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Access Operation & Maintenance Manual

1. duo 59 39 WISIUDUSEN ebpug 82508 IDIPUDH uoisuoix3 201 5 499204 PUD suuds sjexXooy eAug Sdojispug uoisueixj NOlLdl492S3G 8 8 1 21 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 28 DECAL DIAGRAM Doorloop Handset gt lt LS 5 Label bel to PLS 215 PLS 211 or or PLS 216 pump PLS 225 Pus 22 mE Six Digits Lift No For Example 777777 1 22 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 29 LOLER TEST AS ey By Engineer ah fjor 1 S I d Rear Right Tested by PASSENGERS LIFT SERVICES Vehicle Door 0121 862 0200 Floor CLE Ces Six Digits Lift No For Example 777771 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 30 RAISE LIFT PLATFORM 3 s NUNMOG 2 Buttom Standard Handset ACC 25672 k VN Yellow Handset PLS A MOBILITY NETWORKS COMPANY Ordering spare parts Section 2 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 32 Ordering spare parts for Access Lift ATTN PLS Service Parts
2. SUV 39 1994 pions 5 og 2461009 NOILdIMOS 97 134204 1487 4940 39 Jaddn 1UBIM 4addn 146 2940 2254 29 IS PIS 70 Pt 1411 OSVONVIS 2 A IBIN3SSV 2 13 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 45 Wall SIN 1487 Jamo 1487 Jaddn 3465 Jamo 91249 2 Buupsg Buuds 224564 Way 545625 Ng 49105 obay 9 y NOLLAIMOS3O 1 1487 489904 424204 4 2 14 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 46 STANDARD PLATFORM FRAMES SINGLE MECHANICAL BRIDGE PLATE ITEM PART DESCRIPTION Return Spring gm 8 Nyloc Nut 22 Lower Right Arm MB Washer 23 Upper Right Arm Swivel Joint 24 Upper Left Arm MB Half Nut 25 Lowerr Left Arm M8x20 Standard Bolt 36 Arms Pin Plain Std M16 Washer 60 Arms Pin Threated Std Bridge Plate Cam 70 Platform Frame Push Rod Twin Co
3. RM Driver Operator Name Signature Month 9 Date Driver Operator Name Signature Month 12 Date Juil Lis Driver Operator Name Signature This page must be produced when claiming warranty repairs e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 21 Monthly Safety Checks for Operators Regular lift maintenance is recommended at MONTHLY intervals by the lift operating company The working life of your lift will be greatly prolonged if these steps are adhered to This should include the following 1 2 10 11 12 Check for obvious signs of damage replace parts as necessary Check the operation and stowing of the lift if the platform base is touching the bottom of the box adjust stow height parts shown on page 2 13 26 by raising the N S and O S stowing bolts on the rocker Check the box lock operation page 2 11 by attempting to pull the lift out of the box with the lock engaged If this can be achieved the hook 7 will need to be LOWERED in relation to the handle 12 and the lock nut 180 firmly re tightened Check the carriage lock parts shown on page 2 07 46 operation by attempting to push the lift back into the box once the platform has been fully deployed If this can be achieved the carriage lock mechanism will require adjustment Check the rear roll off ramp operation Check ramp dummy part shown
4. PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 84 1 5 The length of on page 5 08 5 11 be the same for the front and rear brackets although usually the front brackets are lower thus allowing a tilt on the box positive tilt This means that point Y can be a maximum of 25mm lower than point X for ALL lifts Note for POWERMATIC applications this distance should not be greater than 15mm Note check that When platform lowers fully to ground it is level Front and rear of platform land at the same time Roll off ramp reaches the ground easily Note The front bracket should be as close to point Y as possible 1 6 When all four brackets have been attached to the chassis tighten the bracket bolts on ONE SIDE OF THE CHASSIS ONLY leave the other side loose Push the lift box under the vehicle and lift the fixed bracket side into position and clamp It may be necessary to remove and relocate the track bolts protruding from side of lift box If bolts clash with bracket positions replace with turned down head versions Tighten all chassis bolts to brackets see page 5 14 for torque settings and replace track bolts removed The hydraulic support bracket top view page 5 12 should be retained wherever possible This will locate the external hose s correctly Note HANDLE THE LIFT CASSETTE WITH GREAT CARE GALVANIZED SECTIONS ARE VERY SHARP Any track bolts removed should be replaced an
5. 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 10 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 17 PLS A MOBILITY NETWORKS COMPANY ACCESS PASSENGER LIFT AUXILIARY HAND PUMP OPERATION PROCEDURE SAVERY POWERPACK A hand pump allows the lift to be used in the event of any electrical fault The unit which is integral with the powerpack comprises a single acting piston pump with removable operating lever This is found either under the rear of the vehicle on the nearside or internally on the nearside rear Remove the black plastic cover to gain access to the pump To use the pump proceed as follows PREPARATION 1 Take the operating lever from its stowage LOWERING VALVE MANUAL OVERRIDE TO LOWER THE PLATFORM 2 Push in and turn anti clockwise the RED lowering valve TO RAISE THE PLATFORM 3 Close the RED lowering valve by turning clockwise 4 Connect the operating lever to the hand pump 5 Operate the lever until platform is at required height STOWAGE PROCEDURE 6 Using the hand pump stow the platform in the normal way When power is restored to the lift check that the RED lowering valve is correctly closed clockwise 7 Stow the operating lever N B Should the power IN amp OUT system fail the lift can be pulled and pushed into the box by hand PLS 215 Passenger Lift Services Limited Unit 2 Summit Crescent Ind E
6. A MOBILITY NETWORKS COMPANY Access Operation amp Maintenance Manual including Mega Lift Tel 44 0 121 552 0660 www passengerliftservices co uk PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 2 PLS A MOBILITY NETWORKS COMPANY Issue 1 3 March 2010 This document is the exclusive property of PASSENGER LIFT SERVICES and is copyright in which all rights are reserved no copy of this document can be made without the written authority of the proprietors of the copyright Written and complied by A Beck B Sc CAD work by T Urbanski M Sc G Fisher P Edwards Technical contributions from D Wheatcroft Edwards amp A Tompkins amp 2014 12 06 2014 13 31 a 3 PLS A MOBILITY NETWORKS COMPANY Information Section 1 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 4 PLS A MOBILITY NETWORKS COMPANY IMPORTANT The new lift owner operator should refer to this manual for operating instructions future warranty and servicing work This manual should be kept safely for the entire working life of the lift When quoting the lift serial number to the manufacturers this number can be found in the top right hand corner of the S W L sticker located on the roll off ramp The number is also stamped into the aluminium platform main section near side PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 5 Con
7. Check cylinders for oil leaks ensure end gland page 3 05 4 is tight Replace piston ring seal if leaking Remove bottom sheet check all hoses and fittings for leaks wear or perishing When bottom sheet is replaced remember to position retaining bolts with the nuts on the OUTSIDE of stowage box Remove lift from box to check centre bearings and carriage mechanisms Lift is removed by unbolting carriage stops page 2 03 2 and detaching umbilical via the quick release coupling page 3 11 and electrical connector on the rear of the carriage N B When electrical connector is re positioned the cable tie MUST be replaced see drawings on page 5 12 for correct alignment 6 10 11 1 16 Clean the interior of the stowage cassette and degrease the side tracks and centre rack or guide with solvent DO NOT GREASE TRACKS OR CENTRE GUIDE USE SILICONE SPRAY ONLY Check nylon strips on platform surface for wear replace if necessary Check bridging plate operation is correct The bridging plate must land flush with the vehicle floor and NOT form a trip hazard For full adjustment of the mechanism see page 1 20 Check that the lift mounting brackets and track bolts are tight secure page 5 08 and free from damage Corrosion in this area of the lift is likely to occur however if in an advanced state components should be exchanged for new items Check manual hand pump operation see page
