vehicle battery. 1.12 Bad ground Check for good ground between vehicle chas sis and aluminum manifold on power pack. 1.13 Poor plug connections Check all plugs for proper contact. 1.14 Blown fuse Check inline fuse on “12 V” wire from P.C. board. Check P.C. board mounted fuse. Check for power on terminal 8 of terminal block on P.C. board. 1.15 Circuit Sentry Reset or replace if necessary. 1.16 Defective circuit breaker Manually reset Circuit Sentry. 1.17 Improper terminal block wiring Check for proper wiring of terminal block. 2.11 Hydraulic valve open Flush valve by operating manual override switches UP and DOWN at same time for 4 to 5 seconds several times. 2.12 Manual valve open Close manual valve. Flush valve by running UP with manual override. Open valve 4 to 5 seconds several times. 3XPSPRXQWHGKRUL]RQWDO Power pack must be mounted vertically. 2.14 No oil (low) &KHFNÁXLGOHYHO 2.15 Hydraulic hose not connected Check hose connection between pump and cassette. Page 19 Troubleshooting Diagnosis Chart FUNCTION 3.00 PUMP DOES NOT RUN WITH MANUAL OVERRIDE OR HAND-HELD PENDANT 4.00 LIFT WILL GO UP WITH OVERRIDE SWITCH BUT NOT WITH HAND-HELD PENDANT POSSIBLE CAUSE REMEDY 3.11 Up Solenoid Check for power on pump “T” wire going to solenoid. 3.12 Bad power and ground See 1.00 4.11 FULL OUT diagnostic LED not illuminated Check full out switch for proper operation/adjustment. Replace or adjust as necessary. 4.12 Hand-held pendant not working properly Check for UP diagnostic LED when hitting UP EXWWRQRQKDQGFRQWURO5HSODFHFRQWUROER[DV necessary. 4.13 Roll stop switch is not activated or defective Check diagnostic LED for roll stop (barrier) switch status. Roll stop is down or roll stop release pin partially out. Replace switch as necessary. 4.14 See 12.0 5.00 LIFT WILL NOT GO DOWN WITH MANUAL OVERRIDE OR WITH HAND-HELD PENDANT OR GOES DOWN SLOWLY OR DRIFTS DOWN BY ITSELF 6.00 LIFT WILL GO DOWN WITH OVERRIDE BUT NOT WITH HAND-HELD PENDANT 7.00 LIFT WILL NOT GO OUT WITH OVERRIDE OR HAND-HELD PENDANT Page 20 5.11 Hydraulic down valve bad Check for power on valve ”T” wire going to solenoid when pushing manual override or remote button. Replace if necessary. 5.12 Dirty down valve (clogged) Flush valve by pushing manual override up and down buttons at same time for 4 to 5 seconds several times. 6.11 FULL OUT diagnostic LED not illuminated. Check for proper operation of Full Out switch with diagnostic LED. Replace or adjust switch as necessary. 6.12 Door Full Close switch (if equipped) out of adjustment or defective. Check switch for proper operation/adjustment. Adjust or replaceswitch as necessary 6.13 See 12.0 7.11 Defective circuit breaker Reset or replace if necessary. 7.12 No power on terminal 8 Check vehicle door full open switch and wiring. 7.13 Interlock circuit incomplete Verify interlock installation 7.14 Poor plug connections &KHFNKDUQHVVFRQQHFWLRQV((%DQG% 7.15 Bad in/out motor Check power at motor. Replace motor if necessary. 7.16 Bad power and ground See 1.00 Troubleshooting Diagnosis Chart FUNCTION POSSIBLE CAUSE REMEDY 8.00 LIFT WILL NOT STOW WITH HAND-HELD PENDANT 8.11 Faulty Below Stow switch. BELOW STOW (BELOW) diagnostic LED not illuminated 9.00 ROLL STOP WILL NOT OPERATE UP OR DOWN WITH HAND-HELD PENDANT OR OVERRIDES 9.11 Ground Sensor pressure switch Reset or replace if necessary. 9.12 Poor plug connections &KHFNKDUQHVVFRQQHFWRUV$DQG$(1 1()DQG) 9.13 Faulty roll stop actuator motor or actuator out of adjustment. Check power at motor. Adjust or replace actuator if necessary. 9.14 Bad power and ground See 1.00 9.12 Defective circuit breaker Reset or replace if necessary. 9.13 Bad relay(s) Check Barrier Up and Barrier Down power relays. Replace if necessary. Notice: Down and Barrier Down override switches must be pressed at same time to lower roll stop. 10.00 ROLL STOP OPERATES WITH OVERRIDES BUT WILL NOT GO UP WITH HAND-HELD PENDANT 11.00 ROLL STOP OPERATES WITH OVERRIDES BUT WILL NOT GO DOWN WITH HAND-HELD PENDANT 12.00 SWITCHES DO NOT ACTIVATE LED(S) Check for proper operation of Below Stow switch. Replace or adjust switch as necessary. 8.12 See 12.0 9.14 See 5.0 10.11 Hand-held pendant not working properly Check for UP diagnostic LED when hitting UP EXWWRQRQKDQGFRQWURO5HSODFHFRQWUROER[DV necessary. 10.12 Roll stop (Barrier Down) LED off Check roll stop switch for proper operation with (barrier) LED on board. Replace or adjust as necessary. 10.13 See 12.0 11.11 GROUND SENSOR (GND SENS) diagnostic LED not illuminated Check Ground Sensor pressure switch. Replace or adjust as necessary. 11.12 BELOW STOW (BELOW) diagnostic LED not illuminated Check Below Stow switch for proper operation. Replace or adjust as necessary. 11.13 FULL OUT diagnostic LED not illuminated Check Full Out switch for proper operation. Replace or adjust as needed. 11.14 See 12.0 12.11 Improper terminal block wiring &KHFNWHUPLQDOEORFNIRUFRUUHFWZLULQJFRQÀJXration. 12.12 No power going to switches &KHFNSRZHURQFRQQHFWRU$SLQVDQG 12.13 Faulty wiring Check continuity of wires from switches to connector A2. 12.14 Faulty connections Check for proper connections on each switch and on each connector on the harnesses. Replace contact if necessary. See diagram at right. Page 21 Troubleshooting Diagnosis Chart 13.00 DOORS DO NOT OPEN 13.11 Faulty wiring Check for proper wiring to door openers. CONTACT REMOVAL 1. Remove orange wedge using needle nose pliers or a hook shaped wire to pull wedge straight out. Page 22 7RUHPRYHWKHFRQWDFWVJHQWO\ SXOOZLUHEDFNZDUGVZKLOHDW the same time releasing the lock LQJÀQJHUE\PRYLQJLWDZD\IURP the contact with a screwdriver. +ROGWKHUHDUVHDOLQSODFHDV removing the contact will displace the seal UVL601C / UVL603C (12V) Lift Electrical Schematic DOOR CLOSE SWITCH PRESSURE SWITCH NO NO C RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 NOT USED NOT USED NOT USED NOT USED WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 POWER PACK / LIFT HOUSING HARNESS #73910A-600 BK-1.31-16 1 2 NOT USED OR-0.823-18 