Download Braun A5 User's Manual
Transcript
Service Manual for: CKA Vista HZg^Zh Public Use Wheelchair Lifts Series A5 DOT — Public Use Lift “DOT — Public Use Lift” verifies that this platform lift meets the “public use lift” requirements of FMVSS No. 403. This lift may be installed on all vehicles appropriate for the size and weight of the lift, but must be installed on buses, school buses, and multipurpose passenger vehicles other than motor homes with a gross vehicle weight rating (GVWR) that exceeds 4,536 kg (10,000 lb). WARNING Man u "Providing Access to the World" ® ® Patent #5,261,779 Patent #6,599,079 33917 Rev. A Patent #6,065,924 Patent #6,692,217 February Patent #6,238,169 Patent #6,739,824 2008 Patent #6,464,447 Patent #6,837,670 Read manual before installing or servicing lift. Failure to do so may result in serious bodily injury and/or property damage. Patents Pending Braun NVL Series International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA 1-800-THE LIFT ® (574) 946-6153 FAX: (574) 946-4670 al 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 service-related material. Refer to the FMVSS No. 403 Quick Reference Installation Sheet for installation instructions, operating instructions and maintenance procedures. Braun Vista Series™ lifts are built for dependability and will provide years of pleasure and independence as long as the lift is installed and serviced as specified by a Braun certified technician, and the lift is operated by an instructed person. Sincerely, THE BRAUN CORPORATION Ralph W. Braun Chief Executive Officer Warranty and Registration Instructions Immediately upon receiving the lift, examine the unit for any damage. Notify the carrier at once with any claims. Series No. Pump Code Model No. Serial No. Cylinder Code OWNER'S WARRANTY REGISTRATION NVL917IB A5-00025 55 14CG Two warranty/registration cards (shown right) are located in the lift-mounted manual storage pouch. The sales representative must process one of the cards. The consumer must fill out the other card and mail it to The Braun Corporation. The warranty is provided on the back cover of this manual. The warranty cards must be processed to activate the warranty. 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 Two Braun Serial No./Series No. identification tags (shown below) are posted on the lift. One I.D. tag is posted on the opposite pump side vertical arm. A second I.D. tag is located on the opposite pump side tower. Both I.D. tags provide the product identification information provided on the warranty/registration card. Record the information in the space provided (or document on a copy). This information must be provided when filing a warranty claim or ordering parts. The Braun Corporation 1-800-THE LIFT™ BRAUNLIFT.COM™ Model No. DOT Public Use Lift MODEL# NVL917IB Max. Lifting Capacity - 800 lbs. Series No. SERIAL NUMBER A5-00025 PUMP CODE CYLINDER 55 14CG Serial No. MFG DATE 09/20/06 Pump Code e5*72/245*95/54*0110*00 PATENT PENDING- 5,261,779-6,065,924-6,238,169-6,46 4,447-6,599,079-6,692,217-6,739,824 Sample Serial No./Series No. Identification Tag Cylinder Code Date of Manufacture Contents Troubleshooting and Maintenance Lift Terminology............................................................. 2 Switch and Sensor Locations ..................................... 3 Certification Checklist Diagnostic Procedures ......... 4 Platform Fold Pressure Adjustment ............................ 5 Platform Angle Adjustment ....................................... 6-7 Platform Stop Blocks .................................................... 7 Platform Foor Level Adjustment .................................. 8 Bridging Microswitch Adjustment ............................... 9 LCD Lift Codes ....................................................... 10-11 Lubrication Diagram.................................................... 12 Maintenance and Lubrication Schedule ............... 13-16 Lift Electrical Schematic ............................................ 17 Lift Wiring Diagram .................................................... 18 Hydraulics Hydraulic Schematic .................................................. 19 Hydraulics Parts List .................................................. 20 Hydraulics Diagram .................................................... 21 Repair Parts Pump Module Pump Module Parts List ....................................... 22 Pump Module Diagram ......................................... 23 Lift Exploded View Repair Parts List .................................................... 24 Exploded View ........................................................ 25 Notes ............................................................................ 26 Page 1 Lift Terminology Hand-Held Pendant Control 32819 DOW Lift-Tite™ Latches (2) Towers (2) Top Parallel Arms (2) Visual Threshold Warning N UP Main Cylinders (2) LD UNFO FOLD 32820 ® Audible Threshold Warning Unfold Assist Compression Springs (2) Adjustable Quiet-Ride Stow Blocks (2) (not visible) Platform Lights Vertical Arm Covers (4) Threshold Warning Plate Pump Module (Rear) Handrails (2) Opposite Pump Side Vertical Arm Base Plate Inner Roll Stop Bottom Parallel Arms (2) Saddle (2) Inboard Platform Upper Fold Arm (2) Lower Fold Arm (2) Outboard Platform Pump Side Vertical Arm Platform Side Plates (2) Outer Barrier (Automatic Outboard Roll Stop) Inboard Left Page 2 Right Outboard Switch and Sensor Locations Inboard Left Right Threshold Strip Switch 31221A (Qty. 2) Outboard *Stow Microswitch 23184 (Qty. 2) 32819 DOWN UP LD UNFO FOLD 32820 ® *Ground Detect Magnet 31664 *Ground Detect Magnetic Sensor 30433A60 *Rotary Position Sensor 31194A *IB Occupancy Microswitch Assy. 31643A *Outer Barrier Raised *Bridging Microswitch 975-0443RNA (Rear Pump) 975-0443FNA (Front Pump) Magnetic Sensor 30433A60 *Outer Barrier Raised Magnet 31664 *Note: Mirror image for right (front) pump lifts. Page 3 Certification Checklist Diagnostic Procedures The following operations and conditions must be functionally verified in order for the lift to be FMVSS 403/404 compliant. If an operation does not function as described or a condition is not met, follow the referenced procedures to correct the problem or contact a Braun Corporation Product Support representative at 1-800-THE LIFT®. • Vehicle movement is prevented unless the lift door is closed, ensuring the lift is stowed. 1. Verify on the pump module mounted interlock connector that the lift not stowed signal (pin 5) has an open signal - OR - lift stowed signal (pin 7) has a +12 volt signal - OR - (pin 9) has a ground signal (depends on interlock used). 2. Refer to the interlock installation instructions. • Lift operation shall be prevented unless the vehicle is stopped and vehicle movement is prevented. 1. Verify vehicle secure signal (pin 6) has a +12 volt signal. 2. Refer to the interlock installation instructions. • The platform will not fold/stow if occupied. - Refer to Platform Fold Pressure Adjustment procedures. • The inner roll stop will not raise if occupied. - Call Product Support • The outer barrier will not raise if occupied. - Call Product Support • Verify platform lighting when lift is deployed and pendant illumination when lift is powered. 1. Replace bulb(s) in the light housing. 2. Check fuse (5 amp fuse on circuit board; F13) • A visual and audible warning will activate if the threshold area is occupied when the platform is at least 1" below floor level. 1. 2. 3. 4. Remove the threshold warning plate Verify the threshold strip switch connectors are connected Replace the threshold strip switch Reinstall the threshold warning plate • Platform movement is prohibited beyond the position where the inner roll stop is fully deployed (up). - Call Product Support. • Lift platform movement shall be interrupted unless the outer barrier is deployed (up). - Call Product Support. Page 4 Platform Fold Pressure Adjustment 1. Position the platform at the floor level loading position. 