8. on page 2 15 72 which holds ramp in vertical position whilst lift is stowed Lubricate roll off pivots with silicone spray Check bridging plate operation parts shown on pages 2 15 2 18 see page 1 20 for full adjustment instructions Check platform extension operation and security of alloy sheet DO NOT overtighten M6 bolts which hold extension alloy Check platform end stops part shown on page 2 15 177 are tight and vertically aligned Check hand rail operation and security If components are corroded they should be replaced due to potential hazard to users Check location pivot pins via the M8 S S grub screws these should be thread locked into position When cleaning the vehicle wash the working platform of the lift Check pull out handle is fully secure Check Up Down pump for fluid leaks and loose corroded electrics Top up reservoir with lift at ground position with PLS Blue hydraulic oil do NOT overfill Coat any exposed electrics with dielectric grease or similar to protect Lubricate lift in accordance with Lubrication Diagram page 1 21 IF INDOUBT CONTACT THE MANUFACTURER 1 15 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 22 Maintenance 6 monthly for appointed Service Engineers As monthly safety checks plus 1 2 3 Check arm pivot pins bearings and retaining grub screws page 2 13 2 14 Check cylinder pivot pins and grub screws page 2 13 2 14
9. was issued in confirmation of a satisfactory weight test Position Date Qualifications Signed 5 15 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 98 Installation Examination and P 1 S Confirmation of Weight Certification mn Certificate No NETWORKS COMPANY Lift Serial No The following test conforms to the Lifting Operations and Lifting Equipment Regulations 1998 LOLER 98 for Passenger Carrying Vehicle Tall Lifts Operating Company Lift owners Address Location of Examination Address Base Vehicle Reg Date of Last Examination Safe Working Load Kgs Date of this Examination Relief Valve Setting BAR Date of next Examination Reason for Examination Test Applied Hand Pump Working Ramp Stop Operation Hand Rail Condition Bridging Plate Operation Umbilical Hose Condition Platform Stability All Bearings amp Pins General Corrosion Condition All Important Fastenings Handset Condition OK All Electrical Wiring Operation Time OK Condition of Lift Box Hoses in Good Condition Fittings Brackets Unions in Good Condition Welds amp General Fabrication OK All Hydraulic Cylinders Crash Test Applied In Out Motor OK Downward Creep in 10 Mi
10. 1 11 1 12 lubricate all pivot points REMEMBER TO RETURN MANUAL TAP TO THE CLOSED POSITION Check condition and security of arm side guards page 2 13 61 replace if damaged IF IN DOUBT CONTACT THE MANUFACTURER e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 23 Access Trouble Shooting symptom Somen ift will not come out of box ift fails to power UP Circuit breaker tripped Re set circuit breaker push button in situated on vehicle Handset button failure Check wiring inside handset or change module Box lock not fully disengaged Make sure lock handle is fully up and lock pin is free of hook Lift is powered up inside box Press DOWN on handset to lower lift or open the down valve to release pressure Motor not working or slipping Check wiring connections plugs and pins also check pinion location pin which may have slipped imed into rack out and jam Re set circuit breaker push button in situated on vehicle battery ndset button failure Check wiring inside handset or change module ge lock is j components system oil changes the OUT motion to UP carriage switch setting Power lift UP to re set or unscrew hydraulic fitting on lifting cylinder ircuit Handset arria module situated on vehicle battery module Re set switch mounted on carriage lock which changes the DOWN motion to IN Make sure platform extension is fully home Make sure platform is
11. 12 06 2014 13 31 Page 71 CARRIAGE HOSE MICROBORE nec OS IVSE OX REF CARRIAGE On MANIFOLD INNER BOX HOS TO MAIN PUMP P IPE FITTIN 3 11 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 72 PUMP 3 12 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 73 ACCESS LIFT HOS L mm OVERALL CRITICAL CARRIAGE 5 5 SWIVEL F MALE STRAIGHT SWIVEL F MALE 45 FITTING 0 25 FLEXIBLE HYDRAULIC HOSE 0 25 DIA TO DIN 853 15 6 SAE 100 RIAT PLATFORM HOSES IDENTIFICATION 29000 2 1210 900 O ALL CRIMP ENDS 280 OVERALL TUBE 9 16 FLARE TUBE END NUT 9 15 JIG MAD 9 16 JIC MALE SWIVEL P MALE STRAIGHT FITTING 0 25 J 10mm O DIA SEAMLESS TO 1 4 BSP HYDRAULIC TUBE FLEXIBLE HYDRAULIC HOSE IDENTIFICATION 29000 3 TO 853 15 DN6 I D 1 4 WP 225 BAR 700 mm 000 1 SWIVEL F MALE STRAICHT FITTING SWIVEL F MALE 90 FITTING 0 25 0 25 FLEXIBLE HYDRAULIC HOSE 2500 mm 0 25 I DIA TO DIN EN853 1SN 6 SAE 100 RIAT 3200 mm INNER BOX HOSES ID
12. 2014 13 31 ase 79 CARRIAGE OUT SWITCH p AHO x rt WHITE c ED c c gt FLOOR SWITCH N THESE 2 SWITCHES ALWAYS USED BROWNWHITE DOORSAFE SWITCH p CARRIAGE IN 7 SWITCH 1 5 c RED c RED PLATFORM CONN RED LLOW N GREEN BLUE WHITE PINK DEUTSCH 6 WAY FEMALE CONN DEUTSCH 6 WAY MALE CONN 7 CORE UMBILICAL CABLE GREEN YELLOW NOT USED STOW SWITCH N wu e BLACK ef RED 12V IN OUT SOLENOID SOUNDER OPTIONAL TO PUMP CONNECTION POWERMATIC WITH HYDRAULIC BRIDGE CARRIAGE LOOM 4 04 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 80 BRIDGE VALVE CONTYROL RELAY ES RED YELLOW BLAC LOCK RELAY ORANGE LOCK SWITCH DE a FITTED IF WHITE BLACK 25mmacruaroR p OPTIONAL ORANGE Yew YELLOW ____ EE BRIDGE VALVE CONNECTOR OLD VERSION FLOOR SWITCH CONNECTOR WHITE fa x B B c c WHITE 1 4 SPADE MALE aa GREEN YELLOW FLOOR SWITCH IN CARRIAGE POWERMATIC WITH HYDRAULIC BRIDGE PLATFORM LOOM 4 05 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 81 ACTUATOR TOYLNOD MOOT FINDER RELAY TYPE 56 32 LOOM CONN RED YELLOW ORANGE DOWN COIL 71031405 NMOG FINDER RELAYS TYPE 56 32 GROUND CONNECTED TO INTERNAL BOLT VALVE COIL FINDER
13. 2222 8 IDI KJ P m OS im I 223 a EE ks KES gt NS I NR PART NO CYLINDER PART DESCRIPTION Ta 5 PISTON 0 RING 5 SEAL GLAND GLAND O RING SINGLE ACTING HYDRAULIC RAM CYLINDER BORE 38 10 1 500 TM12 CYLINDER 0 0 47 625 1 875 ACC25569 HOSE BURST VALVE ROD DIA 25 4 1 000 ACC25684 DOWERTY WASHER STROKE 159 00 FAST 57 M16 LOCK NUT 25290 CYLINDER ROD EXTENSION MAXIMUM PRESSURE 207 BAR LIFTING CYLINDER CLEVIS 93mm O ALL ACC26556 CYUNDER ROD EXTENSION SHORT ME GA TYPE ACC25289 ED CROSS SECTION CLEVIS 215mm O ALL PART REF ACC26456 CYLINDER BODY SPACER 25809 SEAL KIT 3 08 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 69 431 80 82 50 CLOSED PART NO lt SSS GEEIS E SSI CYLINDER PART DESCRIPTION PISTON PISTON O RING PISTON SEAL GLAND GLAND O RING WIPER ROD M12 BINX NUT ACC25569 HOSE BURST VALVE ACC25684 DOWERTY WASHER FAST 57 M16 LOCK NUT ACC25290 CYLINDER ROD EXTENSION CLEVIS 93mm O ALL ACC26556 CYLINDER ROD EXTENSION CLEVIS 160mm O ALL ACC25289 CYLINDER ROD EXTENSION CLEVIS 215mm O ALL CYLINDER B
14. 59 Right hand arm rocker Mega Quote lift number 60 Arm pin threaded Standard lift ACC 25286 61 Arm guard Quote lift number 62 Cylinder pin ACC 25291 63 Arm bush ACC 25641 64 Cam and crank bracket ACC 25029 65 Arm rocker spring ACC 25734 66 Arm bearing ACC 26376 67 Arm pin threaded Mega lift ACC 25790 68 Arm bearing carrier ACC 25370 69 Arm guard Mega Quote lift number 70 Platform fabrication Quote lift number 71 Platform alloy Quote lift number 72 Dummy pin ACC 25034 low cut ACC 25035 high cut 73 18 dia roller ACC 25344 74 Extension Platform roller bearings 75 Bearing inner bush 76 Extension platform Quote lift number 77 Roller fastener bolt FAS 80111 78 Bridge plate crank arm ACC 25070 std ACC 25789 mega 79 Bridge plate spigot ACC 25611 80 Bridge plate torsion bar Quote lift number 81 Standard push rod ACC 25101 82 Twin push rod ACC 25102 83 Return spring ACC 26391 84 8 nyloc nut FAS 80000 85 M8 washer FAS 80021 86 Swivel joint ACC 25104 87 M8 half nut FAS 80026 88 M8x20 hex Hd Setpin FAS 80045 89 M16 washer FAS 80086 90 Bridge plate cam ACC 25071 6 02 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 104 91 Push rod twin collar ACC 25103 92 Push rod collar ACC 26204 93 Box lock pin ACC 25977 94 Rocker pivot pin ACC 26111 95 M8x8 countersunk socket head screw FAS