BU-0.823-18 A B C A B C RD BK GND VALVE T PUMP T 12V 12V PWR BK-3.31-12 OR-1.31-16 BU-1.31-16 RD-3.31-12 WH-3.31-12 RD-0.326-22 BK-0.823-18 GND VALVE T PUMP T 12V A1 RD-0.823-18 NOT USED BK-0.823-18 NOT USED NOT USED YL / RD-0.823-18 GN / RD-0.823-18 NOT USED NOT USED TN-0.823-18 VT-0.823-18 WH / TN-0.823-18 1 2 3 4 5 6 7 8 9 10 11 12 UVL REMOTE CONTROL GN-1.31-16 OR-1.31-16 BK-1.31-16 CIRCUIT BREAKER (Self Reset) 20A Q1 DOWN SOLENOID BU-0.518-20 Y1 SYMBOL DESCRIPTION WH-3.31-12 1 2 3 4 5 6 FRAME GROUND BU-1.31-16 1 2 3 4 5 6 CIRCUIT BREAKER P1 CONNECTORS GROUND MOTOR SOLENOID V1 V2 BU-1.31-16 WH-3.31-12 JUNCTION GROUND STOW M MOTOR RELAY SOLENOID 86 85 87 30 87A SOLENOID OR RELAY RD-33.6-2 CU-0.518-20 CU-0.518-20 DOWN UP WH-0.823-18 BK-0.823-18 OR-0.823-18 GN-0.823-18 RD-0.823-18 WH HYDRAULIC PUMP MOTOR BK-33.6-2 NO C M1 GROUND MICROSWITCH NOTICE: 5 CIRCUIT BREAKER FUSE NOTICE 1) JUNCTIONS ONLY OCCUR AT MARKED INTERSECTIONS. BK-13.3-6 M SWITCH NC NC BK BK-13.3-6 Y2 C RD GROUND BAT. WH-3.31-12 NO BK F2 5A P2 BAR DN S10 BK-3.31-12 OR-1.31-16 FUSE AUX. A2 CLOSE BK M M3 O2 1 2 K7 80A RD-33.6-2 DIODE RD-33.6-2 AUX. Q2 BAT. 2) ALL WIRES AND COMPONENTS OPERATE AT 12 VOLTS DC. N2 WH RD BK WH RD BK 3) WIRE IDENTIFICATION: WIRE COLOR - WIRE SIZE IN MM2 - WIRE SIZE IN AWG 4) A LIFT ON/OFF POWER SWITCH MUST BE INSTALLED. USE BRAUN SWITCH #36678KS OR CE EQUIVALENT. BLACK JUMPER WIRE MUST BE REMOVED FROM SOCKETS 8 AND 11 WHEN INSTALLING POWER SWITCH CIRCUIT. 5) A 80A CIRCUIT BREAKER MUST BE INSTALLED. USE BRAUN CIRCUIT BREAKER KIT #85804A OR CE EQUIVALENT. 6) AN E-STOP SWITCH WITH 3A INLINE FUSE MUST BE INSTALLED. USE BRAUN E-STOP SWITCH KIT #36679KS OR CE EQUIVALENT. Use caution when working on components inside pump module. An available energy of over 240 VA creates an energy hazard. BATTERY POSITIVE TERMINAL (12V) BU-0.518-20 C1 K6 PUMP T WH-1.31-16 CU-0.518-20 RD K5 Q1 GN-1.31-16 OR-1.31-16 RD-1.31-16 BARRIER ACTUATOR MOTOR RD-0.823-18 BK-0.823-18 BK-0.326-22 RD-0.823-18 K4 OR-1.31-16 I P G F O R BU-1.31-16 C2 HC PWR HC UP HC DOWN HC STOW HC CLOSE HC GND VALVE T WH-1.31-16 BU-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BK-1.31-16 1 2 3 4 5 6 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 M1 NOT USED RD-1.31-16 BK-1.31-16 L1 WH RD BK Page 23 BAR DN SW PWR 1 2 3 4 5 6 BK-1.31-16 SAFETY GND SENS FULL OUT NOT FULL OUT BELOW STOW N1 F1 B1 WIRED HAND-HELD CONTROL #73946A-100-1 O1 BAR UP PWR BAR DN PWR RD-0.823-18 S6 OR-1.31-16 RD-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 BK / WH-1.31-16 F2 E-STOP SWITCH BK-0.823-18 A B C A B C A B C M2 A B C K1 WH-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 RD-1.31-16 S5 L2 BK-1.31-16 BU / BK-1.31-16 OR / BK-1.31-16 GN / BK-1.31-16 GN-1.31-16 OR-1.31-16 RD-1.31-16 F3 BU-1.31-16 NC S4 WH-1.31-16 BK-1.31-16 RD-0.823-18 BK-0.823-18 GN-0.823-18 A B C A B C J1 OR / BK-1.31-16 NOT USED BK-1.31-16 BK / WH-1.31-16 NOT USED BK-1.31-16 C NC NOT USED GN / BK-1.31-16 BK-1.31-16 I1 BU / BK-1.31-16 NOT USED BK-1.31-16 H1 A B C A B C A B C A B C A B C A B C NOT USED BU-1.31-16 WH-1.31-16 NO K2 H2 CARRIAGE / PLATFORM HARNESS #73930A RD-0.823-18 BK-0.823-18 OR-0.823-18 BU-0.823-18 BELOW STOW C NC S3 RD-0.823-18 GN-0.823-18 BK-0.823-18 RD-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / W-1.31-16 BK-1.31-16 WH-1.31-16 SW PWR BAR DN BAR DN PWR BAR UP PWR IGN PWR SW PWR LIFT OUT FLOOR LVL FLOOR IN SAFETY GND SENS FULL OUT NOT FULL OUT BELOW STOW 1 2 3 4 NO C NC WH-1.31-16 SW PWR BAR DN BAR DN PWR BAR UP PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT GND SENS SAFETY FLOOR IN FLOOR LVL SW PWR IGN PWR NO S2 G1 1 2 3 4 FULL OUT NO C NC G2 RD / WH-1.31-16 GN / WH-1.31-16 RD / BK-1.31-16 BK-1.31-16 GND SENS FLOOR LVL NO S1 3A BK-2.08-14 WH-1.31-16 M2 BK-1.31-16 C FUSE NOTICE: 4 RD-0.823-18 S7 NOTICE: 6 UVL PC BOARD #73900LFCE-12V BAR UP BAR DN LIFT OUT LIFT IN LIFT POWER SWITCH F1 LIFT HOUSING / CARRIAGE HARNESS #73920A LIFT OUT 1 2 3 4 5 6 7 8 BK0.823-18 BK-0.823-18 5A BK-1.31-16 M 1 2 3 4 5 6 7 8 WH-3.31-12 WH-3.31-12 WH-3.31-12 WH-3.31-12 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 BK-0.823-18 FUSE IN-OUT MOTOR OR-1.31-16 A1 B2 E2 E1 BEEP/FL 1 DOOR CL 2 OPEN 3 PRESSURE 4 INTERLK 5 SAFETY 6 H.C. PWR IN 7 12V OUT 8 IGN PWR IN 9 FLOOR LVL 10 FULL OPEN 11 CLOSE 12 NC S9 BK-2.08-14 A2 N H J E Q D A C M K B L RD-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 RD-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 WH / BK-1.31-16 RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 RD-0.823-18 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 OR-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 NOT USED NOT USED NOT USED NOT USED WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 D2 BAR DN GND SENS SAFETY FLOOR IN FLOOR LVL BAR UP PWR BAR DN PWR MOTOR OUT PWR MOTOR IN PWR MOTOR IN PWR MOTOR OUT PWR BAR DN PWR BAR UP PWR BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 12V PWR D1 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 WH-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 SW PWR IGN PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT PUMP T 1 2 3 4 5 6 7 8 9 10 11 12 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 WH-3.31-12 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BAR DN GND SENS SAFETY FLOOR IN FLOOR LVL RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD / BK-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 SW PWR IGN PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT REMOTE CONTROL Y-HARNESS #73941A-1 BK-1.31-16 RD-0.823-18 GN-0.823-18 OR-0.823-18 BK-0.823-18 WH-0.823-18 NOT USED BK-1.31-16 C NC S8 RD-33.6-2 UVL603C24 (24V) Lift Electrical Schematic Page 24 DOOR CLOSE SWITCH PRESSURE SWITCH NO NO C RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 NOT USED NOT USED NOT USED NOT USED WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 POWER PACK / LIFT HOUSING HARNESS #73910A-600 BAR DN SW PWR 1 2 A B C A B C RD BK BK-0.326-22 RD-0.326-22 BK-0.823-18 