2. Loosen the hex nut on the adjustment screw (do not remove hex nut). 3. Turn the adjustment screw counter clockwise until the platform does not fold when the Fold button is pressed. 4. Turn the adjustment screw clockwise in 1/4 turn increments and press the Fold button until the platform folds completely (Note: Return the platform to floor level position after each attempt to fold the platform). 5. Turn the adjustment screw an additional 1/8 turn after the platform folds successfully. 6. Tighten the hex nut without moving the adjustment screw. 7. Verify the platform will not stow while occupied. DO NOT adjust this valve! Platform Fold Adjustment Allen Screw (located beside solenoid valves) Note: Secure adjustment screw and tighten hex nut following adjustment. Page 5 Platform Angle Adjustment Adjusting the platform angle based on the relationship of the platform at ground level directly affects the angle of the platform when positioned at floor level. Millennium “NL” Series Figure C Unfold the lift and visually examine the angle of the platform when positioned at floor level. Lower the platform fully and note the angle of the platform when it reaches ground level also. The outboard end of the platform (toe) must contact the ground first when the platform is lowered (all lift models). Angle A equals Angle B. ✓ Millennium “NL” Series: The platform angle should be adjusted so there is a balance between the angle at both positions (equal amount of angle). Angle A should equal angle B as shown in Figure C. Century “NCL” Series: Vista “NVL” Series: The platform angle must be adjusted so the outboard end of the platform (toe) is angled down slightly when positioned at floor level. See Figure D. The outboard end of the platform must contact the ground first to ensure the spring-loaded outer barrier unfolds fully. A Wedges B Approximately 1” Clearance Inboard Outboard Century “NCL” Series Vista “NVL” Series Adjustment Procedures: Adjustment Allen screws are provided on each side of the lift platform for adjusting the platform angle. Details and photos are provided on the opposite page. Figure D Base Plate Wedges: Installations where base plate wedges are used require more platform angle adjustment than normal. Toe must angle down slightly. Platform Stop Blocks: When adjusting platform angle, ensure both stop blocks are making full contact with the vertical arms (details on opposite page). Floor Level Adjustment: Following platform angle adjustment, set floor level positioning as detailed in Platform Floor Level Adjustment (details on page 8). Page 6 Floor Level Floor Level Barrier must unfold fully. Wedges Inboard Outboard Platform Angle Adjustment Adjustment Allen screws are provided on each side of the lift platform for adjusting the platform angle. Adjust platform angle as specified on previous page. To raise the outboard end of platform - turn adjustment screw clockwise. Note: Both adjustment screws must be adjusted equally. Apply Loctite® to adjustment screws following adjustment. To lower the outboard end of platform - turn adjustment screw counterclockwise. Platform Angle Adjustment Screws Adjustment Screw Allen Head B A Turn counterclockwise to lower outboard end of platform Turn clockwise to raise outboard end of platform Platform Stop Blocks Right Must make full contact. Gap not permitted. Wrong Stop Block Guideline All Lift Models Vertical Stop Arm Block C Both stop blocks must make full contact with the edge of vertical arms. Vertical Arm When adjusting platform angle, setting floor level position or adjusting bridging microswitch ensure both stop blocks are making full contact with the vertical arms. Stop Block D Page 7 Platform Floor Level Adjustment Before setting floor level position: tion if unable to stop platform when powering lift. • Adjust platform angle as detailed on page 6. 2. Turn Lift Power switch Off. • Ensure both stop blocks are making full contact with vertical arms (details on page 7). 3. Press Floor Position Set button (located between pump housing and lift tower). Floor Level Adjustment: 4. While pressing the Floor Position Set button, turn the Lift Power switch On. 1. Position platform at desired floor level position (passenger loading/unloading height). Position platform such that: a. the inner roll stop is laying flat on the threshold plate b. platforrm has not begun to fold Note: Use hand pump to position platform at proper posi- Diagnostics: Diagnostic codes have been established in event the lift platform floor position does not set (the lift does not sound three “beeps” - see Step 5 above). The control board located inside the pump hous- E 5. Continue pressing the Floor Position Set button until the lift sounds three “beeps.” 6. Release the Floor Position Set button. Floor Level Set Button 7. Cycle lift to verify that platform stops at the set floor level position. Note: If platform does not stop at the intended position - repeat adjustment procedures. If repeating procedures fails - refer to Diagnostics section below. ing is equipped with an LCD screen. Remove the pump cover to access the LCD screen. The following diagnostic codes will help resolve floor position setting problems: 91 – The platform position is out of a predetermined acceptable range Century/Vista Jumper LCD Screen 92 – The Bridging Microswitch is not activated (adjust switch or lower the platform) 93 – The Inner Roll Stop Occupied switch is not activated (adjust switch) 94 – The Outer Barrier Up switch is not activated (adjust switch) 95 – The Outer Barrier Latched sensor is not activated (Century and Vista: Verify jumper is installed on the outboard barrier latch switch – see photo at right; Millennium: Check latch) Page 8 F Bridging Microswitch Adjustment Adjustment Screw Bridging Microswitch: Bridging Microswitch G H The bridging microswitch is located at the bottom of the right (front) vertical arm. See Photos A and B. An adjustment screw is built into the platform stop block. The bridging microswitch will be deactivated if the outboard end of the platform contacts the unloading surface before the inboard end while the DOWN switch is pressed. The deactivated bridging microswitch interrupts power to the DOWN switch circuit and stops the down travel of the platform (while allowing the outer barrier to deploy). Inboard Vertical Edge of Vertical Arm Platform Stop Block Switch Activation Lever Adjustment Guidelines: Caution: This adjustment is factory set and typically should not require adjustment. Before adjusting the bridging microswitch: • Adjust platform angle as detailed on page 6. • Adjust floor level position as detailed on page 8. • Ensure platform is in the fully unfolded position. • Ensure both stop blocks are making full contact with vertical arms (details on page 7). Failure to follow these guidelines will result in an overtight adjustment that will bend the adjustment screw, break the bridging switch and/or result in lift operation failure. Bridging Microswitch Adjustment 1. Position the platform at floor level (or slightly below). Ensure the platform is not partially folded. From the stowed position, press the UNFOLD switch until the pump stops running and the platform comes to a full stop. From below floor level, press the UP switch until the pump stops running and the platform comes to a full stop. 2. Check both platform stop blocks to ensure there is no gap between the stop blocks and the vertical arms. See Photos B, C and D on page 7. A gap may indicate that the platform is not fully unfolded or the platform angle adjustment bolts are not adjusted equally on both sides. 