15. Carr Mega Arm Rocker Left Arm Rocker Spring Arm Pin Plain Mega Solenoid Mounting Bracket Lock Spring Motor Bracket Spring Umbilical Guide Loom Support 1 m f as f am Loom Support 2 PLS Access amp Main Manual 2014 12 06 2014 13 31 42 PART DESCRIPTION Stowage Box Carriage Stop Box Lock Hook Box Lock Housing Plate Box Lock Spacer Box Lock Spring Box Lock Handle Latch Box Lock Handle M12 Washer 5 16 Bolt Half Nut M12 All Metal Lock Nut M12 Int Fan Disk Washer a 2 2 2 2 2 2 2 2 2 2 N PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 43 OINJOTIL 384205 gN ecl 9xGW 6 19205 xuns BXGIA GG JOJON ce 12950 48 JOION YE JeusoM BIN GS 1089 Japlnous 79 1081861 INN 39 N SN TE M8Josqnus 184905 M8J2S Bum 1900 1089 Z 2029 40 0 N 9bouu02 c 4 9155 O C FE gt EN J 2 12 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 44 N ay ar 2 2 EE AN DLXGN buuds 18
16. Department Customer Lift No Contact Order No Address Tel No Date Discount 96 Postcode Carriage Quantity Description Part No Price each Total Sub Total Sub Total after discount Carriage VAT Total 2 01 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 33 TES dNVH 110 NOILLdIHISIG 5 2 02 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 34 PART DESCRIPTION Lift Stowage Corrioge Stop Side Guide Runners Bottom Golvanised Sheet Top Galvanised Sheet Centre Guide Manual Centre Rack Powermatic Box Lock Hook Box Lock Housing Plate Box Lock Spacer 10 Box Lock Spring 1 18 M10x25 Hex Hed Std Setpin 4 11 Box Lock Handle Latch 1 Reduced Head Thickness 12 Lock 1 19 8 20 C Sunk Socket 3 13 Umbilical Cover 1 Screw 14 Hose Fixing Bracket 1 20 Box Micro Switch Bracket 1 15 Box Cable Cover 1 109 Top Brush 1 Carriage Switch Bracket 1 Side Brush 2 M10x25 Bolt 10 9 Brush Spacer 2 to 4 2 ND Varies PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 35 STANDARD LIFT STOWAGE BOX EK TYPE FLATBA PLS Access amp Main Manual 2014 12 06 2014 13 31 2 05 PART DESCRIPT
17. PART NUMBERS CYLINDER PART DESCRIPTION ROD GLAND O RING SPRING WASHER PISTON PISTON SEAL CYLINDER BODY SINGLE ACTING HYDRAUL ROD DIA STROKE 2 750 MAXIMUM PRESSURE RAM CYLINDER BORE 25 40 1 000 CYLINDER O D 33 30 1 312 15 87 625 207 BAR BRIDGE PLATE CYLINDER HYDRAULIC BRIDG PLATE CROSS SECTION PART REF ACC25567 3 04 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 65 3 05 LIFTING CYLINDER ASSEMBLY TYPICAL CYLINDER PART DESCRIPTION SUPPLIERS CYLINDER REF O RING STANDARD TYPE 5048 31 75 19 05 159 5 GLAND O RING US HYBRID 8008 35 22 159 5 M12 BINX NUT HOSE BURST VALVE DOWERTY WASHER M16 LOCK NUT CYLINDER EXTENSION CYLINDER EXTENSION 5 CYLINDER EXTENSION MEGA LONG TYPE 6244 2 CYLINDER BODY 1 5 1 11 62 S A SPACER MEGA TYPE 6244 1 1 5 1 8 25 S A CYLINDER PART DESCRIPTION PISTON PISTON O RING 5 SEAL GLAND GLAND O RING WIPER ROD ACTING HYDRAULIC RAM M12 BINX NUT CYLINDER BORE 31 75 1 250 ACC25569 HOSE BURST VALVE CYLINDER 0 0 275 1 625 Q ls a uo s u N ACC25684 DOWERTY WASHER FAST 57 M16 LOCK NUT ACC25290 CYUNDER ROD EXTE
18. RELAY TYPE 56 32 LOOM CONN SLINN 1OHLNOO 39GIl48 OLLVINHAMOd TOHLINOO 4 06 PLS Access amp Main Manual 2014 12 06 2014 13 31 oe 82 PLS A MOBILITY NETWORKS COMPANY Lift installation amp testing Section 5 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 83 1 GENERAL INSTRUCTIONS FOR LIFT INSTALLATION 1 1 Panel Vans The tail lift is supported with four brackets which are bolted through the vehicle chassis On nearly all PANEL VANS the rear brackets pick up on existing holes in the chassis although the near side rear bracket may require relocating towards the front of the vehicle to allow for the lock mechanism see page 5 08 5 11 This will require drilling new holes the chassis or bracket to suit Some front bracket holes may require enlarging depending on bolts used Note when drilling through box section always use spacer tubes to prevent deformation of the vehicle sections Never drill two holes less than 10mm apart Do not drill too closely to the edge of a chassis member The brackets are positioned roughly in each of the four corners of the lift box They will nor mally coincide with spaces between TRACK BOLTS or OVER the specially turned down studs 1 2 Coach Built Vehicles in addition to 1 1 On most coach built vehicles it will be necessary to drill new holes in the chassis for the installation brackets occasio
19. be accepted for a Replacement vehicle hire b Loss of earnings The warranty agreement does not supersede the suppliers liability for all components defined in the Sales of Goods Act 1979 and the supply of Goods Act 1982 Months 24 to 36 of the warranty require the vehicle to be returned to PLS for Free of charge warranty work Otherwise labour and travel time will be charged at 40 per hour 1 01 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 8 Access Lift Technical Data The lift is designed to transport One person in a wheelchair with or without an attendant with a size not larger than the width length of platform space available or weight over the stated badge capacity 300Kgs unless upgraded by PLS Or Two walking passengers The operator should not attempt to transport more than two people at a time because of increased risk of passenger discomfort The passengers also may require extra space for mobility devices such as walking sticks and frames Capacity Standard Lift 300Kgs possible upgrade to 350Kgs available by special request Specifications Lift type Underfloor cassette Voltage 12Volts standard 24Volts available Power system Electro hydraulic pump Hydraulic fluid type PLS Blue specific formulation or ATF Control Pendant via wanderlead Bridge plate width 680mm or 730mm or 780mm usable Platform width 725mm or 775mm or 825mm Platform length 1240mm or 1410mm to 1780m
20. minor adjustments Firstly the bridging plate should be slightly higher than the vehicle floor To raise the tail lift height it is necessary to lower the platform below stowing level see page 1 19 for FULL instructions Undo the cylinder locking nut and lengthen the cylinder pistons equally on both sides of the lift 4 2 If at this stage the bridging plate is lowering too soon it will be necessary to adjust the bridge plate activator see page 1 20 for full instructions Take the lift to vehicle floor height at this position the gap between the bar B and the roller on the bridge plate hinge 1 should be no more than 2 to 3mm If this gap is greater loosen lock nut F then wind the bar out making it longer Raise and lower the lift to check adjusted operation Remember to re tighten nut F For comprehensive bridging plate adjustment please see page 1 20 5 05 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 88 4 3 When the lift is operational the bottom sheet can be fitted inside the lift cassette It should be slid into the box then secured with 2 off M6 x 15mm bolts fastened through the strap at the mouth end of the box Note threads should protrude downward i e nuts on outside of box 4 4 The lift can now be fully weight tested to 12596 of its maximum carrying capacity 375Kgs The pump should then be set at 300Kgs capacity This is achieved by turning the allen headed bolt P
21. should be secured to the near side corner at the back rear of the vehicle and run through the floor with the hydraulic hose and umbilical wiring if Lift is a Powermatic type PLS usually drill through the vehicle floor with a 44mm diameter hole saw and protect the wiring and hoses with split 43mm conduit The lifts are usually supplied for external pump fitting to give space inside the vehicles However internal mounting will extend the working life of the powerpack greatly 2 3 The three core cable is normally run up the near side pillar of the vehicle panel vans and across to the door using fittings supplied If a door switch is used this is drilled through the door on the hinge side and adjusted to strike the pillar The handset wire is run through a grommet on the lock side of the door and all connections are made behind the door cover panel If a cab switch is required mainly coach built vehicles run a 3 core cable to the front of the vehicle see wiring diagrams On most coach built vehicles the handset pendant control is fixed to the back panel of the vehicle adjacent to the near side door and connections made using the small black plastic box supplied 2 4 The hydraulic connection is made between the back of the pump plate and the connection on the side of the cassette using the flexible hose supplied in kit This hose length can vary depending on pump position required The pump is attached to the mounting bracket using 2 o