RD-0.823-18 UVL REMOTE CONTROL NOT USED RD-1.31-16 BK-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 CIRCUIT BREAKER (Manual Reset) 8A Q1 BAT. Y1 CIRCUIT BREAKER 1 2 3 4 5 6 P1 CONNECTORS JUNCTION STOW DOWN UP MOTOR RELAY SOLENOID 86 85 87 30 87A V1 RD V2 BU-1.31-16 WH-3.31-12 GROUND WH-3.31-12 BK-13.3-6 Y2 RD-33.6-2 SOLENOID OR RELAY HYDRAULIC PUMP MOTOR BK-33.6-2 BK-13.3-6 M M1 NO MICROSWITCH GROUND NC NOTICE: 5 WH CIRCUIT BREAKER NC NOTICE GROUND MOTOR SOLENOID SWITCH C DOWN SOLENOID BU-0.518-20 WH-3.31-12 CU-0.518-20 CU-0.518-20 GROUND DESCRIPTION FUSE S10 F2 5A FRAME GROUND WH-0.823-18 BK-0.823-18 OR-0.823-18 GN-0.823-18 RD-0.823-18 60A DIODE 1) JUNCTIONS ONLY OCCUR AT MARKED INTERSECTIONS. BK BK-3.31-12 OR-1.31-16 FUSE AUX. SYMBOL C BK GND VALVE T PUMP T 24V RD-33.6-2 RD-33.6-2 AUX. Q2 BAT. 2) ALL WIRES AND COMPONENTS OPERATE AT 12 VOLTS DC. N2 WH RD BK WH RD BK 3) WIRE IDENTIFICATION: WIRE COLOR - WIRE SIZE IN MM2 - WIRE SIZE IN AWG 4) A LIFT ON/OFF POWER SWITCH MUST BE INSTALLED. USE BRAUN SWITCH #36678KS OR CE EQUIVALENT. BLACK JUMPER WIRE MUST BE REMOVED FROM SOCKETS 8 AND 11 WHEN INSTALLING POWER SWITCH CIRCUIT. 5) A 60A CIRCUIT BREAKER MUST BE INSTALLED. USE BRAUN CIRCUIT BREAKER #85804A24 OR CE EQUIVALENT. 6) AN E-STOP SWITCH WITH 3A INLINE FUSE MUST BE INSTALLED. USE BRAUN E-STOP SWITCH KIT #36679KS OR CE EQUIVALENT. Use caution when working on components inside pump module. An available energy of over 240 VA creates an energy hazard. BATTERY POSITIVE TERMINAL (24V) BU-0.518-20 1 2 3 4 5 6 7 8 9 10 11 12 M WH RD BK NOT USED OR-0.823-18 BU-0.823-18 M3 O2 1 2 BK-3.31-12 OR-1.31-16 BU-1.31-16 RD-3.31-12 WH-3.31-12 A1 1 2 3 4 5 6 BAR DN BK GND VALVE T PUMP T 24V 24V PWR BU-1.31-16 M1 NO K7 A2 CLOSE BARRIER ACTUATOR MOTOR RD-0.823-18 BK-0.823-18 K6 P2 GN-1.31-16 OR-1.31-16 RD-1.31-16 M K5 C1 Q1 RD-0.823-18 NOT USED BK-0.823-18 NOT USED NOT USED YL / RD-0.823-18 GN / RD-0.823-18 NOT USED NOT USED TN-0.823-18 VT-0.823-18 WH / TN-0.823-18 CU-0.518-20 RD K4 OR-1.31-16 I P G F O R BU-1.31-16 HC PWR HC UP HC DOWN HC STOW HC CLOSE HC GND VALVE T C2 WH-1.31-16 WH-1.31-16 BU-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BK-1.31-16 1 2 3 4 5 6 BK-1.31-16 SAFETY GND SENS FULL OUT NOT FULL OUT BELOW STOW N1 F1 1 2 3 4 5 6 WIRED HAND-HELD CONTROL #73946A-100-1 O1 BAR UP PWR BAR DN PWR B1 PUMP T WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 WH-1.31-16 BK / WH-1.31-16 F2 RD-0.823-18 S6 A B C A B C A B C L1 BK-1.31-16 BU / BK-1.31-16 OR / BK-1.31-16 GN / BK-1.31-16 GN-1.31-16 OR-1.31-16 RD-1.31-16 E-STOP SWITCH BK-0.823-18 OR-1.31-16 RD-1.31-16 M2 A B C L2 K1 WH-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 RD-1.31-16 S5 GN-1.31-16 OR-1.31-16 BK-1.31-16 OR / BK-1.31-16 NOT USED BK-1.31-16 BK-1.31-16 NC S4 WH-1.31-16 BK-1.31-16 RD-0.823-18 BK-0.823-18 GN-0.823-18 A B C J1 NOT USED GN / BK-1.31-16 BK-1.31-16 I1 BU / BK-1.31-16 NOT USED BK-1.31-16 BK / WH-1.31-16 NOT USED BK-1.31-16 C NC A B C A B C A B C A B C A B C A B C A B C NOT USED BU-1.31-16 WH-1.31-16 NO K2 CARRIAGE / PLATFORM HARNESS #73930A RD-0.823-18 BK-0.823-18 OR-0.823-18 BU-0.823-18 BELOW STOW C NC S3 H2 H1 3A F3 BU-1.31-16 NO RD-0.823-18 GN-0.823-18 BK-0.823-18 RD-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD-1.31-16 WH-1.31-16 RD-1.31-16 BK-1.31-16 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / W-1.31-16 BK-1.31-16 WH-1.31-16 SW PWR BAR DN BAR DN PWR BAR UP PWR IGN PWR SW PWR LIFT OUT FLOOR LVL FLOOR IN SAFETY GND SENS FULL OUT NOT FULL OUT BELOW STOW 1 2 3 4 NO C NC WH-1.31-16 SW PWR BAR DN BAR DN PWR BAR UP PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT GND SENS SAFETY FLOOR IN FLOOR LVL SW PWR IGN PWR NO S2 G1 1 2 3 4 FULL OUT C NC G2 RD / WH-1.31-16 GN / WH-1.31-16 RD / BK-1.31-16 BK-1.31-16 GND SENS FLOOR LVL NO S1 BK-2.08-14 WH-1.31-16 M2 BK-1.31-16 C FUSE NOTICE: 4 RD-0.823-18 S7 NOTICE: 6 UVL PC BOARD #73900LFCE-12V BAR UP BAR DN LIFT OUT LIFT IN LIFT POWER SWITCH F1 LIFT HOUSING / CARRIAGE HARNESS #73920A LIFT OUT 1 2 3 4 5 6 7 8 BK0.823-18 BK-0.823-18 5A BK-1.31-16 M 1 2 3 4 5 6 7 8 WH-3.31-12 WH-3.31-12 WH-3.31-12 WH-3.31-12 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 BK-0.823-18 FUSE IN-OUT MOTOR OR-1.31-16 A1 B2 E2 E1 BEEP/FL 1 DOOR CL 2 OPEN 3 PRESSURE 4 INTERLK 5 SAFETY 6 H.C. PWR IN 7 12V OUT 8 IGN PWR IN 9 FLOOR LVL 10 FULL OPEN 11 CLOSE 12 NC S9 BK-2.08-14 A2 N H J E Q D A C M K B L RD-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 RD-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 WH / BK-1.31-16 RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 RD-0.823-18 BK-1.31-16 RD / BK-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 OR-1.31-16 GN / WH-1.31-16 RD / WH-1.31-16 RD / WH-1.31-16 GN / WH-1.31-16 BU / WH-1.31-16 BK / RD-1.31-16 NOT USED NOT USED NOT USED NOT USED WH / RD-1.31-16 OR / RD-1.31-16 BU / RD-1.31-16 RD / GN-1.31-16 D2 BAR DN GND SENS SAFETY FLOOR IN FLOOR LVL BAR UP PWR BAR DN PWR MOTOR OUT PWR MOTOR IN PWR MOTOR IN PWR MOTOR OUT PWR BAR DN PWR BAR UP PWR BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 24V PWR D1 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 WH-3.31-12 1 2 3 4 5 6 7 8 9 10 11 12 SW PWR IGN PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT PUMP T 1 2 3 4 5 6 7 8 9 10 11 12 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 WH-3.31-12 BK-1.31-16 WH-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 NOT USED RD / BK-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BAR DN GND SENS SAFETY FLOOR IN FLOOR LVL RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 GN / BK-1.31-16 OR / BK-1.31-16 BU / BK-1.31-16 BK / WH-1.31-16 BK-1.31-16 WH-1.31-16 BK-1.31-16 RD / BK-1.31-16 RD-1.31-16 GN-1.31-16 OR-1.31-16 BU-1.31-16 SW PWR IGN PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT REMOTE CONTROL Y-HARNESS #73941A-1 BK-1.31-16 RD-0.823-18 GN-0.823-18 OR-0.823-18 BK-0.823-18 WH-0.823-18 NOT USED BK-1.31-16 C NC S8 RD-33.6-2 NOTES This page intentionally left blank. Page 