3. Loosen the two jam nuts on the bridging switch activation screw (see Photo G). Tighten the screw until the activation lever is fully depressed. Verify that there is no play in the activation lever and tighten the jam nuts. 4. Test lift for proper operation. Page 9 LCD Lift Codes To better understand the Braun LCD Trouble shooting display you must first understand the numbers that appear on the screen. There are Flashing Codes, Solid Error Codes, and Solid Normal Operational Codes. Flashing Codes #65-89: About 10 seconds after an operation has stopped there are a set of scrolling flashing numbers that indicate whenever a particular sensor or switch has been activated. These numbers will start at number 65 and scroll up to number 89, then start the sequence over. Remember they are not error codes. Keep in mind that the lift will display codes for different positions and certain flashing codes must be present for that position, you will not always get an error code. Solid Error Codes #50-64: These are the numbers that will come on the screen when the audible and visual alarm goes off, and will direct you to where the problem exists. These numbers will only stay on the screen for about 10 seconds and then the flashing codes will scroll indicating what sensors are active. This sequence of codes will keep repeating. It is important to be looking at the screen when trying to get the lift to fail. Solid Normal Operational Codes: There are also solid numbers that will appear while and after the lift is moving that indicate the lift operation and platform position. Troubleshooting Procedures 1. While looking at the LCD screen, operate the lift until the failure occurs. Read the number that comes on the display the moment the alarm goes off and the light starts to flash. This code will only stay on the screen for 10 seconds. 2. Look up the number on the correct error code sheet and determine what part on the lift is causing the failure. Go to the part on the lift that is suspected of causing the failure and look for anything obvious like magnets missing, broken wires etc. If nothing is found, the next step is to determine if that sensor is sending a signal to the board. 3. Bring the platform to the level that the sensor should be activated using the backup pump if needed. At this point, look up the flashing code that corresponds to that sensor in the error code sheet, look at the LCD screen and wait for the flashing scrolling numbers to appear. If the number is not included in the scrolling numbers, you know that sensor is the problem. You should then check the harness or try another magnet with the south side of the magnet facing the sensor and see if the number will come up on the display. 4. If the problem is still not found or the harness is suspected, the voltages should to be checked to and from the sensor to find the exact location of the problem. First determine the 3 wire colors for this sensor at the board and understand the 3 voltage readings needed to operate the sensor, the 12V power, 8V power, and the 8V input signal to the PC board when activated by a magnet. First check for a 8V input signal coming from the sensor to the wire going into the PC board, if there is 11V on this wire, the sensor is not being activated by the magnet. Next check the 12V and 8V wires at the PC board plug leading to the sensor. Once verified at the plug on the PC board, the voltages should then be checked at the next plug down on the harness going to the sensor until the location of the problem is found. Anytime you see the code for that specific switch you will have 8 volts on that colored wire on the 8 or 18 pin connector from that switch. IE: Outboard Barrier is closed “72” will appear on the screen and also 8V will be present on the signal wire from that switch, if no code is present the voltage will be 11V. Page 10 LCD Lift Codes Listed below are codes that the lift controller outputs during lift operation. The codes will be displayed on an LCD screen located on the lift control board inside the pump module. See the Manual Operating Instructions in the operator's manual for pump cover removal instructions. Non-Flashing Numbers 01 – Platform stowed 02 – Platform unfolding 03 – Platform unfolding paused 04 – Platform at floor level 05 – Platform beginning to lower 06 – Platform lowering (threshold cannot be occupied from this point down) 07 – Outer barrier moving to horizontal position 08 – Platform at ground level 09 – Outer barrier moving to vertical position 10 – Platform raising 11 – Platform raising paused at floor 12 – Platform folding (limited pressure) 13 – Platform folding (full pressure) 14 – Timed fold (cinching lift tite) or (anti-rattle state) 15 – Platform folding stopped 16 – Paused fold 17 – Platform between ground and 3” above ground 18 – Platform above 3” 19 – Outer barrier moving to horizontal postion 23 Outer barrier going back down after occupant detected 28 – Illegal function/not defined 29 – Interlock fault not recognized (or has been cleared but a motion button is still pressed) 30 – Platform location unknown 31 – Platform location transition state; attempting to locate position 35 – Two or more motion buttons are being pressed 36 – The retention belt cannot be buckled while trying to fold or unfold 37 – Motion button being pressed is not a valid motion 50 – Outer barrier is not up above inboard barrier locked position 51 – Threshold is occupied when platform is 1” or more below floor level 52 – Inner rollstop is not up and locked below inner rollstop locked position 53 – Inner rollstop occupied sensor is not activated between floor and inner rollstop up position 54 – Outer barrier is occupied before it is up 55 – Outer barrier is not latched when above the inner rollstop locked position (Millennium only) 56 – Outer barrier is not up and latched and bridge switch did not deactivate 57 – Outer barrier is not up and latched and ground detect switch did not deactivate (Century and Vista only) 58 – Outer barrier is not up and latched and the platform is 3” above the ground 59 – Outer barrier is not up after pausing platform travel 60 – Verify the IB occupied switch is functioning correctly when lift is below floor level. The kickout gas springs are worn, replace before using 75 – Low voltage detected; must turn off power switch to reset LCD 77 – Vehicle secure interlock has not been activated 90 – Position will be set if you keep holding the button until it beeps 91 – Position is out of a predetermined acceptable range of floor position 92 – Bridge switch is not made, needs adjusting 93 – Inner rollstop occupied switch is not made, position needs to be moved or switch should be adjusted 94 – Outer barrier is not made, fix and try again 95 – Outer barrier latch is not made (check for jumper on Century and Vista lifts, check latch on Millennium lifts) 99 – Controller program is not valid; replace controller Flashing Numbers Flashing 65 – Unfold button is pressed Flashing 66 – Fold button is pressed Flashing 67 – Down button is pressed Flashing 68 – Up button is pressed Flashing 69 – Bridge switch is activated Flashing 70 – Outer barrier latch switch is activated Flashing 71 – Ground detect switch is activated Flashing 72 – Outer barrier up switch is activated Flashing 73 – Inner rollstop up switch is activated Flashing 74 – Inner rollstop occupied switch is activated Flashing 76 – Outboard barrier occupied switch is activated Flashing 78 – Threshold tape switch “A” is activated Flashing 79 – Threshold tape switch “B” is activated Flashing 80 – Position set button is pressed Page 11 Maintenance and Lubrication Lubrication Diagram Lift-Tite™ Latch Dampening Spring (2 springs - 4 Points) LO 32819 Parallel Arm Pivot Pin Bearings (16) LO N DOW UP Lift-Tite™ Latches (Tower Pivot Points - 2) LO Hydraulic Cylinder Pivot Bushings (8) LO LD UNFO FOLD 32820 ® Saddle Bearing Buttons (2) DE Parallel Arm Pivot Pin Bearings (16) LO Handrail Pivot Pins (2) LO Inner Roll Stop Lever Bearings (2) and Slots (2) LO Platform Fold Gear Rack (2) and Gear Link Assembly Teeth (2) DE Saddle Bearing (1) DE Saddle Support Bearings (8) LO Gear Link Assembly Bearings (4) LO Upper Fold Arm Cam Followers (4) LO Upper and Lower Fold Arm Contact Area (2) LG Lower Fold Arm Bearings (8) LO Platform Side Plate Slots (2) LG Outer Barrier Pivot Arm Bearings (4) LO Platform Fold Link Bearings (6) LO Platform Pivot Pin Bearings (4) LO Lift-Tite™ Latch Rollers (2) LO Platform Fold Gear Rack Bearings (4) LG Outboard Platform Bearings (2) LG Outer Barrier Link Slot (2) LG Outer Barrier Activation Foot Bearings (2) LO Outer Barrier Link Pivot Points (2) LO See the Maintenance/Lubrication Schedule for recommended applications per number of cycles. Lubricant LO - Light Oil DE - Door-Ease LG - Light Grease Page 12 Type Specified (recommended) Lubricant Light Penetrating Oil LPS2, General Purpose (30 weight or equivalent) Penetrating Oil Stainless Stick Door-Ease Style (tube) Stick (tube) Light Grease Lubriplate (Multipurpose) Available Amount 11 oz. Aerosol Can 1.68 oz. 14 oz. Can Braun Part No. 15807 15806 15805 Maintenance and Lubrication Schedule Proper maintenance is necessary to ensure safe, troublefree operation. Inspecting the lift for any wear, damage or other abnormal conditions should be a part of all transit agencies’s daily service program. Simple inspections can detect potential problems. The maintenance and lubrication procedures specified in this schedule must be performed by a Braun authorized service representative at the scheduled intervals according to the number of cycles. Braun dual parallel arm lifts are equipped with hardened pins and self-lubricating bushings to decrease wear, provide smooth operation and extend the service life of the lift. When servicing the lift at the recommended intervals, inspection and lubrication procedures specified in the previous sections should be repeated. Clean the components and the surrounding area before applying lubricants. 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 the components. Platform components exposed to contaminants when lowered to the ground may require extra attention. Lift components requiring grease are lubricated during assembly procedures. When these components are replaced, grease must be applied during installation procedures. Specified lubricants are available from The Braun Corporation (part numbers provided above). All listed inspection, lubrication and maintenance procedures should be repeated at “750 cycle” intervals 750 Cycles following the scheduled “4500 Cycles” maintenance. These intervals are a general guideline for scheduling maintenance procedures and will vary according to lift use and conditions. Lifts exposed to severe conditions (weather, environment, contamination, heavy usage, etc.) may require inspection and maintenance procedures to be performed more often than specified. WARNING Maintenance and lubrication procedures must be performed as specified by an authorized service technician. Failure to do so may result in serious bodily injury and/or property damage. Maintenance Indicator: The Lift Ready green LED mounted on top of the pump cover will begin to blink after every 750 cycles. The blinking LED will not affect the functions of the lift, but is a reminder to complete necessary maintenance and lubrication. Once the lift has been serviced, fully stow the lift. Once stowed, press the UP button on the hand pendant and the Floor Level Set button on the back side of the pump cover until the Lift Ready green LED stops blinking. Discontinue lift use immediately if maintenance and lubrication procedures are not properly performed, or if there is any sign of wear, damage or improper operation. Contact your sales representative or call The Braun Corporation at 1-800-THE LIFT®. One of our national Product Support representatives will direct you to an authorized service technician who will inspect your lift. Outer barrier link pivot points (2) Apply Light Oil - See Lubrication Diagram Outer barrier link slots (2) Apply Light Grease - See Lubrication Diagram Gear link assembly bearings (4) Apply Light Oil - See Lubrication Diagram Gear link assembly teeth (2) Apply Door Ease - See Lubrication Diagram Outboard platform bearings (2) Apply Light Grease - See Lubrication Diagram Platform fold link bearings (6) Apply Light Oil - See Lubrication Diagram Platform fold gear rack bearings (4) Apply Light Grease - See Lubrication Diagram Platform fold gear rack teeth (2) Apply Door Ease - See Lubrication Diagram Lift-Tite™ latches (tower pivot points - 2) Apply Light Oil - See Lubrication Diagram Lift-Tite™ latch gas (dampening) spring pivot points (2 springs - 4 points) Apply Light Oil - See Lubrication Diagram continued Page 13 Maintenance and Lubrication Schedule 750 Cycles Inspect Lift-Tite™ latches and gas springs for wear or damage (bent, deformed or misaligned), positive securement (external snap rings) and proper operation Resecure, replace damaged parts or otherwise correct as needed. Note: Apply Light Grease to Lift-Tite™ latch tower pivot point if replacing latch. Inspect outer barrier for proper operation Correct or replace damaged parts. Inspect platform fold gear rack and gear weldment teeth for foreign objects, wear or damage (bent, deformed or misaligned), positive securement and proper operation Remove foreign objects, replace damaged parts and resecure as needed Inspect lift for wear, damage or any abnormal condition Correct as needed. Inspect lift for rattles Correct as needed. Perform all procedures listed in previous sections also 1500 Cycles continued Page 14 Outer barrier activation foot pivot bearings (2) Apply Light Oil - See Lubrication Diagram Outer barrier pivot arm bearings (4) Apply Light Oil - See Lubrication Diagram Upper fold arm cam followers (4) Apply Light Oil - See Lubrication Diagram Upper/lower fold arms (2) Apply Grease (synthetic) to contact areas between upper/lower fold arms. See Lubrication Diagram Platform pivot pin bearings (4) Apply Light Oil - See Lubrication Diagram Lower fold arm bearings (8) Apply Light Oil - See Lubrication Diagram Inner roll stop lever bearings (2) Apply Light Oil - See Lubrication Diagram Inner roll stop lever slot (2) Apply Light Oil - See Lubrication Diagram Saddle support bearings (8) Apply Light Oil - See Lubrication Diagram Parallel arm pivot pin bearings (16) Apply Light Oil - See Lubrication Diagram Handrail pivot pins (2) Apply Light Oil - See Lubrication Diagram Hydraulic cylinder pivot bushings (8) Apply Light Oil - See Lubrication Diagram Inspect Lift-Tite™ latch rollers for wear or damage, positive securement and proper operation (2) Correct, replace damaged parts and/or relubricate. Inspect outboard roll stop feet for proper operation, positive securement and detached or missing torsion spring Correct, replace damaged parts and/or relubricate. Inspect inner roll stop for: • Wear or damage • Proper operation. Roll stop should just rest on top surface of the threshold (base) plate. • Positive securement (both ends) Resecure, replace or correct as needed. See Platform Angle Instructions and Floor Level Adjustment Instructions. Inspect handrail components for wear or damage, and for proper operation Replace damaged parts. Maintenance and Lubrication Schedule continued 1500 Cycles Inspect microswitches for securement. Resecure or replace if needed. Make sure lift operates smoothly Realign towers and vertical arms. Lubricate or correct as needed. Inspect external snap rings: • Lower fold arms (6) • Inner roll stop lever bracket pins (2) • Lift-Tite™ latch gas (dampening) springs (4) • Gear link assembly (4) • Lift-Tite™ Latch (2) • Vertical channel/platform link (2) • Upper fold arm cam followers (4) • Outer barrier pins (2) Resecure or replace if needed. Inspect inner roll stop locks and torsion springs for wear or damage and for proper operation. Replace damaged parts. Apply Light Oil to inner roll stop lock pivot points. Inspect platform fold axles for wear or damage and positive securement Replace damaged parts and resecure as needed. Inspect platform fold link rollers and bearings for wear or damage and positive securement Resecure, replace or correct as needed. Note: Apply Loctite® to threads if needed. Remove pump module cover and inspect: • Hydraulic hoses, fittings and connections for wear or leaks • Harness cables, wires, terminals and connections for securement or damage • Control board, circuit breaker, power switch and lights for securement or damage Resecure, replace or correct as needed. Perform all procedures listed in previous section also 4500 Cycles Inspect cotter pins on platform pivot pins (2) Resecure, replace or correct as needed Hydraulic Fluid (Pump) - Check level. Note: Fluid should be changed if there is visible contamination. Inspect the hydraulic system (cylinder, hoses, fittings, seals, etc.) for leaks if fluid level is low. Use Braun 32840-QT (Exxon® Univis HVI 26) hydraulic fluid (do not mix with Dextron III or other hydraulic fluids). Check fluid level with platform lowered fully and roll stop unfolded fully. Fill to within 1/2” of the bottom of the 1-1/2” fill tube (neck). Inspect cylinders, fittings and hydraulic connections for wear, damage or leaks Tighten, repair or replace if needed. Inspect parallel arms, bushings and pivot pins for visible wear or damage Replace if needed. Inspect parallel arm pivot pin mounting bolts (8) Tighten or replace if needed. Inspect vertical arms, handrails and pivot pins for visible wear or damage Replace damaged parts and lubricate if needed Inspect upper/lower fold arms, saddle, saddle support and associated pivot pins, bushings, and bearings for visible wear or damage Replace if needed. Inspect gas springs (cylinders - 4) for wear or damage, proper operation and positive securement Tighten, replace or correct as needed continued Page 15 Maintenance and Lubrication Schedule continued 4500 Cycles Inspect saddle bearing (1) and saddle bearing buttons (2) Apply Door-Ease or replace if needed. See Lubrication Diagram. Inspect vertical arm plastic covers Resecure or replace if needed. Inspect power cable Resecure, repair or replace if needed. Mounting Check to see that the lift is securely anchored to the vehicle and there are no loose bolts, broken welds, or stress fractures. Decals and Antiskid Replace decals if worn, missing or illegible. Replace antiskid if worn or missing. Consecutive Repeat all previously listed inspection, lubrica750 Cycle tion and maintenance procedures at 750 cycle Intervals intervals. Page 16 Lift Electrical Schematic BK(24 GA COPPER) BK/WH(24 GA SILVER) NOTE: ALL WIRES ARE 22 GA. UNLESS OTHERWISE NOTED. DOWN BK 1 1 2 2 P15 J32 IB OCCUPANCY MICROSWITCH OR RD GN GN RD BK J26 P26 3 3 2 2 1 1 GN RD BK WH BK C NC STOW INTERLOCK (-) MICROSWITCH C C6 NO GN(20) WH(20) BN(20) 1 1 2 2 3 3 1 1 2 2 3 3 1 1 2 2 C 2 2 12 12 1 1 3 3 6 6 5 5 4 4 7 7 8 8 9 9 10 10 11 11 J8 NC BU(16) BU(16) RD BK GN DESCRIPTION PK(20) WH(20) BK RD RD BK GN 5 4 2 3 1 6 P8 WH(20) NO P3 5 4 2 3 1 6 1 1 2 2 P9 P4 J9 J3 J4 6 1 5 2 4 3 6 1 5 2 4 3 J7 3 2 1 4 3 2 1 4 P7 WH(20) BK(20) RD(20) GN(20) BK(20) FUSE HOLDER(16) GN(20) WH(20) BK(20) BU(16) RD(20) 1 2 3 4 5 6 WH(26) BU(26) BK(26) YL(26) RD(26) GN(26) J31 1 2 3 4 5 6 RD(20) BK(20) RD(20) BK(20) 1 1 2 2 P31 GN(20) RD(14) C BK(20) RD(20) WH(20) GY/RD(18) C5 NO (GROUND) J25 BU(16) BK(20) GN(20) STOW INTERLOCK (+) MICROSWITCH OR P25 RD(20) BK(20) LIFT STOWED SIGNAL YL/LT. BU(20) S BRIDGE MICROSWITCH J16 J16 BN(20) GY/RD(18) BK(20) N P16 P16 1 2 3 4 5 6 7 8 9 GN(20) WH(20) (GROUND) (+12V INPUT) (+12V OUTPUT) LIFT NOT STOWED YL/LT. BU(20) VEHICLE SECURE SIGNAL GY/RD(18) J21 LIFT CONTROL MODULE P26 GROUND DETECT SENSOR BK(20) RD(20) INTERLOCK 1 2 3 4 5 6 7 8 9 BK RD GN 18 15 13 14 7 12 10 11 17 9 8 6 4 5 16 3 1 2 J26 MAGNET P21 YL(26) RD(26) GN(26) GN RD OR BK WH GN RD BK GN RD OR 18 15 13 14 7 12 10 11 17 9 8 6 4 5 16 3 1 2 P13 J5 S WH BK J20 1 1 2 2 BK(20) RD(20) MAGNET N 1 1 2 2 P20 8 7 6 5 4 3 2 1 J20 2 2 1 1 P27 YL(26) RD(26) GN(26) BK(18) BK(18) P20 J13 BK(18) BK(18) 8 7 6 5 4 3 2 1 PLATFORM LIGHTS (OPTION) OUTBOARD BARRIER RAISED SENSOR P5 GN WH BK RD L G P6 ) (18 OR OR J15 6 5 4 3 2 1 E J27 BK P15 8) (1 WH WH GN 2 2 1 1 WH BK/WH(24 GA SILVER) BK(24 GA COPPER) OR RD GN NC UNFOLD BU C1 NO P28 1 1 2 2 3 3 RD BK WH GN FOLD RD(18) J28 6 5 4 3 2 1 GN(18) THRESHOLD SENSOR J6 BK(18) P32 ) (18 WH PK NOT USED PK 1 1 2 2 OR(18) UP IB JUMPER J15 RD LIFT SWITCH BOX SYMBOL BATTERY GY/RD(18) CHASSIS GROUND LIFT POWER SWITCH CIRCUIT BREAKER / FUSE NC P2 WH(18) BU(18) RD(18) GN(18) BK(18) OR(18) CONNECTORS J2-A 7 6 1 5 2 4 3 7 6 1 5 2 4 3 WH(26) BU(26) BK(26) YL(26) RD(26) GN(26) JUNCTION M MOTOR SOLENOID SOLENOID SWITCH RD(4) IN-LINE FUSE CIRCUIT SENTRY (CIRCUIT BREAKER) RD(2) PUMP BODY GROUND RD (2) POWER STUD FLOOR LEVEL MEMORY SET PUSH BUTTON RD BK J30 F E D C B A F E D C B A NEG. - POS.+ RD BK GN 00000 E COUNTER GN DIODE LED + COUNTER 00000 - E MAGNETIC SWITCH MAGNET LIGHT NVL917-05-025.ai (UP) GROUND DUAL RELIEF SOLENOID GN(20) HYDRAULIC GN(20) BU(16) RD(14) GN(20) BK(6) GN(20) M PRESSURE SWITCH ROTARY POSITION SENSOR RD BK GN GN(20) PUMP GN(14) GN(20) GN(20) BK(4) NC INTERLOCK LED BK(18) GN(20) NO C BK RD(20) THRESHOLD WARNING LIGHT RD THRESHOLD WARNING BEEPER PK(20) DOWN SOLENOID WH(20) UP/FOLD SOLENOID WH(20) MICROSWITCH BEEPER GN(20) ROTARY POSITION SENSOR Page 17 Li Un f fo Sc t E ld he lec fo m tri r: at ca ic l Lift Wiring Diagram BK(18) J20 4 5 6 7 7 8 9 COLOR NO. COLOR 1 NOT USED 1 NOT USED NOT USED 2 NOT USED 3 NOT USED 4 NOT USED 5 BROWN(20) YL / LT. BU(18) +12V SIGNAL 6 7 GRAY / RED(18) BLACK(20) NOT USED 8 NOT USED 9 WHITE(20) YL / LT. BU(18) GROUND SIGNAL BK(20) RD(20) 2 1 4 3 J9 NO. COLOR 1 NOT USED RED(20) & GREEN(20) 3 BLACK(20) & WHITE(20) GRAY / RED(18) RD(20) BK(20) RD(20) J16 RD(20) 1 2 1 2 1 2 P16 COM. RD(20) N.O. COM NO NC N.C. C-H P9 WH(20) RL5 RL6 GY/RD(18) Lift Power Switch BK(20) 915-4539NA Stow Interlock (+) Microswitch P31 100245-001 GN(20) 3 3 2 1 5 6 6 5 4 6-COND WIRE CODE COM NO NC C-H Stow Interlock (-) Microswitch C6 COLOR NO. COLOR 1 BLACK(20) 1 BLACK(20) 2 FUSE HOLDER(16) 2 RED(20) 3 LT. GREEN(20) 3 GREEN(20) 4 WHITE(20) 4 WHITE(20) 5 BROWN(20) 5 BROWN(20) 6 NOT USED 6 NOT USED 9 8 7 6 3 2 1 5 4 NO. COLOR 1 GREEN 2 RED 3 NOT USED 4 NOT USED 5 RED 6 7 BLACK NOT USED 8 NOT USED 9 BK OR RD GN 4 3 2 1 COLOR NO. RED 10 2 ORANGE 11 3 GREEN 12 COLOR GREEN 4 RED 13 NOT USED 5 BLACK 14 WHITE 6 GREEN 15 BLACK 7 NOT USED Interlock LED RED ORANGE 16 NOT USED 8 WHITE 17 NOT USED 9 BLACK 18 NOT USED GN(20) 3 2 1 6 5 4 6-COND WIRE CODE NO. 1 BU FS7 Up/Down Switch Fold/Unfold Switch NO. COLOR A NOT USED B NOT USED C NOT USED D GREEN E BLACK F RED BLACK 11 GREEN 12 BLACK 2 RED(20) 3 NOT USED 4 BLUE(16) 5 BLACK(20) 6 PINK(20) Outboard Barrier Raised Sensor 3-COND WIRE CODE 3-COND WIRE CODE NO. 1 COLOR NO. COLOR YELLOW(26) 1 ORANGE 2 RED(26) 2 RED 3 GREEN(26) 3 GREEN J27 975-0443RNA - Rear Pump 975-0443FNA - Front Pump FS14 + - Counter P27 30433A60 BK RD FS13 Bridge Microswitch E J25 BU(16) BU(16) COM NO P25 1 2 WH 1 2 BK NC FS12 GN 3-COND WIRE CODE 3-COND WIRE CODE 3-COND WIRE CODE 3-COND WIRE CODE NO. COLOR NO. COLOR NO. COLOR NO. 1 YELLOW(26) 1 BLACK 1 BLACK 1 2 RED(26) 2 RED 2 RED 2 RED 3 GREEN(26) 3 GREEN 3 GREEN 3 GREEN FS1 FS20 Threshold Warning Light + J30 32832A 1 2 3 3 2 1 WH(20) Switch Box Floor