22. stowed correctly Motor not working or slipping Check wiring connections plugs and pins also check pinion location pin which may have slipped out and jammed into rack PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 24 Platform will not extend Extension legs not free from stow pegs platform UP to release extension stops Extension is locked via a plastic clip mounted underneath the platform pull out extension Platform does not retract fully Roll off ramp hose catching Reposition hose pipe Move lift platform a higher position before attempting to stow Push extension away with more force or re align lock position Lack of lubrication Spray all pivots and moving parts with silicone Roll off cylinder failure Bleed the hydraulics at the cylinder If cylinder is leaking fluid replace seals or whole cylinder Bridging plate not dropping to Lift not raised to max up position Power lift UP fully to floor height Vehicle floor Mete respi ard test bridge plate mechanism Alloy is damaged Bridging plate not returning to Mechanism requires adjusting Re set and test bridge plate mechanism vertical position 1 18 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 25 Floor height adjustment of platform also vertical stowing position on rear of vehicle Should it be necessary to adjust the lift to vehicle floor height or if an imbalance of cylinder s
23. 0 PLS A MOBILITY NETWORKS COMPANY Hydraulic Section 3 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 61 ACCESS LIFT HYDRAULIC SCHEMATIC VV V ROLL OFF RAMP CYLINDER arc LIFTING CYLINDERS WITH CRASH VALVE S TEST POINT MANUAL HAND PUMP MAIN PUMP TYPE MAY VARY PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 62 ACCESS LIFT HYDRAULIC BRIDGE PLATE SCHEMATIC v P BRIDGE PLATE I VALVE AND MANIFOLD NON RETURN VALVE BRIDGE PLATE R n Ak al CYLINDER 5 CONTROL VALVE AAAA ROLL OFF RAMP CYLINDER a lt LIFTING CYLINDERS TEST POINT WITH CRASH VALVE S MANUAL HAND PUMP MAIN PUMP TYPE MAY VARY PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 63 CYLINDER PART NUMBERS CYLINDER PART DESCRIPTION ROD WIPER GLAND O RING SPRING WASHER PISTON l Cn PISTON SEAL m CYLINDER BODY SINGLE ACTING HYDRAULIC RAM CYLINDER BORE 25 40 1 000 CYLINDER O D 33 30 1 312 ROD DIA 15 87 625 STROKE 41 30 1 625 MAXIMUM PRESSURE 207 BAR 3 03 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 64 25 00 CLOSED m AK FAG 2 amp ME lt NASAN FY CYLINDER
24. 1 2 22 2 23 2 24 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 6 Contents cont Mega handrail assembly 2 25 Standard roll off ramp assembly 2 26 Oil control pump assembly 2 27 Savery pump assembly 2 28 3 Hydraulic section Access lift hydraulic schematic 3 01 Lift with hydraulic bridge plate schematic 3 02 Roll off ramp cylinder 3 03 Bridge plate cylinder 3 04 Lifting cylinder assembly 3 05 Standard lifting cylinder 3 06 Hybrid lifting cylinder 3 07 Short mega lifting cylinder 3 08 Mega lifting cylinder 3 09 Long mega lifting cylinder 3 10 Layout of hydraulic hoses 3 11 Layout of hydraulic hose for hydro bridge plate 3 12 Hose identification 3 13 3 14 4 Electrical section Powermatic pump wiring diagram 4 01 Powermatic carriage loom diagram 4 02 Hydraulic bridge plate electrical diagram 4 03 Hydraulic bridge plate carriage loom 4 04 Hydraulic bridge plate platform loom 4 05 Hydraulic bridge plate control units 4 06 5 Lift installation amp testing section Fitting sequence 5 01 506 Load testing a fitted lift 5 07 Bracket fit to box section chassis 5 08 5 09 Bracket fit to open section chassis 5 10 5 11 Umbilical positioning 5 12 Solenoid and relay types 5 13 PLS recommended torque settings 5 14 LOLER certificate 5 15 Weight test certificate 5 16 Welding information 5 17 6 Part numbers section Lift parts reference guide 6 01 6 04 e PLS Access amp Main Manual 2014 12 06 2014
25. 13 31 Page 7 TERMS CONDITIONS Warranty Cover amp Period The P L S warranty covers parts and labour and is effective for 36 months from date of commission by P L S Procedure 1 An operator requiring attention to a unit would contact P L S quoting serial number 2 P L S will instruct either the factory Service Department or contact an appointed Service Agent issuing an official order number to effect the repair 3 All parts will be issued free of charge subject to the return of the faulty components N B Any work carried out or charges generated without authorisation will not be reimbursed Conditions 1 2 Warranty does not extend to units which have not been regularly serviced by duly appointed personnel Including a 6 monthly LOLER certification All warranty work must be carried out by factory appointed personnel using approved parts and materials The units must be made available for repair during normal working hours 08 00 17 00 Hours Monday to Friday excluding public holidays No delivery costs or travel time will be reimbursed except by prior agreement and as specified on the official order Warranty does not include the cost of Consumable parts i e fuses bulbs and electrical connections b Driver misuse Accident damage d Items which are subject to the level of wear which would normally involve replacement during normal service and maintenance operations No claim will
26. 4 13 31 age 39 Cam Follower Nut Cam Follower Washer Carriage Lock Misro Switch Bracket Buzzer Nut Buzzer Buzzer Bracket Solenoid Solenoid Bracket Solenoid Mounting Bracket Carriage Lock Hatchet Carriage Lock Spring Micro Switch Motor Bracket Spring Hatchet Lock Guide Umbiliccl Guide Loom Support 1 Micro Switch Actuation Roller 171 Loom Support 2 50 Micro Switch Brocket 4H 2 08 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 40 PART DESCRIPTION Micro Switch Brocket Beoring Circlip Carriage Mototr Gear Gear Bearing Inner Ring Carriage Drive Gear Motor Brocket Motor Cam Follower Cam Follower Nut Cam Follower Washer Carrioge Lock Micro Switch Bracket Buzzer Nut Buzzer Buzzer Bracket Solenoid Solenoid Bracket Carriage Lock Hotchet 2 09 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 41 gc Y Micro Switch 3 Hatchet Lock Guide 1 Micro Switch Actuation 2 Roller Micro Switch Bracket 4H Mega Carriage Mega Lower Right Arm Mega Upper Right Arm Mega Upper Left Arm Mega Lower Left Arm Mega Arm Rocker Right Rear Bearing Carrier Mega Front Bearing
27. 7 PART DESCRIPTION Plotform Frome Plotform Alloy Dummy Pin Extension Plotform M8 Noloc Nut Roll Off Romp M8x30 Standard Screw Hinge Plate Handle Hydraulic Cylinder 8 45 C sunk Socket Setscrew Tube Spacer M8 Standard Washer Roll Pin 4x12 MB Spring Washer Roll Pin 4x24 STANDARD ROLL OFF ASSEMBLY 2 26 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 58 ACCESS SERIES OIL CONTROL PUMP LAYOUT ITEM DESCRIPTION 26 24V 12V DC Motor 127 Pump Body 28 Oil Reservoir 29 Hand Pump 30 Presure Adjustment 51 Down Valve 132 Up Solenoid 55 Pump Cover 134 Pump Mounting Plate x AI 136 Autor Reset Circuit Bracket Pump Cover Mounting Bracket 3f Hydraulik Pipework 2 27 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 59 ACCESS SERIES PUMP LAYOUT Test Point DESCRIPTION 24V 12V DC Motor Pump Body Oil Reservoir Hand Pump Presure Adjustment Down Valve Up Solenoid Pump Cover Pump Mounting Plate Autor Reset Circuit Bracket Pump Cover Mounting Bracket Hydraulik Pipework 2 28 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 6
28. 80015 96 M8 x10 grubscrew ACC 25537 97 M5x6 grubscrew ACC 25594 98 M6x6 grubscrew FAS 80003 99 Split pin FAS 80106 100 Roll off ramp Quote lift number 101 Hinge plate 25073 102 Handle ACC 25455 103 Roll off ramp hydraulic cylinder ACC 25445 104 M8 washer FAS 80026 105 M8 spring washer FAS 80101 106 M8x30 setscrew FAS 80053 107 M8x 45 countersunk socket head screw FAS 80158 108 Tube spacer ACC 25570 109 Top brush ACC 25476 110 Handrail pivot pin ACC 26209 111 Handrail Quote lift number 112 Handrail side guard fixing bracket Quote lift number 113 Handrail side guard Quote lift number 114 Handrail side guard hinge Quote lift number 115 Handrail side guard hinge p clip ACC 25561 116 Platform fabrication mega Quote lift number 117 Handrail side guard mega Quote lift number 118 Handrail side guard hinge mega Quote lift number 119 Handrail mega Quote lift number 120 Platform alloy mega Quote lift number 121 Bridge plate rocker bar ACC 25106 122 Arm pin plain mega ACC 25431 123 Lift Stowage Box step back Quote lift number 124 Roll pin 4 dia x 12mm ACC 25534 125 Roll pin 4 dia x 24mm FAS 80050 Savery Power Pack 12v or 24v Oil Control Power Pack 12v or 24v 126 127 128 129 130 131 132 133 134 135 136 Pump body Oil reservoir Hand pump Pressure adjustment Down valve Up solenoid Pump cover Pump mounting plate Auto reset circuit Pump cover mounting bracket Power pa