25 Hydraulic Parts List UVL601C / UVL603C / UVL603C24 Series 04 Item Qty. 1 1 Description Part # Pump Assembly 12 Volt - UVL Power Pack (shown) 36383 1 Pump Assembly 24 Volt - UVL Power Pack 2 1 Motor, Pump - 12 Volt 14785-IS 1 Motor, Pump - 24 Volt 16504-IS 3 1 Valve, “Down” (with Solenoid) - 12 Volt 14901 1 Valve, "Down" (with Solenoid) - 24 Volt 16505 4 1 Clamp, Reservoir - H-48 17069 5 1 Reservoir Replacement Kit (Includes Item #10) 6 2 O-Ring (only), Hand Pump Mounting 17351 7 1 Hand Pump (Backup) with O-Rings (Includes Item #6) 87065 8 3 Screw, 1/4-20 x 1 3/4”, Allen Head 9 1 Handle with Grip 87060-24V 88188K 17351 17206A 10 1 Fitting, 3/8” Male NPT x 3/8” Barbed 87618 11 2 Clamp, Hose - 5/8” O.D. - Worm Drive 84325 12 1 Tubing, 3/8” x 5/8”, Tygothane - Clear 82066R012 13 1 Plug, 3/8” Plastic Hose 14 1 Fitting, 90°-1/8” Male Pipe x 1/8” Barbed 15 1 Tube, 1/4” O.D. x 1/8” I.D. - Plastic 16 1 Plug, 1/8” Plastic Tube 81583 17 1 Adapter, 1/4” Male NPT x 7/16-20 Male JIC 37° 10130 18 1 Hose Assembly, 3/16” x 82” - Female Swivel 7/16-20 JIC 37° 19 1 Fitting, 90° - 7/16-20 Male JIC 37° x 1/4” Male NPT 87569 20 1 Coupling, Hydraulic Quick Connect x 1/4” Female NPT 87614 21 1 Nipple, Hydraulic Quick Connect x 1/4” Female NPT 87615 22 1 Nut, 9/16-18, Hex Jam 23 1 Fitting Assembly, Bulk Head 24 1 Hose Assembly, 1/8” x 60” - Female Swivel 7/16-20 JIC 37° 25 1 Fitting, 90° - 9/16” Male O-Ring x 7/16-20 Male JIC 37° 26 1 Valve, Flow Control 87049 27 1 Adaptor, Hydraulic Internal 87560 81580 87563 81557R014 35262A-82 83077 73777A 35261A-060 87622 28 1 Fitting, Female Swivel 7/16-20 JIC 37° x 1/4” Male NPT 87596 29 1 Fitting, Tee - 7/16-20 Male JIC 37° x 7/16-20 Male JIC 37° x 7/16” Male O-Ring 87621 30 1 Fitting, 90° - Female Swivel 7/16-20 JIC 37° x 1/8” Male NPT 87619 31 1 Fitting, Coupling - 1/8” Female NPT x 1/8” Female NPT 87543 32 1 Switch, Pressure - Cylinder 33 1 Cylinder, UVL Retracting 87047 34 1 Fitting, 90° - Female Swivel 7/16-20 JIC 37° x 7/16-20 Male JIC 37° 87592 35 1 Solenoid, Up - Prestolite - 12V (shown) 28308 1 Solenoid, Up - Trombetta - 24V 36 1 Diode Assembly, Up Solenoid 73960A 32930 73906A 37 1 Hose Assembly, 1/8” Female Swivel 7/16-20 JIC 37° x 4” 38 1 Fitting, 1/8” Female NPT x 7/16-20 Male JIC 37° 39 1 Switch, Pressure - Pump 87052 40 1 Power Cable, Up Solenoid to Motor 29049 41 1 Clamp, Hose - Solenoid Mounting 29663 Page 26 16004A-004 87623 Hydraulics Diagram UVL601C / UVL603C/ UVL603C24 Series 04 1 41 40 36 35 13 24 11 2 12 9 Arrow must face pump 7 25 27 26 28 11 32 29 8 3 31 10 30 6 33 16 4 39 14 38 5 15 23 37 22 21 20 17 8 19 34 NOTICE 18 36513 Use caution when working on components inside pump module. Available energy of 1680 VA creates an energy hazard. Remove power from pump module and any spark source before working with hydraulic ÁXLGDQGFRPSRQHQWV:HDU proper eye protection. Use protective gloves for prolonged FRQWDFWZLWKK\GUDXOLFÁXLG Page 27 UVL601C & UVL603C (12V) Pump Module Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 60 61 62 63 64 Page 28 Qty. 1 1 1 1 1 4 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 5 1 1 6 1 6 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 6 2 2 2 2 1 1 2 1 Description Pump Module, Complete (Items 1-46) Hose Assembly, 3/16" Diameter x 82"- Female 7/16-20 JIC 37°-SW/SW Hose Assembly, 1/8" Diameter x 4"- Female 7/16-20 JIC 37°-SW/SW Coupling, Hydraulic Quick Connect x 1/4" Female NPT Fitting, 90°- Male 7/16-20 JIC 37° x 1/4" Male NPT Plate, Power Pack Mounting Screw, 5/16-18 x 1/2", Serrated Washer Head, Hex Fitting, 90°-Female Swivel 7/16-20 JIC 37° x Male 7/16-20 JIC 37° Fitting, Tee - Female Swivel 7/16-20 JIC 37° x Male 7/16-20 JIC 37° x 2 Adapter, 1/4" Male NPT x 7/16-20 Male JIC 37° Switch, Pressure 250/1000 PSI Fitting, 1/8" Female NPT x Male 7/16-20 JIC 37° Jumper Assembly, 12 Gauge x 4" Pump Assembly, UVL Power Pack - 12 Volt Fitting, 3/8" Male NPT x 3/8" Barbed Clamp, Hose - 5/8" O.D. - Worm Drive Tubing, 3/8" x 5/8", Tygothane - Clear Plug, 3/8" Plastic Tube Plug, 1/8" Plastic Tubing Tube, 1/4" O.D. x 1/8" I.D. - Plastic Diode Assembly, Up Solenoid Eyelet, 5/16" Insulated - Red Fitting, 90°-1/8" Male Pipe x 1/8" Barbed Diode Assembly, Down Valve Solenoid Terminal, 1/4" Male Spade - Fully Insulated - 14/16 Gauge Circuit Breaker, 20 Amp Screw, #10-32 x 3/8", Pan Head, Phillips, Thread Cut Washer, .326" X .562" X .042"-SS Bumper, 1/2" Dia. x 1/4" Tall - Rubber Electrical Board Assembly / 12 Volt / RoHS Chip, UVL 600 Program Stow Lock Screw, #6 x 3/8" Self Tap, Flat Head Bracket, PC Board Mounting Standoff, .25" PCB - Nylon Edge Liner, 1/8", Q-Trim Edge Liner, 1/8", Q-Trim Clip, Cable - 7/16" Plastic Solenoid, Motor UVL - 12V Clamp, Hose Power Cable, Up Solenoid to Motor Tag, Caution Do Not Connect - Red (Not Shown) Cable Tie, 14 1/2" (Not Shown) Kit, Fuse Replacement (Not Shown) Fuse, 5 Amperes Relay, 30 Amperes, 12 Volt Tag, Vent Tube Plug Removal - UVL (Not Shown) Cable Tie, 3 3/4" x .09", White (Not Shown) Hand Control Assembly Pump Cover (Cover Assembly 73820A-04 Includes Items 48-55) Decal, UVL Patent & Trademark (Not Shown) Decal, Electrical Components-Lift-Intl-UVL (Not Shown) 'HFDO)XVH6SHFLÀFDWLRQV,QWO89/1RW6KRZQ Decal, Electrical Components-Module-Intl-UVL (Not Shown) Decal, Hazard-Electrical Shock-Intl-Pictoral (Not Shown) Decal, Warn Damage Control Board-ESD (Not Shown) Decal, Manual Operation - UVL (Not Shown) Screw, 1/4-20 x 3/8", Pan Head Phillips Clamp-Spring-Pump Handle Screw, 10-32 x 3/8" Flat Head Phillips Washer, #10 Flat Nut, #10-32 Hex Handle, Pump Bracket, Power Pack Mounting Washer, 1/4" External Star Tooth Lock Ground Cable - Black Part No. 73800AC-04 35262A-82 16004A-004 87614 87569 73822 82881 87592 87587 10130 87052 87623 73943A 36383 87618 84325 82066R012 81580 81583 81557R014 73906A 86267 87563 73907A 78036 16453 82755 83583 82064 73900LFCE-12V 85900-102 82764 73824NW-02 86739 13910R006 13910R008 15777 28308 17069 29049 81796 24534 36676K 85835 13259 25807 86003 73946A-100-1 73820-03 29884 36650 36649 36513 30787 28461 82769 12350 82767 11541 11542 17206A 73825 83588 68874 UVL601C / UVL603C (12V) Pump Module Diagram 38 16 20 15 "PUMP T" WIRE ON ELECTRICAL BOARD 17 18 15 56 48 39 TO DOWN VALVE 14 6 "VALVE T" WIRE ON ELECTRICAL BOARD 24 19 58 5 6 56 64 37 13 61 57 23 59 63 21 12 22 TO DOWN VALVE 12 62 60 "12V" WIRE ON ELECTRICAL BOARD "GROUND" WIRE ON ELECTRICAL BOARD 58 "12V POWER" WIRE ON ELECTRICAL BOARD 57 59 60 26 25 56 36 31 27 10 33 6 47 T LIF UP T LIF WN DO OW T ST LIF 32 11 29 28 34 3 ORE DOOS CL 6 33 30 35 4 2 43 44 9 7 8 NOTICE Page 29 Remove power from pump module and any spark source before working with hydraulic ÁXLGDQGFRPSRQHQWV:HDU proper eye protection. Use protective gloves for prolonged FRQWDFWZLWKK\GUDXOLFÁXLG 1 Use caution when working on components inside pump module. An available energy of over 240 VA creates an energy hazard. 