Level Memory Set Push Button 1 2 3 3 2 1 Rotary Position Sensor L 1 2 3 3 2 1 COLOR WHITE(20) & WHITE(20) WH G E FS4 PK(20) RED 10 6-COND WIRE CODE WH 5 1 A B C D E F 6-COND WIRE CODE NO. WH 1 2 4 N.O. N.C. 985 -2532NA COM. WH(20) BN(20) 12 11 10 12-COND WIRE CODE P4 C5 J31 6 P8 985-0531NA J16 32638A J21 P3 P7 7 BK(20) GN(20) 1 2 BK(20) P16 1 2 GY/RD(18) P21 NO. J8 J4 8 18-COND WIRE CODE J7 2 4 32639A Beeper - BK FS8 RD BLACK FS5 FS9 GN(20) COLOR Ground Detect Sensor WH(20) FS21 J26 P26 30433A60 P26 975-2543NA J26 RD(20) GN(20) COLOR PINK 1 ORANGE 2 NOT USED 2 RED 3 COLOR PINK 3 GREEN RL 4 RL3 Power Stud GN(14) Connects to Vehicle Battery (+) Positive Post Circuit Sentry (Circuit Breaker) Bat. A U X B A T BK(6) C-H FS2 FS11 NO N.O. WH NC N.C. C1 BU(16) Back Plate 1 BK COM. COM 4 GN(20) 1 2 BK(24) COPPER 31221A BK / WH(24) SILVER Threshold Sensors BK / WH(24) SILVER 1 Note: Shown with lift in stowed position. Page 18 2 BK(24) COPPER 2 1 P28 IB Occupancy Microswitch Dual Relief RD(2) Aux. Motor Power Feed Wire Dual Relief Lift Power Cable 205-0712-37 RD(2) J28 (Side view of solenoids removed from pump.) Down 2 32929A 31221A 2 2 1 BK(24 GA COPPER) Down Ground Lead Wire 13362A BK 1 IB Jumper Harness P15 RL1 or GN NO. 1 FS10 Note polarity of diode. It must be oriented as shown. Detail at left shows two different styles of diode identification. 1 RD NO. GN(20) 2 3-COND WIRE CODE WH In-Line Fuse 26082A-4 3 3 J15 Pump Module Power Feed RD(4) 2 3-COND WIRE CODE P15 RL2 1 FS3 7 RL BK(20) Up/Fold Solenoid Hydraulic Pump RD(14) BK / WH(24 GA SILVER) GN(20) J15 YL/LT. BU(18) LIFT STOWED / NOT STOWED SIGNAL (Located in cavity #5, #7 or #9 - see chart above) J3 J13 J5 J6 Lift Control Module 4-COND WIRE CODE NOT USED Interlock Connection GY/RD(18) VEHICLE SECURE SIGNAL +12V INPUT P5 J32 9 ORANGE JUMPER #2 (CAVITY #3 TO #8) P13 BK(24 GA COPPER) GY/RD(18) VEHICLE SECURE +12V INPUT 8 P6 BK / WH(24 GA SILVER) 6 7 NOT USED 1 P32 LIFT NOT STOWED GROUND SIGNAL 5 2 BK(4) 5 6 3 Pump Ground 4 NOT USED 7 4 22166A 3 NOT USED 6 8 ORANGE JUMPER #1 (CAVITY #2 TO #4) 985-4530NA 2 5 985-2541NA + - NO. GREEN 9 31033A54 9-COND WIRE CODE 4 18 17 16 15 14 13 12 11 10 3 31033A99 9-COND WIRE CODE WHITE 975-0535NA 4 9 8 BLACK 3 985-2533NA 1 6 5 RED 2 J20 RD(20) BK(20) 3 2 1 2 985-A1534NA COLOR 1 2 1 2 1 1 GN(20) Note: All wires 22 GA. unless otherwise noted. 4 2 6-COND WIRE CODE P20 P20 5 3 NO. 2 1 2 1 6 RD(14) BK(18) BK(18) BK(18) Platform Lights (Option) Hydraulic Schematic Orifice Orifice Down Valve Lifting Relief Valve 2500 PSI Secondary Valve M Folding Relief Valve 1900 PSI 800 PSI Opposite Pump Cylinder Pump Side Cylinder BACKUP PUMP Description PUMP Symbol Fixed Displacement Pump Pump Motor Description Symbol Hydraulic Port M 2 Way 2 Position Solenoid Valve Backup Pump Pressure Compensated Flow Control Single Acting Cylinder Relief Valve Check Valve Filter Screen Unfold Orifice Vented Reservoir Manual Shutoff Valve Page 19 Hydraulics Parts List Item Qty. 1 1 Description Pump Assembly (M-268-0112) 120G / 12V / Dual Relief Part # 2 1 Lead Wire Assembly, #6 Guage 29049 3 1 Clamp, Hose (M258) 29663 30915-12V 4 1 Diode Assembly, Up Solenoid 5 1 Solenoid, 4-Post - Prestolite 73906A 28308 6 1 Motor, Pump - 12 Volt - Low RPM 29690 7 1 Valve Assembly, “Dual Relief” (complete) 31120K 8 1 Cartridge (only), “Dual Relief” Valve - (shown below) 31121 9 2 Coil (only) - (shown below) 10 1 Valve Assembly, “Down” (complete) 31122 11 1 Cartridge (only), “Down” Valve - (shown below) 26078 12 3 Screw, 1/4-20 x 2-1/4”, Allen Head 26080 13 1 Hand Pump (Backup) with O-Rings (Item 14) 26074 14 4 O-Ring (only), Hand Pump Mounting 17351 15 1 Clamp, Reservoir - H-48 (M259) 17069 16 1 Reservoir, Hydraulic Fluid 30160 17 1 Cap, Reservoir Filler - Screw On 30167 31348K 18 1 Fitting, 90° - 1/8” NPT x 1/8” Barb - Plastic 87563 19 1 Connector, Plastic “Y”, 1/8” O.D. 18877 20 1 Hose, Thermal Plastic - Black, 1/8” I.D. 21 1 Handle with Grip 22 1 Fitting, Male 7-16-20 SAE O-Ring to Male 7/16-20 JIC 37° 24504 23 1 Elbow, 7/16-20 JIC 37 Female Swivel (1) - 7/16-20 JIC 37° Male (2) 26579 24 1 Hose Assembly, 1/8” (Opposite-Pump-Side) 16004A-086 25 1 Hose Assembly, 1/8” (Pump-Side) 16004A-046 26 2 Elbow, 90°, 7/16-20 SAE O-Ring Male - 7/16-20 JIC 37° Male, Orifice 27 2 Cylinder ✓ 28 2 Elbow, 90°, 1/4 NPT Male to 1/4” Barbed 29 1 Hose, Thermal Plastic - Black, 1/8” I.D. 23742R* (68”) 30 1 Hose, Thermal Plastic - Black, 1/8” I.D. 23742R* (30”) ✓ Seal Kits: If repairing a cylinder, order Seal Kit #1500-0500P. * Raw material items ordered and priced per inch (order specified length). 23742R* (6”) 17206A 26667 C1514.3-9408 15150 7 “Dual Relief” Valve (complete) 9 Coil #31122 Hydraulic Fluid When adding or changing hydraulic fluid, use Braun 32840-QT (Exxon® Univis HVI 26) hydraulic fluid (do not mix with Dextron III or other hydraulic fluids). Page 20 8 Cartridge #31121 10 “Down” Valve (complete) 9 Coil #31122 11 Cartridge #26078 Hydraulics Diagram 1 2 4 3 27 27 6 5 Hydraulic Pump Motor 21 10 26 26 7 17 14 22 23 15 Backup Pump 18 Pump Side Cylinder Opposite Pump Cylinder 13 12 Manual 16 20 19 24 25 28 28 29 30 Page 21 Pump Module Parts List Part Numbers of Items Dedicated per Lift Model Item 1 2 3 Qty. 1 1 1 1 Description Pump Module (complete), 12 Volt, Rear Plate, Backing / Mounting - Rear Cover, Pump, 2-Piece - Back / Bottom (915-0513RNAPT or 915-0513FNAPT Includes Items 2 and 15 - 21) Cover, Pump - 2-Piece - Top / Front (985-0519RNAPT or 985-0519FNAPT Includes Items 3 and 38 - 50) Item 4 5 6 7 8 9 10 11 11a 11b 11c 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 Qty. 1 1 1 1 1 1 1 1 1 8 1 1 1 1 1 1 1 3 1 1 4 2 2 2 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Pump Assembly (M268-0112) 12V-120G - Dual Relief / ARS (Includes Items 5 & 6) Power Cable, Up Solenoid to Motor Solenoid, Up - 4-Post - Prestolite Clamp, Hose - Solenoid Mounting Diode Assembly, Up Solenoid Fitting, Male 7/16-20 O-Ring to Male 7/16-20 JIC 37° Elbow, Female Swivel 7/16-20 JIC 37° to (2) Male 7/16-20 JIC 37° Control, Hand Pendant Assembly (See below for available options) Control, Hand Pendant Assembly - Non-Shielded Cable - Straight tSee note below Control, Hand Pendant Assembly - Shielded Cable - Straight tSee note below Control, Hand Pendant Assembly - Shielded Cable - Coiled tSee note below Control Board Assembly Standoff, Snap-In Switch, Push Button Recepticle, Clip On Lens, Threshold Warning - Red Decal, Warning / Pressure Relief Valve (Not shown) Spacer, Lens - NHTSA Metal Ring Base - Lamp Socket, Lamp Screw, #8-32 x 1/2” Pan Head Phillips - Thread Cut Bulb, Light Diode, Green LED, Panel Mount Rivet, Snap - .124” Hole x .197”/.236” Thick Washer, 5/16” Flat Bolt, 5/16-18 x 3/4”, Nylock, Hex * See note below Bolt, 5/16-18 x 1/2”, Nylock, Hex * See note below Cable, Ground Washer, 5/16” External Tooth Beeper, Constant - High Output Switch, Toggle Decal, Lift Power - On/Off (Not shown) Stud, Power Feed Rubber Boot, Red tSee note below Harness, Lift Interlock Connection Wire Assembly, Lift Stowed Connection tSee note below Pump Handle with Grip Rivet, Pop, SD43BS - 1/8” - .13”/.19” Plug, Window - Clear Stud, Wing Head - 1/4 Turn Retainer, Push On Washer, Nylon, 1/4” I.D. x 11/16” O.D. x .030” Clip, Pump Handle - Top Clip, Pump Handle - Bottom Decal, Manual Instructions - Public (Not shown ) Decal, Removal / Installaton - Pump Cover (Not shown) Decal, Warning - Control Board Damage - ESD (Not shown) Decal, Removal / Installation Pump Handle (Not shown) Decal, Dual Relief Adjustment (Not shown) Decal, LCD Lift Codes (Not shown) Cable, Pump Module Power Hookup (Not shown) Harness, Power - Stow Interlock (Not shown - see Wiring Diagram) Harness, Interlock / Lighting (Not shown - see Wiring Diagram) Harness, Up / Down Solenoid (Not shown - see Wiring Diagram) Harness, Threshold