29. C CIRCUIT BREAKER 5A 24V BA 12V YELLOW HANDSET RED BLACK RED BLACK WHITE BLACK WHITE VEHICLE INTERLOCK SWITCH ONLY FITTED WHERE REQUESTED lt 5 o o a YELLOW UMBILICAL 3 UMBILICAL 1 UMBILICAL 2 UMBILICAL 5 UMBILICAL 6 POWERMATIC PUMP WIRING DIAGRAM 4 01 PLS Access amp Main Manual 2014 12 06 2014 13 31 ase 77 FLOOR SWITCH GARRIAGE OUT ri om 2 AERIS RED c ALWAYS USED a 2 DOORSAFE SWITCH CARRIAGE IN m SWITCH ER PLATFORM CONN RED 1 2 WHITEBROWN DEUTSCH 6 WAY MALE CONN GREEN YELLOW NOT USED STOW SWITCH YELLOW ma Me 12V IN OUT SOLENOID SOUNDER OPTIONAL TO PUMP CONNECTION POWERMATIC CARRIAGE LOOM 4 02 PLS Access amp Main Manual 2014 12 06 2014 13 31 ge 78 TO BATTERY ve THROUGH CIRCUIT BREAKER CAB SWITCH OR DOOR SWITCH NO CIRCUIT BREAKER 24V BA 12V BLACK RED YELLOW HANDSET PUMP BLOCK RED BLACK RED BLACK WHITE BLACK WHITE VEHICLE INTERLOCK SWITCH ONLY FITTED WHERE REQUESTED BLACK RED YELLOW WAY DEUTSCH CONNECTOR UMBILICAL 4 UMBILICAL 3 S lt 8 UMBILICAL 1 UMBILICAL 2 UMBILICAL 5 UMBILICAL 6 POWERMATIC WITH HYDRAULIC BRIDGE PUMP WIRING DIAGRAM 4 03 PLS Access amp Main Manual 2014 12 06
30. Certificate No NETWORKS COMPANY Lift Serial No The following test conforms to the Lifting Operations and Lifting Equipment Regulations 1998 LOLER 98 for Passenger Carrying Vehicle Tall Lifts Operating Company Lift owners Address Location of Examination Address Base Vehicle Reg Date of Last Examination Safe Working Load Kgs Date of this Examination Relief Valve Setting BAR Date of next Examination Reason for Examination Test Applied Hand Pump Working Ramp Stop Operation Hand Rail Condition Bridging Plate Operation Umbilical Hose Condition Platform Stability All Bearings amp Pins General Corrosion Condition All Important Fastenings Handset Condition OK All Electrical Wiring Operation Time OK Condition of Lift Box Hoses in Good Condition Fittings Brackets Unions in Good Condition Welds amp General Fabrication OK All Hydraulic Cylinders Crash Test Applied In Out Motor OK Downward Creep in 10 Mins In Out Pump Condition Overload Test Applied Up Down Pump Condition S W L Test Applied Description of Defects Identified and Remedial Work Required I the undersigned confirm that the above Lift was examined in accordance with LOLER 98 regulations on Examining Company And that Certificate No
31. ENTIFICATION 29000 4 MALE STRAIGHT FITTING SWIVEL F MALE STRAIGHT FITTING 0 25 0 25 2000 mm FLEXIBLE HYDRAULIC HOSE T 0 25 I DIA TO DIN ENB53 1SN 6 SAE 100 RIAT 6500 mm 3 13 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 74 SAVERY PUMP HOSES IDENTIFICATION 29000 7 FLEXIBLE HYDRAULIC HOSE 0 25 I DIA DIN 853 15 6 5 100 RIAT SWIVEL F MALE STRAIGHT FITTING 0 25 SWIVEL F MALE 90 FITTING 0 25 HOSES IDENTIFICATION 29000 8 FLEXIBLE HYDRAULIC HOSE 0 25 DIA TO DIN 853 15 6 5 100 RIAT SWIVEL F MALE STRAIGHT FITTING SWIVEL F MALE STRAIGHT FITTING 0 25 0 25 UNIVERSAL OUTER BOX HOSES IDENTIFICATION FLEXIBLE HYDRAULIC HOSE 0 25 DIA TO DIN EN853 1SN 6 5 100 RIAT pr SWIVEL F MALE STRAIGHT FITTING SWIVEL F MALE STRAIGHT FITTING 0 25 0 25 HOSES IDENTIFICATION 29014 ACCESS LIFT MICROBORE HOSES L mm FLEXIBLE HYDRAULIC HOSE REF 1WO3 1500 1 SWIVEL F MALE STRAIGHT FITTING SWIVEL F MALE 90 FITTING 0 25 027 2100 3 14 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 75 PLS A MOBILITY NETWORKS COMPANY Electrical Section 4 PLS Access amp Main Manual 2014 12 06 2014 13 31 ase 76 PUMP BLOCK CHASSIS TO BATTERY ve THROUGH CIRCUIT BREAKER CAB SWITCH OR DOOR SWITCH NO N
32. ION age 36 2 Corrioge Stop 2 5 Side Guide Runners 2 4 Bottom Galvanised Sheet 1 5 Golvonised Sheet 1 6 Centre Guide Manual 6A Centre Rock Powermatic 1 7 Box Lock Hook 8 Box Lock Housing Plate 1 9 Box Lock Spacer 1 18 M10x25 Hex Hed Std Setpin 4 10 Box Lock Spring 1 Reduced Head Thickness 11 Box Lock Handle Latch 19 M8x20 C Sunk Socket 3 12 Box Lock Handle 1 Screw 13 Umbilical Cover 20 Box Micro Switch Bracket 1 14 Bracket 1 15 Box Cable Cover 1 Lift Stowage Box Stepback 1 16 Carriage Switch Bracket 1 Side Brush _ 2 17 M10x25 Bolt 10 9 Varies 165 Side Brush Spacer 2 EN amp Main Manual 2014 12 06 2014 13 31 9 37 PLS Access STANDARD LIFT STOWAGE BOX STEPBACK TYPE PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 38 PART DESCRIPTION Micro Switch Bracket Stondand Carriage Lower Right Arm Upper Right Arm Upper Left Arm Lower Left Arm Arm Rocker Front Bearing Carrier Bearing EDS T Circlip Rear Bearing Carrier For Flatback Box Carriage Motor Geor Gear Inner Bearing Ring Carriage Drive Gear Parts no 31 32 33 34 35 Motor Bracket Are For Powermotic Lifts Only Motor Arm Pin Ploin Std Cam Follower PLS Access amp Main Manual 2014 12 06 201
33. LS 215A Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 12 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 19 Daily Check Sheet ERENS pm en AR KT EE S EA E m T m TEEN RTT NEN geat meg TT en E Bridge plate allo Notes N B The above is to be used in conjunction with the operating company guidelines and Risk Assessments 1 13 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 20 Access Service Data Sheet Date lift was first issued E EN Lift requires monthly checks and lubrication by driver operator Refer to Maintenance manual for instructions Every six months service and twelve monthly weight test should be carried out by an appointed service engineer Month 2 Date I ime RE Driver Operator Name Signature Month 5 Date lE Joins Driver Operator Name Signature Month 8 Date EE Driver Operator Name Signature Month 11 Date fd Driver Operator Name Signature Month 3 Date ARE EE Ee Driver Operator Name Signature Month 6 Date
34. NSION CLEVIS 93 O ALL MAXIMUM PRESSURE ACC26556 CYLINDER ROD EXTENSION CLEVIS 160mm O ALL 25289 CYLINDER ROD EXTENSION CLEVIS 215mm O ALL CYLINDER BODY SPACER 25513 SEAL KIT PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 66 LIFTING CYLINDER SIANDARD TYPE CROSS SECTION PART REF ACC25444 3 06 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 67 381 00 CLOSED 4 GN 63 50 CLOSED 1 Gr SE PART CYLINDER PART DESCRIPTION PISTON PISTON O RING GLAND O RING WIPER SINGLE ACTING HYDRAULIC RAM ROD CYLINDER BORE 35 00 M12 BINX NUT T CYLINDER 0 0 45 00 ACC25569 BURST VALVE ROD DIA 22 00 25684 DOWERTY WASHER AN FAST 57 15 LOCK NUT STROKE 159 00 25290 CYLINDER ROD EXTENSION MAXIMUM PRESSURE 207 BAR LIFTING CYLINDER CLEVIS 93mm O ALL ACC26556 CYLINDER ROD EXTENSION HYB R D CLEVIS 160mm O ALL CROSS SECTION ACC25289 CYLINDER ROD EXTENSION SES imm MAL PART ACC25996 CYLINDER BODY SPACER ACC26619 SEAL KIT PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 68 381 00 CLOSED 82 50 CLOSED gt H3 22225 158 N
35. ODY SPACER ACC25809 SEAL KIT SINGLE ACTING HYDRAULIC RAM CYLINDER BORE 38 10 1 500 CYLINDER 0 0 47 625 1 875 ROD DIA 25 4 1 000 STROKE 209 55 8 250 MAXIMUM PRESSURE 207 BAR LIFTING CYLINDER MEGA TYPE CROSS SECTION PART REF ACC25994 3 09 PLS Access amp Main Manual 2014 12 06 2014 13 31 ase 70 581 00 22 875 CLOSED 82 55 3 25 CLOSED 27777 2 E EG A CY OO 5 4 2 PART CYLINDER PART DESCRIPTION PISTON PISTON O RING PISTON SEAL GLAND GLAND O RING WIPER SINGLE ACTING HYDRAULIC RAM ROD CYLINDER BORE 38 10 1 500 Y ASS ES ss E Z CLL Le m M12 BINX NUT 25569 5 BURST VALVE CYLINDER O D 47 625 1 875 ACC25684 DOWERTY WASHER FAST 57 M16 LOCK NUT ROD DIA 25 4 1 000 25290 Sep ROD N STROKE 295 27 11 625 LIFTING CYLINDER CLEVIS 93mm O ALL ACC26556 CYLINDER ROD EXTENSION MAXIMUM PRESSURE 207 BAR LONG MEGA TYPE CLEMS 160mm O ALL N cor ACC25289 CYLINDER ROD EXTENSION CROSS SECTION CLEVIS 215mm O ALL RPO VEREER BODY PART REF ACC25849 SPACER ACC25809 SEAL KIT Ga po 3 10 PLS Access amp Main Manual 2014