2 8181 UVL603C24 (24V) Pump Module Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 60 61 62 63 64 Page 30 Qty. 1 1 1 1 1 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 6 1 6 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 6 2 2 2 2 1 1 2 1 Description Pump Module, Complete (Items 1-46) Hose Assembly, 3/16" Diameter x 82"- Female 7/16-20 JIC 37°-SW/SW Hose Assembly, 1/8" Diameter x 4"- Female 7/16-20 JIC 37°-SW/SW Coupling, Hydraulic Quick Connect x 1/4" Female NPT Fitting, 90°- Male 7/16-20 JIC 37° x 1/4" Male NPT Plate, Power Pack Mounting Screw, 5/16-18 x 1/2", Serrated Washer Head, Hex Fitting, 90°-Female Swivel 7/16-20 JIC 37° x Male 7/16-20 JIC 37° Fitting, Tee - Female Swivel 7/16-20 JIC 37° x Male 7/16-20 JIC 37° x 2 Adapter, 1/4" Male NPT x 7/16-20 Male JIC 37° Switch, Pressure 250/1000 PSI Fitting, 1/8" Female NPT x Male 7/16-20 JIC 37° Jumper Assembly, 12 Gauge x 4" Pump Assembly, UVL Power Pack - 24 Volt Fitting, 3/8" Male NPT x 3/8" Barbed Clamp, Hose - 5/8" O.D. - Worm Drive Tubing, 3/8" x 5/8", Tygothane - Clear Plug, 3/8" Plastic Tube Plug, 1/8" Plastic Tubing Tube, 1/4" O.D. x 1/8" I.D. - Plastic Diode Assembly, Up Solenoid Eyelet, 5/16" Insulated - Red Fitting, 90°-1/8" Male Pipe x 1/8" Barbed Diode Assembly, Down Valve Solenoid Terminal, 1/4" Male Spade - Fully Insulated - 14/16 Gauge Circuit Breaker, 8 Amp - Manual Reset Screw, #10-32 x 3/8", Pan Head, Phillips, Thread Cut Washer, .326" X .562" X .042"-SS Bumper, 1/2" Dia. x 1/4" Tall - Rubber Electrical Board Assembly / 24 Volt / RoHS Chip, UVL 600 Program Stow Lock Screw, #6 x 3/8" Self Tap, Flat Head Bracket, PC Board Mounting Standoff, .25" PCB - Nylon Edge Liner, 1/8", Q-Trim Edge Liner, 1/8", Q-Trim Clip, Cable - 7/16" Plastic Solenoid, Motor UVL - 24V Clamp, Hose Power Cable, Up Solenoid to Motor Tag, Caution Do Not Connect - Red (Not Shown) Cable Tie, 14 1/2" (Not Shown) Kit, Fuse Replacement (Not Shown) Fuse, 5 Amperes Relay, 12/20 Amperes, 24 Volt Tag, Vent Tube Plug Removal - UVL (Not Shown) Cable Tie, 3 3/4" x .09", White (Not Shown) Hand Control Assembly Pump Cover (Cover Assembly 75820A-09 Includes Items 48-55) Decal, UVL Patent & Trademark (Not Shown) Decal, Electrical Components-Lift-Intl-UVL (Not Shown) 'HFDO)XVH6SHFLÀFDWLRQV,QWO89/1RW6KRZQ Decal, Electrical Components-Module-Intl-UVL (Not Shown) Decal, Hazard-Electrical Shock-Intl-Pictoral (Not Shown) Decal, Warn Damage Control Board-ESD (Not Shown) Decal, Manual Operation - UVL (Not Shown) Screw, 1/4-20 x 3/8", Pan Head Phillips Clamp-Spring-Pump Handle Screw, 10-32 x 3/8" Flat Head Phillips Washer, #10 Flat Nut, #10-32 Hex Handle, Pump Bracket, Power Pack Mounting Washer, 1/4" External Star Tooth Lock Ground Cable - Black Part No. 73800AC24-04 35262A-82 16004A-004 87614 87569 73822-2 82881 87592 87587 10130 87052 87623 73943A 87060-24V 87618 84325 82066R012 81580 81583 81557R014 73906A 86267 87563 73907A 78036 30364 82755 83583 82064 73900LFCE-24V-2 85900-102 82764 73824NW-02 86739 13910R006 13910R008 15777 32930 17069 29049 81796 24534 36676K 85835 168001-1416 25807 86003 73946A-100-1 75820-09 29884 36650 36649 36513 30787 28461 82769 12350 82767 11541 11542 17206A 73825 83588 68874 UVL603C24 (24V) Pump Module Diagram 38 16 20 15 "PUMP T" WIRE ON ELECTRICAL BOARD 17 18 15 56 48 39 TO DOWN VALVE 14 6 "VALVE T" WIRE ON ELECTRICAL BOARD 24 19 58 5 6 56 64 13 37 61 57 23 59 63 21 60 12 22 TO DOWN VALVE 62 58 "GROUND" WIRE ON ELECTRICAL BOARD 57 59 60 "24V POWER" WIRE ON ELECTRICAL BOARD 25 36 26 "24 V" WIRE ON ELECTRICAL BOARD 56 31 27 INLINE FUSE HOLDER WITH 5 AMP FUSE 33 6 47 T LIF UP T LIF WN DO 10 OW T ST LIF 32 29 28 ORE DOOS CL 6 11 34 33 30 35 43 3 44 4 2 9 7 8 NOTICE Page 31 Remove power from pump module and any spark source before working with hydraulic ÁXLGDQGFRPSRQHQWV:HDU SURSHUH\HSURWHFWLRQ8VH protective gloves for prolonged FRQWDFWZLWKK\GUDXOLFÁXLG 1 8VHFDXWLRQZKHQZRUNLQJRQFRPSRQHQWV LQVLGHSXPSPRGXOH$QDYDLODEOHHQHUJ\RI RYHU9$FUHDWHVDQHQHUJ\KD]DUG 81812 UVL601C - Repair Parts List Item Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 1 4 4 1 5 1 1 2 4 1 3 1 3 2 1 1 1 1 1 2 4 2 2 8 1 6 2 2 2 1 1 1 1 1 1 1 2 1 27 2 2 1 1 2 6 2 2 1 4 2 2 2 1 1 2 6 3 2 2 4 1 2 5 3 4 2 1 1 1 2 Page 32 Description Housing Weldment Clamp, Lift Mounting Nut, 1/4" NC Rivet Chain Release Assembly Screw, 1/4-20 x 1, Serrated Hex Bracket, In-Out Cam, Inboard Bracket, In-Out Cam, Outboard Bearing, 1/2" ID. x 1/2" Split Screw, 1/4-20 x 3/4", Washer Head Chain Tensioner Weldment Roller, Chain Idler, Nylon Screw, 5/16 x 1 1/4" Shoulder, Soc. Hd., 1/4-20 Nut, 1/4-20 Nylock, Full Thread Nut, 1/2-20, Hex, Jam Cover, Chain Tensioner Fitting Assembly, Bulk Head Nut, 9/16-18 Hex Jam ZP Nipple, Hydraulic Quick Disconnect Carriage Weldment Shaft Bearing Weldment Bearing, Track Roller 20 x 52mm Shaft, Eccentric Bearing Weldment E-Clip 3/4" Bowed .580 Groove E-Clip 3/4" .580 Groove DIA Washer, .2811" ID x .625" OD x .055" Screw, 1/4-20 x 3/8", Serrated Hex Washer, Front Scissor Arm Bearing, 1 5/8" O.D. x 3/4" I.D. Bushing, 3/4" ID x 3/8", Peer12FB06 Cylinder, Assembly, 600 UVL U-Channel, Edge