Switch Extension (Not shown - see Wiring Diagram) Harness, Stow Interlock (Not shown - see Wiring Diagram) tSee note below Harness, Hand Control - Pump Housing to Circuit Board (Not shown - see Wiring Diagram) Harness, Jumper (Not Shown - see Wiring Diagram) NVL917IB 985-5516RNA 985-2501RN 915-0513RNPT 915-0519RNPT NVL917FIB 985-5516FNA 985-2501FN 915-0513FNPT 915-0519FNPT Part Numbers of Items Identical on all Lift Models Part No. 30915-12V 29049 28308 29663 73906A 24504 26579 32832A 32833A 32421A 100159-001 31011 31753 28803 30704 22249 31386 30971 30703 30974 19841 29545 29874 10063 29608 10012 22166A 16368 33251 31787 21494 26084 82046 32639A 32638A 17206A 12954 30443 28804 28805 12690 915-5517 915-5518 31412 29051 30787 29052 32201 32410 26082A-4 985-4530NA 985-0531NA 985-2533NA 985-A1534NA 915-1538NA 100245-001 985-2541NA * Apply red #271 Thread Locker Loctite® to the four hex bolts (items 26 and 27) if a blue nylon patch is not present on the bolts when retrofitting an M268 pump assembly. Loctite® is available from The Braun Corporation under part number 11522-1. t Indicates items available for replacement part purposes only. These items are not included with replacement pump modules. Page 22 Pump Module Diagram 42 Pump Mounting Bolts 39 38 Apply red #271 Thread Locker Locktite® to the three pump mounting bolts (items 26 and 27) if a blue nylon patch is not present on the bolts when retrofitting an M268 pump assembly. Loctite® is available from The Braun Corporation under part number 11522-1. 43 40 41 37 3 44 11a 11b 11c 38 32819 WN DO 32819 UP DO WN UP FO UN LD LD FO WN DO UP UN FOL D 32820 FOL D UN ® FOL D 32820 FOL D ® 3 3235 16 22 18 23 19 2 21 15 20 12 25 26 27 13 28 29 14 30 7 31 1 5 4 24 33 34 8 36 35 27 9 6 10 Note: Rear pump module shown, front pump module mirror image. Page 23 Repair Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Item 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 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 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 Qty. 14 4 8 4 4 2 1 1 4 1 1 1 1 10 10 1 2 2 8 4 2 2 2 2 2 2 2 10 1 1 2 2 1 2 2 1 2 1 16 8 1 1 2 6 1 2 8 2 2 2 2 1 6 4 2 4 1 2 4 2 10 4 6 2 4 4 2 2 6 2 2 6 2 2 2 2 2 10 2 2 6 2 2 1 6 2 2 2 2 2 2 2 Page 24 Description Part Numbers of Items Dedicated per Lift Model Base Weldment Cover, Pump, 2-Piece, Back-Bottom Cover, Pump, 2-Piece, Top-Front Assembly, Link, Outer Barrier, Rear Assembly, Link, Outer Barrier, Front Bridge Switch Assembly Block, Platform Stop - Bridging - Rear Block, Platform Stop - Bridging - Front Plate, Backing/Mounting Parallel Arm Assy., Top-Front w/Bearings Parallel Arm Assy., Top-Rear w/Bearings Parallel Arm Assy., Bottom Rear w/Bearings and Sensors Parallel Arm Assy., Bottom Front w/Bearings Description NVL917IB NVL917FIB 975R5148NW33 915-0513RNPT 915-0519RNPT 975-0219RNA 975-0219FNA 975-0443RNA 25778 900-0311 985-2501RN 915-0437FA 985-5437RNA 975-0458NA 917-0457NA 975F5148NW33 915-0513FNPT 915-0519FNPT 975-0220RNA 975-0220FNA 975-0443FNA 900-0311 25778 975-2437RA 985-5437FNA 975-2437RA 917-0457NA 975-0458NA Part Numbers of Items Identical on All Lift Models Washer, .516" I.D. x 1" O.D. x .0269", Auto BK Washer, Finger, Disc Spring Snap-Ring 1/2" Snap-Ring 5/16" O-Ring, 5/16" I.D. x 1/16" O.D. Screw, Socket Head, 3/8-16 x 1/2" with 1/2" Shoulder Gear Assembly, Front Gear Assembly, Rear Nut, 1/4-20 Hex Lock Stud, Wing Head Retainer, Push-On Grommet, ID .312", FR .250", GD .813" T500" Pump Assembly, (M268 with Backup Pump) Pin, Pivot, Parallel Arm Screw Drive #8 x 3/16" Long Black Receptacle, Clip-On Bumper, Stow, Millennium Bolt, 5/16-18 x 1/2", Button Head, Socket Cap Rivet, Pop, SD43BS - 1/8" - .13/.19 Bolt, 5/16-18 x 1/2" Nylock, Hex Washer, 5/16" Flat Bolt, 3/8-16 x 1/2" Nylock, Hex Bolt, 5/16-18 x 3/4", Button Head, Soc Cap Hd Bolt, 3/8-16 x 3/4" GR5-Hex, Auto, BK Bolt, 5/16-18 x 3/4" Nylock, Hex Pin, Bearing, Platform Side Gear Rack, Platform Fold Bearing, Flange, 1/2" x 1/4" Weldment, Latch, Lift/Tite, Rear Weldment, Latch, Lift/Tite, Front Screw, #4-40 x 5/8", Round Head Clip, Cable, 5/16", Plastic Screw, #8-32 x 1", Mach. Truss Head Nut, #4-40 w/Lockwasher Nut, #8-32, Hex Assembly, IB Occupied Cylinder, 14.625"/29.146" Retracted Inner Roll Stop Bearing, Flange, 3/4" x 3/8" Bushing, 3/4" I.D. x 1/2" Vertical Channel Weldment, Front, 48" Cover, Plastic, Parallel Arm, O/S Front-w/Tape Tape, 1" Wide S-Face Foam, x 14" (1 Shown) Tape, 1" Wide S-Face Foam, x 10" (3 Shown) Cycle Counter-LCD Without Reset Handrail Weldment Rivet, Push In - 8MM Bumper, Rubber, 31/32" O.D. Screw, #8-18 x 1/2", Self-Tap, Phillips Bulb, Light 20-W, Halogen Reflector Washer, .328" I.D. X .75" O.D., .062" T-UHMW Base Cover Assembly - 33" (Traction Tape Not Shown) Washer, Thrust, .875" O.D., .50" I.D., .058" ST Nut, 3/8-16, Hex Lock Cotter Pin, 1/4" x 2", Black Washer, 1/4" Flat Cover, Plastic, Parallel Arm, I/S Front-w/Tape Threshold Strip Switch Retainer, Push, 5/32" Threadless Shaft Bolt, Shoulder, 5/16" x 5/8", 1/4-20 Thread Washer, 1/2" Flat Black Zinc Bolt, 3/8-16 x 1", Hex Washer, 3/8", Lock, Black Lever, Inboard Outer Barrier Clamp, Insulate, 1 3/8" I.D. Washer, 5/16" Lock, Black Gas Spring, Fold Arm Ball Stud, Gas Spring, 13MM x 3/8-16 F. Thread Washer, 3/8", Lock Screw, 1/4-20 x 1/4", Set Clip, Safety, 3/8-16 x 3/4", Flange Bolt, 3/8-16 X 3/4", Flange Button Head, Socket Cap Bolt, 5/16-18 x 2", Flange, Hex Nut, 5/16-18, Serrated Flange Arm, Slide Support (Replace In Pairs) Slide, Platform, Rotate Spacer, .5" O.D. x .334" I.D. x 1.515" LG Bearing, Flange, 3/4" x 1/4" Weldment, Platform Pivot Arm - 48" Pin, Pivot, Lower Arm Ring, Snap, 3/4", External Bearing, UHMW, Flat, 1.226" Ball Stud, 10MM Vertical Channel Weldment, Rear Plastic End Cap, 1" I.D. x 1 1/4" O.D. Grip, Handle, Yellow Spring, Dampener, Retract Bolt, 5/16-18 x 1 1/4" Low Socket Hd., Cap, Bk. Bumper, .75"x .625" Long Screw, 1/2-20 x 1 1/2" Set Lock, Black Block, Guide-Platform Stow Pin, Platform Part No. 15328 27276 13273 24570 26614 25929 975-2328FRABKN 975-2328RRABKN 10775 28804 28805 27726 30915-12V 917-0403 31086BK 28803 26154 26281 12954 10012 10063 29729 24440 12463 29608 975-2360 975-2329BKN 24442 29412RW 29412FW 14810 26948 19912BK 19537 10777 31643A C1514.3-9408 915-0147NWY 24011 900-0456 975-0448FNW 915-0704NA 82015R014 82015R010 30547 985-4618NW 30063 10950 13583 31060 31438 975-5148CNA33Y 29371 13617 15886BK 10062 975-0701NA 31221A 31728 31816 25346 10025 10069BK 975-0404N 29765 10068 29186 29185 10069 11563 12608 25171 25130 25131 985-6612N 985-0606N 25132 24012 985-0640NW-BKN 900-0413N 18657 205-1760 21301 975-0448RNW 20474 19074 26963 26327 915-0391 18663 28593 975-2325 Item 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 Qty. 10 2 2 2 2 2 5 4 2 3 2 4 1 1 2 2 4 1 1 2 4 1 8 2 2 4 6 8 6 4 2 2 2 2 2 2 2 2 2 2 1 2 6 4 1 1 4 2 1 1 2 4 2 4 4 4 2 4 2 1 2 2 2 4 4 4 2 2 1 4 2 1 5 2 1 2 2 1 1 2 2 2 2 1 3 1 1 1 1 2 2 Description Screw, 5/16-18 x 3/4", SHFS Spacer, UHMW, Vertical Channel Washer, .376" I. D. x .563" O.D., .032" T-18-8 SS Bracket, Mounting, Quiet Ride Gas Spring, 12.2" Extended/8.3" Compressed Bolt, 5/16-18 x 3/4", Carriage, Black Washer, 5/16", External Tooth Nut, 5/16-18 Hex Bracket, Inner Side Panel Guide Bearing, UHMW, Flat, Thin, Black Pivot, Bridge Plate Lever, Upper, Inside Bearing, Flange - 3/4" x 1/2" Weldment, Latch Foot, Rear Weldment, Latch Foot, Front Rod, 5/32" Torsion Spring Bar, Front Rod, 5/32" Torsion Spring Bar, Rear Screw, #4-40 x 3/16" THD FORM Position Sensor Collet Weldment, Tube-IB Fold Arm-Rear Collar, Outer Barrier, Torsion Bar Nut, 3/8-16, Hex Weldment,Tube-IB Fold Arm-Front Screw, 5/16-18 x 5/16", Set Bolt, 5/16-18 x 1 1/2" Hex Head, Cap Bolt, 7/16-20 x 1", SHCS, w/Nylock Patch Ring, 3/8" Retaining Snap Screw, #10-32 x 1/2, Flat Head-Hex w/Patch Washer, Thrust, 1.125" O.D., .625" I.D., .0585" THK Rivet, Pop, 3/16"-.25"/.38", Black Bearing, Flange, 10MM x 12MM, FMB1012DU Nut, 1/4-20 x 3/16", Outer Barrier Washer, Nylon, .34" I.D. x .74" O.D. x .62" T Bolt, 1/4-20, Shoulder, Outer Barrier Nut, 5/16-18, Top Lock, Black Bolt, 1/4-20 x 1/2", Button Head Socket Bolt, 3/8-16 x 2", Hex Head, Cap Roller Assembly Roller Retainer Nut, 5/16-18 Hex, Lock Pivot, Bridge Plate Lever, Upper-Outer Clamp, 1/4" I.D.