36. ORKS COMPANY Part Numbers Section 6 PLS Access amp Main Manual 2014 12 06 2014 13 31 age 102 LIFT PARTS REFERENCE GUIDE REF NO DESCRIPTION PART NUMBER 1 Lift Stowage Box flat back Quote lift number 2 Carriage stop ACC 25027 3 Box side guide carriage runners Quote lift number 4 Box bottom galvanised sheet Quote lift number 5 Box top galvanised sheet Quote lift number 6 Box top centre guide carriage runner Manual Quote lift number 6A Box top centre guide carriage rack Powermatic Quote lift number 7 Box lock hook ACC 25036 8 Box lock housing plate ACC 25669 9 Box lock spacer ACC 25030 10 Box lock spring ACC 26207 11 Box lock handle latch ACC 26368 12 ACC 25037 13 Ubilical cover ACC 25995 14 Umbilical fixing bracket ACC 25976 15 Box internal cable cover ACC 26018 16 Carriage switch bracket ACC 26370 17 10 25 bolt 10 9 high tensile ACC 26626 18 10 20 bolt reduced head FAS 80088 19 M8x20 countersunk head socket screw FAS 80032 20 Box micro switch bracket ACC 25038 21 Carriage fabrication Standard type Quote lift number 22 Lower right lifting arm Quote lift number 23 Upper right lifting arm Quote lift number 24 Upper left lifting arm Quote lift number 25 Lower left lifting arm Quote lift number 26 Left hand stowing rocker Quote lift number 27 Carriage front bearing carr
37. R V IN or OUT to the required position Re tighten lock nut when setting is finalized Note initial pressure levels will be factory set 4 5 The manual override of the lifts hand pump should be tested at this time as well as the hydraulic cylinder crash valves To test the crash valves a suitable tap equipped valve should be connected to the tee location on the hydraulic hose at the power pack The open end of the valve should then be piped into a container to restrict spillage of hydraulic fluid With the lift in the raised position both unladen and laden with test weights quickly open the tap to simulate a hydraulic hose bursting The cylinder crash valves should react by regulating the pressure flow of the fluid the lift will descend in a down wardly motion at a controlled speed Disconnect valve tap and replace blanking cap when finished NOTE A crash test kit is available from PLS parts department 4 6 The tail lift Test Certificates should always be properly filled out at the end of lift installation this comprises of a LOLER and Weight Test documents Certificates are supplied with fitting kit copies are provided on page 5 15 and 5 16 5 EXTRA NOTES FOR POWERMATIC APPLICATIONS 5 1 This system works by incorporating two limit switches inside the lift These detect the position of the unit and transfer the power between the carriage mounted motor for in out motion and the external pump up down movement The installati
38. assengerliftservices co uk 1 08 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 15 PLS A MOBILITY NETWORKS COMPANY AUTOMATIC MEGA COACH LIFT OPERATION INSTRUCTIONS These instructions MUST be read and understood before attempting to operate the lift and floor system TO CONTROL THE LIFT Main isolation switch by the driver b Four button controller i Lift out up ii Lift down in iii Bridge plate handrails deploy unfold iv Bridge plate handrails stow fold TO DEPLOY THE LIFT 1 Unlock safety catch and or un attach safety chain 2 Turn on main isolation switch by driver 3 Power lift out of cassette by pressing the out up button After approx 8 seconds lift is fully deployed and begins to rise automatically 4 Stop the travel of the lift and press the bridge plate handrail deploy button The bridge plate will power to the vertical position followed by the handrails 5 Now press the out up button to take the platform up to the floor to take a passenger down or press the down in button to pick up a passenger waiting to be loaded TO STOW THE LIFT 1 When all loading unloading are completed press the bridge plate handrail stow button and the bridge plate and handrails will fold up to the stowed positions This should be done with the lift above stow height 2 By pressing the down in button the lift will power down to its stowa
39. ated above the lift press UP button the handset release external box lock handle 4 The lift will travel to the out position then automatically begin to rise Stop the lift at a comfortable working height 5 Raise the hand rails making sure that they have located fully into their sockets 6 Pull the platform extension out until the platform surface drops flush TO STOW 1 Press the UP button until the lift is at a comfortable working height This must be above the level of the lift cassette DO NOT attempt to stow the lift from a low position Briefly lift the rear platform surface and push the platform extension fully home Lift the hand rails out of their sockets and fold across the platform surface Press the DOWN button The lift will reach the stow position then automatically divert the power to the IN function With the lift away check that it is stowed correctly by attempting to pull the lift out again without pulling the retaining catch RE ATTACH SAFETY CHAIN ONTO HOLE PROVIDED IN ROLL OFF RAMP 6 Close the vehicle doors to isolate the lift power N B Should the power IN amp OUT system fail the lift can be pulled and pushed into the box by hand PLS 213A Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www p
40. been fitted across the micro switch Replace the cable tie that holds the umbilical to the rear of the carriage lower drawing page 5 12 Make sure that when the lift is powered fully OUT the umbilical is not too tight 2 INSTALLATION of HYDRAULIC S amp ELECTRIC S See Hydraulic amp Electrical sections in manual 2 1 The lift fitting is supplied with a length of 16mm battery cable and a separate length of three core cable 0 75 min These should firstly be run from the lift position to the battery and the position of the isolator switch respectively Follow existing vehicle cables if possible DO NOT ATTACH CABLES TO FUEL LINES OR BRAKE PIPES DO NOT RUN THROUGH HOLES IN CHASSIS OR MEMBERS WITH FUEL LINES AVOID SHARP EDGES BY PROTECTING CABLE WITH CONDUIT OR KNOCK ON EDGING STRIPS The battery cable is protected via a circuit breaker which should be attached to the positive feed on the battery The isolator switch is either a door mounted earthing pin switch mainly panel vans or a cab switch for coach built vehicles These cables are then secured above 5 03 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 86 the pump location on the near side to the front of the rear brackets if mounted externally The type of isolator switch is dependent on the vehicle specification Door mounted switches should be protected from damage and water ingress 2 2 If the pump is to be mounted internally the cables
41. ck parts reference only 6 03 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 105 137 Hydraulic pipework Power pack parts 138 Gear roll pin FAS 80226 139 M8 socket head shoulder bolt FAS 80191 140 M10 socket head shoulder bolt FAS 80192 141 M12 washer FAS 80041 142 M8x45 hex hd Setpin FAS 80065 143 0 25 Step hose Quote lift number 144 0 25 Platform hose Quote lift number 145 0 25 Microbore hose Quote lift number 146 0 25 Microbore hose Quote lift number 147 0 25 Microbore hose Quote lift number 148 0 25 Microbore hose Quote lift number 149 0 25 Barrel tube CON 10150 150 Dowty washer HU 02 151 0 25 Locknut ACC 25732 152 0 25 Male female male CON 10144 153 0 25 Male Male connector CON 10146 154 M12 washer FAS 80041 155 0 25 x0 25 bulkhead CON 10143 156 Adjuster check valve FLA 35528 157 Inline check valve FLA 35131 158 0 25 hex hd Banjo bolt HU 15 159 Bridge plate coil ACC 26049 24V ACC 26052 12V 160 Relay box ACC 26251 161 0 25 Maleallen key plug CON 10149 162 Bridge plate valve ACC 26049 24V ACC 26052 12V 163 3 pin plug ACC 25472 164 Box side brush unit Quote lift number 165 Box side brush unit spacer ACC 25934 166 Solenoid mounting bra
42. cket ACC 25985 167 Carrige lock spring ACC 25552 168 Motor bracket spring ACC 25647 169 Umbilical guide ACC 26061 170 Loom support ACC 25876 171 Loom support ACC 26016 172 Bridge plate Quote lift number 173 Bridge plate hinge Quote lift number 174 Bridge plate hinge roller Quote lift number 175 Bridge plate hinge roller pin ACC 25702 176 Extension platform cam follower ACC 256 73 177 Extension platform stop ACC 25365 178 M5x16 bolt FAS 80072 179 M12 Half nut ACC 25751 180 M12 All metal lock nut FAS 80206 181 M12 Int fan disc washer CON 10246 6 04 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 106 Notes PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 107 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 108 A MOBILITY NETWORKS COMPANY Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 Fax 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk
43. d tightened into position when the box is correctly positioned Turned down studs which are NOT covered by a bracket should be replaced with M10 x 25mm bolts retained with a spring washer 1 7 The zinc plated top sheet should be secured into position at this stage some vehicles will require the sheet fitting into position prior to installing the box as it facilitates handling the cassette much easier The top sheet is secured into position using a run of Polyethylene Sealant around the top edges of the lift cassette If the top sheet is required to be removable it may be located with SHORT M6 bolts or Duct tape if Duct tape is used it will require regular checks and possible replacement 1 8 The final positioning of the box is also determined by the location of the extension arms when the lift is raised to its fully UP position mainly Coach Built vehicles See page 5 10 511 Ensure a floor end gap G of at least 15mm before the end of the platform extension arms comes into contact with the rear of the vehicle it may be necessary to pull the box out from underneath the vehicle It is usual for the RAISED HEIGHT to be less than the DROP DISTANCE Note Check lift doesn t hit vehicle edge with platform extension closed prior to drilling and fixing final cassette position 5 02 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 85 1 9 The cassette box is secured into position via M10 x 30mm Hex head 8 8 strength mi
44. designating individuals who are competent in the safe operation of their equipment and safe welding process A competent person is one who has through a combination of training education and experience acquired knowledge and skills that enable the person to correctly perform that task Employee s responsibilities in managing risks The HSE requires employees while at work to take all reasonably practicable steps to not take any action or make any omission that creates or increases a risk to take all reasonably practicable steps to not take any action or make any omission that creates or increases a risk to their or others health and safety cooperate with the employer to the extent necessary to enable the employer or other person to fulfill duties and obligations imposed on them use equipment supplied the accordance with instructions given the employer consistent with its safety equipment supplied by the employer in accordance with any instructions given by the employer consistent with its safe and proper use This is of particular importance for welding activities as the use of personal protective equipment is essential in such activity 5 17 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 100 Notes amp Manual 2014 12 06 2014 13 31 Page 101 PLS A MOBILITY NETW
45. e lift unattended at ground level if passengers are on board When lift is not in use the controls should be deactivated Ensure that the lift is correctly stowed after loading Operators ensure that Lift will lower to firm level ground Scooter or powered wheelchair is not larger than lift platform any direction Tail lift is in a FULLY operational condition Report any defects Lift bridging plate lands flat onto vehicle floor Roll off ramp is set vertically approx 809 and fully operational Accompany the passenger on the lift if possible but do not overload the lift You have a clear view of the lift platform before the scooter moves onto it NEVER leave passengers unattended at any time The passenger should not be required to operate ANY controls Loading amp Unloading procedure Explain to passenger the sequence of movements that will occur Where possible passenger should dismount scooter and board vehicle separately Ensure that the lift plattorm and area around the lift are free from obstruction Ensure that the lift platform is in the correct position before moving onto it Scooter should be pushed onto the lift plattorm NOT DRIVEN Ensure that persons or equipment do not overhang the platform Scooter breaks are applied BEFORE lift begins motion or wheels blocked All power to scooter is turned OFF Operate lift platform to vehicle floor Scooter is pushed off the lift plattorm NOT DRIVEN The scooter sh
46. er or hot or molten material or due to burning of clothing Fire and explosion due to arc flame sparks or spatter or electrical faults in combination with flammable materials gases or liquids Fumes due to inhalation of harmful fumes and gases from the welding process Noise welding environments are sufficiently noisy to be above the limit level 85dB A Slips trips and falls due to arrangements of tools and power lines in different work environments Manual handling due to the use of heavy tools and equipments Difficult work situations such as work outdoors in confined spaces or on steel structures can also add to the hazards of welding Managing risks associated with welding The best way to manage the risks associated with welding is by implementing risk management programs Risk management is a method that requires the identification of hazards assessment of the risks and implementation of suitable controls to reduce the risk to an acceptable level It is essential to evaluate and review a risk management program Evaluation involves ensuring that control measures have eliminated or reduced the risks and review aims to check that the process is working effectively to identify hazards and manage risks Employer s responsibilities in managing risks If a hazard is identified the employer must ensure that an assessment of the risk is made and a control measure is implemented The employer is responsible for
47. ff M10 x 60mm bolts Note ONLY USE PLS SUPPLIED HYDRAULIC HOSES 2 5 The 16mm earth strap for the pump is attached to a suitable clean point on the vehicle chassis usually a bracket bolt All other wiring should be routed to the pump using the large plastic glands All connections are made in accordance with the instructions on the wiring blocks number to number fitted to the pump The battery feed live feed in is attached to the UP solenoid mounted on the side of the pumps motor of the loose terminal then tightened Note CONNECT THE LIFT WIRING ON THE CARRIAGE FIRST BEFORE CONNECTING THE BATTERY POSITIVE 2 6 When mounting the pump location bracket wherever possible the pump should be positioned above the lift box usually second set of holes from bottom of bracket NOTE THE PUMP MUST BE POSITIONED SO THAT THE HANDPUMP CAN BE OPER ATED SAFELY THROUGHOUT THE ENTIRE TRAVEL OF THE LIFT OPERATION 5 04 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 87 3 FITTING OF THE LIFT PLATFORM INTO THE CASSETTE 3 1 When the lift box has been fitted and both the electric s and hydraulics installed the lift innards can be located into the box With tilting the back edge of the lift a little the cam followers on the side of the lifts carriage will locate on the box tracks The lift can then be pulled up to the horizontal position and pushed forward into the box until it is completely home 3 2 There
48. ge height then automatically divert power to the in function to stow the lift in the back of its cassette box 3 Turn off the main isolation switch 4 Re lock safety catch and or attached safety chain If in doubt please phone the company for further instructions Tel 0121 552 0660 PLS 273 Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 09 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 16 PLS A MOBILITY NETWORKS COMPANY Bridge Plate Manual Override 1 To lower the bridging plate Access the manual override tap underneath the lifting platform from the MIDDLE of the lift Do NOT attempt to turn the tap with your hand arm in between the lifting platform and the lift arms see diagram 1 Screw the tap IN clockwise to release pressure from the cylinder and the bridging plate will drop 2 To raise the bridging plate The release tap should be opened FULLY Diagram 2 shows the release tap inside of the platform Access can also be gained by removing the platform aluminium 2 MANUAL TAP MANUAL TAP PLS 268 Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660