Trim Pin, Cylinder Rod Mounting Long Pin, Cylinder Rod Mounting Grommet, 1.25” DIA x .25” Wide Seal, Crimp On Edge Motor, Electric, In/Out - w/Sprocket and Dowel Plug, 1 1/2" x 2" x 11 Gauge Tube Tape, 1/16" x 3/4" Double Face Screw, 10-32 x 3/8" Pan Head, Thread Cut Cam, Torque Shaft Actuator Clamp, 1 5/16" x 2 1/4" x 1/2", Worm Drive Weldment, Roll Stop, UVL600 Platform Weldment E-Clip, 3/8" Shaft Washer, #10 Internal Tooth Screw, 5/16-24 x 7/8", Flat Hd. Soc. Cap Retainer, Scissor Bearing Cam, Rear Barrier Washer, .328" x .562" x .042" Bearing, Scissor Platform Washer, Rear Scissor Bearing Washer, Rear Scissor Arm Bolt, 1/4-20 x 5/8" Socket Head Shield, Carriage Wire Harness Washer, .390 x .625 x .073, SS Clamp, 1/4" ID Nylon Loop, Black Plate, Switch Bracket, Tap Screw, 1/4-20 x 2 3/4", Serrated Hex Screw, 5/16 x 2 SHLD SKT HD 1/4-20 SS Clamp, Insulate 1" Plate, Rear Barrier (15") Screw, 1/4-20 x 1/4 Pan Head Nylon Limit Switch Assembly Tape, Limit Switch Mounting Pad Screw, 10-32 x 1 1/2", Socket Cap Screw, 10-32 x 7/8", Socket Cap Bracket, Switch In/Out Mounting Nut, 5/16-24 LH Hex Jam ZP Skid, Rear Barrier Nut, 10-32 Serrated Flange ZP Part No. Item Qty. 71101W-2 73733 83020 73760A 82760 73774 73775 84391 24750 76750W 73706 82751 83070 83022 71754 73777A 83077 87615 71201W 73230W 84305 73233W 84377 84376 83511 82761 73748 84004 900-0455 73801A 82000R012 73700 73701-05 84386 82070R036 73780AS 81582 82033R333 82755 73712 26400 71321W 71301CW 84383 11540 82763 73737 74403 83583 84321 73755 73749 82333 73742 83585 84396 68280-2 82759 82758 20535 71401-15 82773 73950A 73747 82717 82778 73719 83076 74402-15 83080 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 2 1 1 1 4 8 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 1 1 1 1 1 1 1 4 1 1 1 2 1 2 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 1 2 1 1 Description Screw, 10-32 x 5/8" PH PN SS Shaft, Rear Barrier Hinge Closure, Weldment, NUVL603C Cover, Platform Wiring Harness Nut, 1/4-20, Serrated Flange Screw, 1/4-20 UNC x 3/8 RD. HD. Spring, Torsion Barrier Actuator Assembly Screw, 1/2" x 2" SHLD SKT HD x 3/8-16 Arm, Weldment, Barrier Clevis Ring, Clevis Pin 5/16" Clip, Hairpin, 5/16" DIA Shaft Screw, 1/2 x 1 1/4" SHLD SKT HD x 3/8-16 Spring, Lower Closure Torsion Plate, Platform Floor Hinge Weldment Rear Barrier Ring, Retaining 5/8" Catch, Weldment, Rear Barrier Block, Nylon Slider Inside Block, Nylon Slider Outside Rivet, Pop, SD64BS-3/16"- .13/.25, Auto Black Bracket, Lower Housing Cover Plug, Poly Finish, 1" Hole, Black Cover, Lower Screw, 10-32 x 3/8", Flat HD PH ZP Lip, LH Side Seal Lip, RH Side Shield Cam, 7/8" UVL Follower Tape, 1" Wide S-Face Foam Chain, Nickel Plated Roller, #35 Connector Link, #35 Chain Rod End, 5/16-24 Male Screw, 1/4-20 x 1 1/2" Washer HD TYPF Cover, Upper Lid, Upper Edge Seal Spring, Barrier Clevis Tension Nut, 3/8-24 Jam, ZP Bolt, 1/4-20 x 1/2" Socket Low HD Bearing, 5/8” ID. x 1/2” Long Tape, 1/8 x 2" Foam Adhesive Screw, 1/4-20 x 3/4 SERR HEX ZP Rod End, 5/16-24 Left Hand Male Nut, 5/16-24 Hex, Jam ZP Nut, 5/16-24 Nylock Plated Tie Rod, Rear Barrier Bolt, 5/16-24 x 1" SKT BTN PLTD Block, Rear Barrier Slider Rocker, Rear Barrier Bolt, 5/16-24 x 2 1/4" SKT Flat Bolt, 5/16-24 x 2" SKT Flat Plated Link, Rear Barrier Bearing, Split 1/4" I.D. x 1/4" Long Bushing, Link, Rear Barrier Pin, .25" x .81" Dowel Bearing, 5/8 I.D. x 5/8" LG Split Washer, .281 x .75 x .06 Brass Manual Release Cable Assy. Kit Cam Follower, 1/4 I.D. x 3/4" O.D. x .5" Washer, 5/16" Flat Link/Rocker Assembly - IB Sponge Strip, 1/2" x 1/4" Bolt, 5/16-24 x 3/4” BHCS, SS Screw, 5/16-18 x 1/2” BHSC-BLK/Auto-BK Bearing, .75 I.D. x .25 LG Split - 12DU04 WMT, Bridgeplate Guide Bolt, 1/4-20 x 1/2" Hex O-Ring, 7/16" I.D. x 5/8" O.D. Viton 75 Pin, Clevis Release Part No. 82884 74413 71330W 75305 83064 12514 85101 74340-3 82770 73325W-2 11390 84382 82771 73335 71306C 71420W 84189 74415W 74410 74409 11513 73108 81576 71732-2 82767 73745 73744 84052 82015R 84314R120 84317 84384 24751 71730-2 71746 85098 83074 82335 84319 82054R048 82768 84385 83075 83079 74407 82348 74408 74404 82346 82347 74406 84395 74411 74412 84394 83592 73770-600 84392 10063 74431A 82063R036 29863 26281 84282 30840W 21988 87861 73741-2 UVL601C - Housing Exploded View Detail 39 39 39 104 39 39 105 39 110 35 38 38 38 38 38 132 39 14 2 38 15 99 6 14 9 10 13 9 2 100 12 1 135 11 2 101 39 136 136 3 60 97 39 16 17 99 18 2 99 75 4 107 98 75 39 9 107 96 127 7 5 5 94 92 91 95 93 Page 33 UVL601C - Carriage Exploded View Detail 30 29 29 109 31 54 57 64 111 63 109 65 45 67 32 49 11 13 39 38 20 25 20 26 21 26 39 56 39 23 24 33 21 57 39 56 26 27 28 62 133 19 27 58 40 129 49 49 51 50 41 56 51 50 52 24 21 52 75 36 37 56 56 24 28 24 53 24 41 39 Page 34 133 21 22 26 60 39 23 129 62 60 39 22 64 45 63 65 60 49 59 26 24 48 37 UVL601C - Platform Exploded View Detail 85 38 38 38 38 61 70 38 70 71 69 72 76 74 76 39 76 86 76 76 76 102 116 88 114 77 39 44 44 77 134 34 46 47 78 113 24 130 112 87 134 24 81 66 45 47 114 128 125 126 137 46 68 115 64 63 57 66 45 82 106 138 8 80 118 55 89 121 108 124 122 123 8 114 117 119 90 79 73 43 55 120 42 84 83 Page 35 UVL603C / UVL603C24 - Repair Parts List Item Qty. 1 1 Housing Weldment Description 2 4 Clamp, Lift Mounting 3 4 Nut, 1/4" NC Rivet 4 1 Chain Release Assembly 5 6 6 1 Part No. Item Qty. 73101W-2 72 1 Shaft, Rear Barrier Hinge Description 73733 73 1 Closure, Weldment Part No. 74413 73330W 83020 74 1 Cover, Platform Wiring Harness 73738 73760A 75 3 Nut, 1/4-20, Serrated Flange, Z/P 83064 Screw, 1/4-20 x 1", Serrated Hex 82760 76 8 Screw, 1/4-20 UNC x 3/8" RD. HD. 12514 Bracket, In-Out Cam, Inboard 73774 77 2 Spring, Torsion 85101 78 1 Barrier Actuator Assembly (UVL603C) 1 Barrier Actuator Assembly (UVL603C24) 7 1 Bracket, In-Out Cam, Outboard 73775 8 2 Bearing, 1/2" ID. x 1/2" Split 84391 9 4 Screw, 1/4-20 x 3/4", Washer Head 10 1 Chain Tensioner Weldment 24750 79 1 Screw, 1/2" x 2" SHLD SKT HD x 3/8-16 76750W 80 1 Arm, Weldment, Barrier