- Nylon Loop Washer, 3/8" Flat, Black Rivet, Snap, .201" x .256"/.295" Bearing, Flange, 1" x 1/2-16FDU08 Cover, Plastic, Parallel Arm, O/S Rear-w/Tape Weldment, Bridgeplate Bracket, Front Spacer, Handrail, .375” Thk. UHMW Washer, .516" I.D. x .75" O.D. x .250", Black Cover, Plastic, Parallel Arm, I/S Rear-w/Tape Weldment, Bridgeplate Bracket, Rear Spring, Torsion - .366 I.D. x .05" Spacer, IB Lock Weldment, IB Lock Bearing, 3/8" I.D. x 1/2" Long Roller, .65" O.D. x 1/2" Long E-Clip, 3/8" Shaft Spacer, Handrail, .230" Thk. UHMW Bearing, Flange, 3/8" I.D. x 1/4" Screw, 1/4-20 x 3/4" BHSCS 18-8 SS Assembly, Rotary Position Sensor Washer, .390" I.D. x .75" O.D., .21" T-UHMW Light Assy, Vertical Channel Pad, Outer Barrier, Foot Stowed Plug, Interior, Plastic Push, Black Spacer, UHMW-.75" O.D. x .39" I.D. x .25" Bearing, Platform, Slide Harness, Sensor, Magnetic w/Plug - 60" Pin, Bearing, Gear Rack Platform Weldment Movable Outer Screw, #10-32 x 1/2" Button Head, Socket, Cap Bearing, Platform, Slide Slide, UHMW,Platform Rotate Rivet, Pop, 3/16" - .13/.25" - SD64BS Spacer, 5/8" I.D., 7/8" O.D. x 3/16" L-UHMW Position Sensor Spacer Link, Weldment, Platform, Vertical Channel Pin, Bearing, Gear Rack Outer Barrier Pivot Arm Front Outer Barrier Pivot Arm Rear Pin, Outer Barrier, Vista Screw, 1/4-20 x 3/4", Flat Head, Socket, Countersink Pin, Bearing, Platform Slide Nut, #10-32 w/Lockwasher Bag, Vinyl - 7" x 10" Washer, #10, Flat, Auto BK Outer Barrier, 33" Platform Weldment Fixed Inner Shim, Bracket, Hanger, Hand Pendant Bracket, Hanger, Hand Pendant Bolt, Carriage, 1/2-20 x 1/2” Clamp, Cable, 1/2", Plastic Part No. 25527 995-0320 31514 915-0392 30550A 15858BK 16368 10058 915-0703 916-5406 916-5433 24027 975-0204RNW 975-0204FNW 28132F 28132R 31043 31093 975-0625RNW 975-2208 10059BK 975-0625FNW 11567 10014 28474 13889 17192P 29378 14993 28128 975-0205N 31439 995-0211 28324BK 15733 10027 1000-2395A 915-5353 11387BK 916-5434 84396 10064 26362 28031 915-0702NA 985-0431FNW 995-0301 25336 975-0703NA 985-0431RNW 30386 30394 985-0630NW 30405 985-0631N 84383 911-5301 24028 81068-000 31094A 31440 31062A 975-2379 P50067-BK 30227 975-2359 30433A60 975-2334 975-5336NW 30375WP 975-2358 31677 11513 31678 31092 975-2333W 975-2202 975-0216RNWY 975-0216FNWY 975-0217N 28986 975-2360 18349 31174 11541 975-0312NY 975-03351NW 33216 33215 12777 10092 Exploded View 36 52 98 112 109 73 52 98 10 113 79 189 98 74 28 98 73 27 148 190 106 134 52 17 100 74 18 18 100 33 16 15 14 16 190 14 53 78 52 14 1 58 26 106 43 17 112 23 114 17 165 34 9 50 17 65 38 29 113 52 53 53 27 28 111 104 42 14 28 27 28 27 15 55 53 52 134 74 74 24 56 167 13 2 33 36 35 52 27 134 112 70 111 74 175 164 3 104 134 196 74 106 95 71 60 113 94 89 71 52 63 106 148 28 52 109 52 106 78 106 134 11 78 58 78 28 27 88 91 57 67 87 91 190 106 74 60 93 94 28 60 52 53 14 53 115 52 114 116 85 152 91 77 15 141 79 50 113 180 41 51 22 153 152 86 16 27 91 99 60 90 85 14 170 115 123 102 52 28 178 79 167 74 106 12 175 28 27 67 196 117 60 106 177 74 94 94 94 141 86 88 74 152 106 91 67 91 152 62 85 68 159 158 129 161 124 75 147 76 169 82 16 183 72 187 20 120 131 119 163 135 64 75 138 131 37 82 133 133 166 128 125 128 172 122 40 136 137 66 82 163 72 174 133 181 41 16 66 32 14 133 122 39 40 97 41 171 182 171 66 66 37 125 128 66 176 179 120 5 135 128 83 131 108 132 39 16 66 81 19 133 133 171 182 133 41 14 98 75 168 82 32 41 80 127 172 22 169 59 173 32 112 130 47 147 145 178 6 84 144 149 181 19 76 41 61 44 156 33 75 159 158 144 32 171 90 161 160 101 14 129 117 107 60 159 48 160 161 117 195 194 178 30 25 142 143 31 60 170 157 126 79 99 48 76 41 96 162 168 161 94 30 140 7 91 160 159 156 157 157 67 193 155 153 149 140 105 103 16 45 169 192 139 46 148 60 91 87 54 81 82 110 107 31 112 169 142 149 77 27 148 126 105 116 15 57 91 93 14 69 148 28 89 162 117 45 146 102 76 101 143 149 52 150 8 139 92 148 52 91 103 96 57 63 151 33 115 27 186 160 98 41 92 85 53 49 157 61 130 69 154 53 59 41 84 110 188 52 80 62 16 68 185 163 72 41 145 173 21 121 72 184 118 163 135 166 83 121 187 136 179 176 191 135 137 138 64 132 131 4 108 185 Page 25 Se Li rie Un ft s fo Ex A5 ld pl N fo od V r: e d L9 1 V 7I ie B w NOTES This page intentionally left blank. Page 26 "Providing Access to the World" ® Over 300 Braun Dealers Worldwide ® "Providing Access to the World" International Corporate Hdqrs: P.O. Box 310 1-800-THE LIFT® (574) 946-6153 Winamac, IN 46996 USA FAX: (574) 946-4670 Service Manual for: CKA Vista HZg^Zh Series A5 Public Use Wheelchair Lifts Braun™ Five-Year Limited Warranty The Braun Corporation of Winamac, Indiana, warrants that it will repair (or replace at Braun’s sole option) any defect in material or workmanship in its wheelchair lift for five years*, providing the lift is installed, operated and maintained properly. This warranty is limited to the original purchaser and does not cover defects in the motor vehicle on which it is installed, or defects in the lift caused by a defect in any part of the motor vehicle. This warranty commences on the date the lift is put in service, providing the warranty registration card is completed and received by The Braun Corporation within 20 days of purchase. If no warranty card is received, the warranty will expire three years from the date of manufacture as identified on the lift serial number tag. This warranty also covers the cost of labor for the repair (or replacement at Braun’s sole option) of parts for three years when performed by an authorized Braun representative. (A labor schedule determines cost allowance for repairs and is available upon request). This warranty does not cover normal maintenance, service, or periodic adjustments necessitated by use or wear. The Braun Corporation will not, under any circumstances, pay for loss of use, incidental, or consequential damages related to the lift or vehicle in which it is installed. This warranty will become null and void if the lift has been damaged through accident, misuse, or neglect, or if the lift has been altered in any respect. * The five-year portion of this warranty covers the following lift’s power train parts: • Cable • Cylinder • Flow Control • Gear Box • Motor • Pump • Hydraulic Hose & Fittings • Solid State Controller All remaining lift components are covered by a three-year warranty. Return Authorization Procedure When processing any warranty claims (parts, repairs, etc.), all requests must be processed through The Braun Corporation Product Support Department. Call 1-800-THE LIFT ® during normal working hours. Product Support will issue a Return Material Authorization (RMA) number and detail the procedures required for processing returns and/or authorizing credit. The lift identification information is provided on the Braun Serial No./Series No. identification tag and the two warranty cards (shown on inside front cover). The lift identification information must be provided when filing a warranty claim or ordering parts. "Providing Access to the World" Braun NVL Series 33917 Rev. A February 2008 ® ® International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA 1-800-THE LIFT ® (574) 946-6153 FAX: (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. Patent #5,261,779 Patent #6,464,447 Patent #6,739,824 Patent #6,065,924 Patent #6,599,079 Patent #6,837,670 Patent #6,238,169 Patent #6,692,217 Patents Pending © The Braun Corporation