Clevis 74340-3 74340-24V-RMN 82770 73325W-2 11 3 Roller, Chain Idler, Nylon 73706 81 1 Ring, Clevis Pin 5/16" 11390 12 1 Screw, 5/16" x 1 1/4" Shoulder, Soc. Hd.,1/4-20 82751 82 1 Clip, Hairpin, 5/16" DIA Shaft 84382 13 3 Nut, 1/4-20 Nylock, Full Thread 83070 83 1 Screw, 1/2" x 1 1/4" Shoulder Socket Head x 3/8-16 82771 14 2 Nut, 1/2-20, Hex, Jam 83022 84 1 Spring, Lower Closure Torsion 73335 15 1 Cover, Chain Tensioner 71754 85 1 Plate, Platform Floor 74306-1 16 1 Fitting Assembly, Bulk Head 73777A 86 1 Hinge Weldment Rear Barrier 74420W 17 1 Nut, 9/16-18 Hex Jam ZP 83077 87 1 Ring, Retaining 5/8" 18 1 Nipple, Hydraulic Quick Disconnect 87615 88 1 Catch, Weldment, Rear Barrier 19 1 Carriage Weldment 73201W 89 1 Block, Nylon Slider Inside 74410 20 2 Shaft Bearing Weldment 73230W 90 1 Block, Nylon Slider Outside 74409 21 4 Bearing, Track Roller 20 x 52mm 22 2 Shaft, Eccentric Bearing Weldment 23 2 E-Clip 3/4" Bowed .580" Groove 84377 93 1 Plug, Poly Finish, 1" Hole, Black 24 8 E-Clip 3/4" .580" Groove DIA 84376 94 1 Cover, Lower 25 1 Washer, .2811" ID x .625" OD x .055" 83511 95 3 Screw, 10-32 x 3/8", Flat HD PH ZP 82767 26 6 Screw, 1/4-20 x 3/8", Serrated Hex 82761 96 1 Lip, LH Side Seal 73745 27 2 Washer, Front Scissor Arm 73748 97 1 Lip, RH Side Shield 73744 28 2 Bearing, Scissor Platform 84321 98 1 Cam, 7/8" UVL Follower 29 2 Bushing, 3/4" ID x 3/8", Peer12FB06 900-0455 99 1 Tape, 1" Wide S-Face Foam 30 1 Cylinder, Assembly, 600 UVL 31 1 U-Channel, Edge Trim 32 1 Pin, Cylinder Rod Mounting Long 33 1 Pin, Cylinder Rod Mounting 34 1 Screw, 1/4-20 x 3/4" SERR HEX ZP 84189 74415W 84305 91 2 Rivet, Pop, SD64BS-3/16"- .13"/.25", Auto Black 11513 73233W 92 1 Bracket, Lower Housing Cover 73108 81576 73732-2 84052 82015R 73801A 100 1 Chain, Nickel Plated Roller, #35 82000R012 101 1 Connector Link, #35 Chain 84317 73700 102 1 Rod End, 5/16-24 Male 84384 73701-05 103 4 Screw, 1/4-20 x 1 1/2" Washer HD TYPF 82768 104 1 Cover, Upper 84314R120 24751 73730-2 35 2 Screw, 5/16-18 x 1/2" BHSC-BLK/Auto-BK 26281 105 1 Lid, Upper Edge Seal 73746 36 1 Motor, Electric, In/Out - w/Sprocket & Dowel (UVL603C) 73780AS 106 1 O-Ring, 7/16" ID x 5/8" OD Viton 75 87861 1 Motor, Electric, In/Out - w/Sprocket & Dowel (UVL603C24) 73780A24 107 2 Nut, 3/8-24 Jam, ZP 83074 37 2 Plug, 1 1/2" x 2" x 11 Gauge Tube 81582 108 1 Bolt, 1/4-20 x 1/2" Socket Low HD 82335 38 1 Tape, 1/16" x 3/4" Double Face 82033R333 109 1 Cam, Rear Barrier Fold 73414 39 27 Screw, 10-32 x 3/8" Pan Head, Thread Cut 82755 110 1 Tape, 1/8" x 2" Foam Adhesive 82054R048 40 2 Cam, Torque Shaft Actuator 73712 111 1 Seal, Crimp On Edge 82070R036 41 2 Clamp, 1 5/16" x 2 1/4" x 1/2", Worm Drive 42 1 Barrier, Weldment, UVL600 43 1 Platform Weldment 26400 112 1 Rod End, 5/16-24 Left Hand Male 73321W 113 1 Nut, 5/16-24 Hex, Jam ZP 83075 73301NW 114 3 Nut, 5/16-24 Nylock Plated 83079 74407 84385 44 2 E-Clip, 3/8" Shaft 84383 115 1 Tie Rod, Rear Barrier 45 6 Washer, #10 Internal Tooth 11540 116 1 Bolt, 5/16-24 x 1" SKT BTN PLTD 82348 46 2 Screw, 5/16-24 x 7/8", Flat Hd. Soc. Cap 82763 117 1 Block, Rear Barrier Slider 74408 47 2 Retainer, Scissor Bearing 73737 118 1 Rocker, Rear Barrier 74404 48 1 Cam, Rear Barrier 74403 119 1 Bolt, 5/16-24 x 2 1/4" SKT Flat 82346 49 4 Washer, .328" x .562" x .042" 83583 120 1 Bolt, 5/16-24 x 2" SKT Flat Plated 82347 50 2 Bearing, 1 5/8" O.D. X 3/4" I.D. 84004 121 1 Link, Rear Barrier 74406 51 2 Washer, Rear Scissor Bearing 73755 122 1 Bearing, Split 1/4" I.D. x 1/4" Long 84395 52 2 Washer, Rear Scissor Arm 73749 123 1 Bushing, Link, Rear Barrier 74411 53 1 Bolt, 1/4-20 x 5/8" Socket Head 82333 124 2 Pin, .25" x .81" Dowel 74412 54 1 Shield, Carriage Wire Harness 73742 125 1 Bearing, 5/8" I.D. x 5/8" LG Split 84394 55 2 Washer, .390" x .625" x .073", SS 83585 126 1 Washer, .281" x .75" x .06" Brass 83592 56 6 Clamp, 1/4" ID Nylon Loop, Black 73770-600 57 3 Plate, Switch Bracket, Tap 58 2 Screw, 1/4-20 x 2 3/4", Serrated Hex 59 2 60 4 61 1 62 1 63 64 84396 127 1 Manual Release Cable Assy. Kit 68280-2 128 1 Cam Follower, 1/4" I.D. x 3/4" O.D. x .5" 84392 82759 129 2 Washer, 5/16" Flat 10063 Screw, 5/16" x 2" SHLD SKT HD 1/4-20 SS 82758 130 1 Link/Rocker Assembly - IB Clamp, Insulate 1" 20535 131 1 Sponge Strip, 1/2" x 1/4" Plate, Rear Barrier - 8" 74401-8 132 2 Screw, 1/4-20 x 1/4" Pan Head Nylon 82773 Pin, Clevis Release 73741-2 133 1 Spring, Barrier Clevis Tension 85098 5 Limit Switch Assembly 73950A 134 2 Bearing, .75" I.D. x .25" LG Split - 12DU04 84282 3 Tape, Limit Switch Mounting Pad 73747 135 2 Bearing, 5/8" ID. x 1/2" Long 65 4 Screw, 10-32 x 1 1/2", Socket Cap 82717 136 1 Plate, Rear Barrier - 15" 73401N-15DS 66 2 Screw, 10-32 x 7/8", Socket Cap 82778 137 1 Skid, Rear Barrier - 15" 74402-15 67 1 Bracket, Switch In/Out Mounting 73719 138 8 Screw, 1/4-20 UNC x 3/8" FL Soc Cap Head 68 1 Nut, 5/16-24 LH Hex Jam ZP 83076 139 2 Spring, Torsion 85101EVO 69 1 Skid, Rear Barrier - 8" 74402-8 140 1 Hinge Weldment Rear Barrier 74420NW 70 2 Nut, 10-32 Serrated Flange ZP (UVL603C) 83080 141 1 Skid, Rear Barrier 75414C 4 Nut, 10-32 Serrated Flange ZP (UVL603C24) 83080 142 2 Screw, #10-32 x 1/2" FHDHXS - Auto Bk w/Patch 17192P 2 Screw, 10-32 x 5/8" PH PN SS 82884 143 2 Screw, #10-32 x 1/2" PH PN ZP 71 Page 36 74431A 82063R036 84319 23471 82744 UVL603C / UVL603C24 - Housing Exploded View Detail 39 39 39 104 39 39 105 39 110 111 38 38 38 38 38 39 14 2 38 15 99 14 9 10 13 6 2 100 12 1 11 39 101 3 2 60 97 39 18 16 17 99 99 2 7 4 103 5 39 127 96 107 5 75 107 9 98 75 5 109 94 92 91 95 93 Page 37 UVL603C / UVL603C24 - Carriage Exploded View Detail 30 29 29 135 31 54 57 64 34 63 135 65 45 67 32 49 11 13 39 38 20 25 20 26 21 26 39 56 39 23 24 33 21 57 39 56 26 27 50 132 35 19 27 58 40 129 49 49 51 28 41 56 51 52 39 21 50 24 75 53 36 24 48 24 41 28 52 24 Page 38 35 21 22 26 60 39 23 129 132 60 39 22 64 45 63 65 60 49 59 26 37 56 56 24 37 UVL603C / UVL603C24 - Platform Exploded View Detail 85 24 C 3 L60 UV 141 70 70 142 143 137 138 138 136 138 138 38 138 139 140 38 139 38 38 03C 6 L UV 38 70 71 69 72 61 76 76 86 76 76 76 77 76 88 77 114 44 74 134 44 102 39 46 47 78 24 116 113 87 106 115 47 130 68 128 125 126 24 112 124 122 123 66 45 133 82 62 8 80 55 121 108 64 63 57 134 118 81 66 45 46 114 89 8 114 117 119 120 90 79 43 73 55 42 84 83 Page 39 ® EC Declaration of Conformity With Council Directive 2006/42/EC Date of Issue: 1 December 2011 Directive: Machinery Directive on machinery safety, 2006/42/EC Conforming Machinery: Hydraulic Lift System UVL601C Series 04 and Newer International Lifts UVL603C Series 04 and Newer International Lifts UVL603C24 Series 04 and Newer International Lifts UVL855R Series 09 and Newer International Lifts UVL855R24 Series 09 and Newer International Lifts Manufacturer: Braun Corporation 631 West 11th Street Winamac, IN 46996 USA Authorized Representative: Braun Corporation Authorized Representative AUTOADAPT AB Åkerivägen 7 S-443 61 Stenkullen SWEDEN Telephone: +46 (0) 302 254 00 E-mail: [email protected] AUTOADAPT UK LTD Unit 1, Windsor Industrial Estate, Rupert Street Aston, Birmingham B7 4PR, UK Phone: +44 (0) 121 33 35 170 E-mail: [email protected] Harmonized Standards Referenced or Applied: BS EN 13857:2008, BS EN ISO 13850:2008, EN ISO 14121-1:2007, BS EN 349:1993+A1:2008, BS EN 953:1997+A1:2009, BS EN 1037:1995+A1:2008, BS EN 982:1996+A1:2008, BS EN 614-1:2006+A1:2009, EN 60204-1:2006, BS EN 1756-2:2004+A1:2009 6SHFLÀFDWLRQVZLWKZKLFK Conformity is Declared: Essential Health and Safety Requirements of Annex 1 of the Machinery Directive We hereby certify that the machinery described above conforms with the essential health and safety requirements of Council Directive 2006/42/EC on the approximation of the laws of the Member States relating to the safety of machinery. Technical File Reference Number Page 40 SF10999A1.BC ® Notes on Declared Standards referenced in the Declaration. BS EN 13857:2008 Safety of machinery. Safety distances to prevent hazard zones being reached by upper and lower limbs. BS EN ISO 13850:2008 Safety of machinery - Emergency stop - Principles for design. EN ISO 14121-1:2007 Safety of machinery - Risk assessment - Part 1: Principles. BS EN 349:1993+A1:2008 Safety of machinery. Minimum gaps to avoid crushing of parts of the human body. BS EN 953:1997+A1:2009 Safety of machinery. Guards. General requirePHQWVIRUWKHGHVLJQDQGFRQVWUXFWLRQRIÀ[HGDQG moveable parts. BS EN 1037:1995+A1:2008 Safety of machinery. Prevention of unexpected start-up. BS EN 982:1996+A1:2008 6DIHW\RIPDFKLQHU\6DIHW\UHTXLUHPHQWVIRUÁXLG power systems and their components. Hydraulics. BS EN 614-1:2006+A1:2009 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles. EN 60204-1:2006 Safety of machinery. Electrical equipment of machines. General requirements. BS EN 1756-2:2004+A1:2009 Tail Lifts-Platform lifts for mounting on wheeled vehicles-Safety Requirements-Part 2: Tail lifts for passengers. Page 41 ® Declaration of Noise Emission The Braun Corporation UVL International Series System Sound Pressure Levels per EN ISO 11202 as based on testing on similar models are as follows: LpAm (Operator Position) LpAm (Bystander Position) Operating Idle 75 dB (A) 68 dB (A) 73 dB (A) 69 dB (A) 4 dB (A) Ambient Correction Factor K3A calculated according to EN ISO 11204 Appendix A. Measurements were made at a height of 1.5 m and 1 m from the Operator Position and Bystander positions. The difference between the extraneous noise level and the sound intensity level at each measuring point is: LpAm ǻ = 6 dB (A) 7KHÀJXUHVTXRWHGDUHHPLVVLRQOHYHOVDQGDUHQRWQHFHVVDULO\VDIHZRUNLQJOHYHOV:KLOHWKHUHLV a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required. )DFWRUVWKDWLQÁXHQFHWKHDFWXDOOHYHORIH[SRVXUHRIWKHZRUNIRUFHLQFOXGHFKDUDFWHULVWLFVRIWKH work room, the other sources of noise, etc. such as the number of machines and other adjacent processes. Also, the permissible level of exposure can vary from country to country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk. Page 42 Braun Corporation 631 W. 11th Street Winamac, IN 46996 USA ® Declaration of Conformity With Directive 2004/108/EC Date of Issue: 1 December 2011 Directive: Radio Interference of Vehicles 2004/108/EC Conforming Machinery: Hydraulic Lift System UVL601C Series 04 and Newer International Lifts UVL603C Series 04 and Newer International Lifts UVL603C24 Series 04 and Newer International Lifts UVL855R Series 09 and Newer International Lifts UVL855R24 Series 09 and Newer International Lifts Manufacturer: Braun Corporation 631 West 11th Street Winamac, IN 46996 USA Authorized Representative: Braun Corporation Authorized Representative AUTOADAPT AB Åkerivägen 7 S-443 61 Stenkullen SWEDEN Telephone: +46 (0) 302 254 00 E-mail: [email protected] AUTOADAPT UK LTD Unit 1, Windsor Industrial Estate, Rupert Street Aston, Birmingham B7 4PR, UK Phone: +44 (0) 121 33 35 170 E-mail: [email protected] Harmonized Standards Referenced or Applied: EN50498:2010 We hereby certify that the machinery described above conforms with Directive 2004/108/EC. Technical File Reference Number SF10999A1.BC Page 43 NOTES This page intentionally left blank. Page 44 "Providing Access to the World" ® Over 300 Braun Dealers Worldwide www.braunability.com/international ISO 9001:2008 631 West 11th Street, Winamac, IN 46996, USA Phone: +1 574 946 6153 Fax: +1 574 946 4670 Service Manual for: UVL601C UVL603C UVL603C24 Under-Vehicle Lift® Series 04 Braun Limited Warranty Consult your local Braun dealer regarding warranty policy. www.braunlift.com/international Patent #5,305,486 37274 Rev. A January 2012 www.braunability.com/international ISO 9001:2008 631 West 11th Street, Winamac, IN 46996, USA Phone: +1 574 946 6153 Fax: +1 574 946 4670 All illustrations, descriptions and specifications in this manual are based on the latest product information available at the time of publication. The Braun Corporation reserves the right to make changes at any time without notice. Original Instructions © The Braun Corporation