49. ier ACC 25084 28 Roller bearing ACC 25645 29 Circlip FAS 80109 30 Carriage rear bearing carrier for flat back box ACC 26519 31 Carriage motor gear ACC 26065 32 Carriage drive gear inner sleeve ACC 25959 33 Carriage drive gear 34 Carriage motor bracket ACC 25198 35 Carriage motor ACC 25449 12v ACC 25671 24v 36 Arm pin plain Standard lift ACC 25285 37 Carriage cam follower ACC 25739 std 38 Carriage cam follower lock nut ACC 25740 45deg 39 Carriage cam follower washer grease nipple 40 Carriage lock micro switch bracket ACC 25061 41 Buzzer nut PNXBUZ222 42 Buzzer 43 Buzzer bracket ACC 26045 44 Solenoid 24 12v 6 01 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 103 45 Solenoid bracket ACC 25350 46 Carriage lock hatchet Quote lift number 47 Mico switch ACC 25598 48 Hatchet lock guide ACC 25026 49 Mico switch actuator roller ACC 25907 50 Micro switch bracket ACC 25046 51 Carriage fabrication Mega type Quote lift number 52 Lower right lifting arm Mega Quote lift number 53 Upper right lifting arm Mega Quote lift number 54 Upper left lifting arm Mega Quote lift number 55 Lower left lifting arm Mega Quote lift number 56 Left hand arm rocker Mega Quote lift number 57 Carrier rear bearing carrier ACC 25085 58 Carriage front bearing carrier mega ACC 26201
50. ing Push ARM CRANK K from the left to right into the platform There should be one thick washer between the inside of the platform and the CAM J Push CAM fully across to the left and rotate forward until it touches the bridge plate rocker bar G Tighten one of the four grub screws L to retain position Drill through the M6 holes in the CAM and just into the CRANK K approx 2mm with a 5mm drill bit Do this to the three exposed M6 tapped holes in the J Utilizing BLUE thread lock fit M6 x 6mm dog nosed grub screws into the available threads Remove the original retaining grub screw thread lock and re tighten Lower the lift platform then power up to floor position to settle the mechanism Set the single collar D forwards to take up any over stroke in the plunger Fig 1 Key 1 20 A Double plunger H Bridge plate hinge roller or cam B Plunger bar Bridge plate hinge C Twin collar J Cam D Single collar K Arm crank E Plunger bar spring L M6 x 6mm grub screw dog nosed F Toggle M Rocker bar retaining pin and split pin G Rocker bar N Cam spacer thick washer e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 27 ANOONIS 00812 315 M3ddOO NOILVOIJIO3dS NOLLWOISSNT Ov AVHdS 5 MNA NOLLVOISMS I 6 L 9 S 2 444 NlMdS soy
51. iple View on right side of the lift rear section of the Platform Arms Open section Chassis Bumper G Vehicle floor Bracket M12 Washer M12 Hex Bolt 912 5 Hole Detail B M10 Washer Bolt Head On nside The Box 910 5 Hole M10 Hex Bolt M10 Washer Usually two or more holes in the end of the chassis 2 10 910 5 Hole Level PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 94 Vi ZZ li Umbilical exit from box Umbilical entrance inside box showing bolt on hose guard 5 12 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 95 28 LA RS 5 NS bi NY 72 RS AN AN n T 5 22 22 if Relay assembly has been updated by above solenoids 5 13 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 96 PLS Recommended Torque Settings Nm Thread Size M4 M5 M6 M8 M10 M12 M14 M16 5 14 Tensile Grades of Fastenings 4 6 8 8 10 9 2 3 2 4 5 4 6 4 9 6 8 10 9 15 3 16 3 26 1 36 8 32 2 51 5 72 56 90 126 89 142 200 136 218 307 19 1 46 1 92 1 159 255 368 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 97 Installation Examination and P LS Confirmation of Weight Certification mm
52. latform Alloy 2 Platform Alloy 2 79 Bridge Plate Spiggot 2 79 Bridge Plate Spiggot 2 Bridge Spiggot 2 BO Bridge Plate Torsion Spring 1 BO Bridge Plate Torsion Spring 2 Bridge Plate Torsion Spring 2 81 Standard Push Rod 1 81 Standard Push Rod 2 M8x8 C Sunk Socket Screw 2 82 Twin Push Rod 1 82 Twin Push Rod 2 Split Pin 2 B83 Return Sprin 2 B3 Return Spring 4 Hydroulic Cylinder 1 95 M8x8 C Sunk Socket Screw 2 95 8 8 C Sunk Sockel Screw 2 Bridge Plate 1 99 Split Pin 2 99 Split Pin 4 Bridge Plcte Hinge 1 172 Bridge Plote 1 172 Bridge Plate 1 Plote Roller 1 173 Bridge Plote Hinge 1 Plate Roller Pin 1 174 Bridge Plote Roller 1 174 Bridge Plate Roller 2 175 Bridge Plote Roller Pin 1 175 Plate Roller Pin 2 BRIDGE PLATE ASSEMBLY SINGLE MECHANICAL PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 55 BRIDGE PLATE ASSEMBLY HYDRAULIC BRIDGE PLATE ASSEMBLY SINGLE MECHANICAL BRIDGE PLATE ASSEMBLY 2 24 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 56 ITEM PART DESCRIPTION M8x10 Grubscrew Pivot Pin Guard Hat P Clip Mega Platform Frame Mega Handrail Side Guard 9 N gt Handrail Side Bracket Handrail Platform Alloy 2 25 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 5
53. llar 71 Platform Alloy Push Rod Collar 72 Dummy Pin Box Lock Pin 73 Rocker Pivot Pin 74 Ex Platform Roller Beorings 8 8 C sunk Socket Screw 75 Bearing s Inner Bush MBx10 Grubscrew 76 Extension Platform 5 Grubscrew 77 Roller Fastener Bolt M6x6 Grubscrew 78 Bridge Plate Arm Crank Split Pin 79 Bridge Flate Spiggot MB Spring Washer 80 Bridge P Torsion Spring Bridge Plate Rocker Bar B1 Standard Push rod a 2 Exten Plat Cam Follower 82 Twin Push Rod 2 15 Extension Platform Stop PLS Access amp Main Manual 2014 12 06 2014 13 31 ase 47 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 48 STANDARD PLATFORM FRAMES DOUBLE MECHANICAL BRIDGE PLATE M8 Nyloc Nut PART DESCRIPTION 85 8 Washer Upper Left Arm 86 Swivel Joint Lowerr Left Arm 87 8 Half Nut Arms Pin Plain Std 88 8 20 Standard Bolt Arms Pin Threated Std 89 16 Washer Platform Frame 90 Plate 91 Push Rod Twin Collar Push Rod Collar Box Lock Pin 94 Rocker Pivot Pin Bearing s Inner Bush 95 8 8 C sunk Socket Screw Extension Platform 96 8 10 Grubscrew 5 6 Grubscrew 78 Plate Arm Crank 98 M6x6 Grub
54. lly t the end PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 91 Bracket Fit To View on right side of the box Box Section Chassis rear section of the car To fit brackets and possition Vehicle floor box refer to General Principle Bumper Box section Chossis Bracket Ground Level A M12 Washer ANN d 912 5 Hole M12 Hex Bolt eg Detail B Detail B Spacer M10 Washer 910 5 Hole Bolt Head On Inside The Box 10 Hex Bolt 10 Washer M10 Washer M10 Nylock 910 5 Hole Spacer M10 Hex Bolt XS Usually two or more holes in the end of the chassis 2xM10 SX 5 09 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 92 5 10 Hydraulic pipe View on left side of the box support bracket section of the Open Open section _ Chossis Vehicle floor 4 Pump mounting bracket adjustable One cable con be two hydraulic pipes Hydraulic connection cover Nylon block Bolt Head On Inside The Box De Lift Direction Bolt Head Or Inside r7 Usually t the end PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 93 Bracket Fit To Open Section Chassis To fit brackets ond possition box refer to General Princ
55. m Weight of lift inc pump module 137Kgs to 234Kgs Working pressure 170 Bar MAX Max amp draw at pump 75 amps Safety systems Dead man button control Platform roll off barrier ramp Bridging plate Main power isolation switch amp or Driver isolation switch Hose valves fitted inside cylinder body Hydraulic hoses rated x 4 Stow position warning light optional Flashing LED side light pods x 2 optional 1 02 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 9 Important Information LOLER 98 What is LOLER The Lift Operations and Lifting Equipment Regulations 1998 which came into force on 5th December 1998 Basically LOLER replaced existing legal requirements relating to the use of Lifting equipment What does LOLER do The Regulations require that lifting equipment provided for use at work is 1 Strong and stable enough for the particular use and correctly marked to indicate safe working loads 2 Used safely in a planned and organised way by Competent People 3 Examined inspected and tested on a regular basis by Competent People How can PLS help Passenger Lift Services offer a Bi Annual examination and weight testing programme carried out only by PLS Approved engineers Each certificate is individually numbered and security marked to ensure authenticity To begin your programme of compliance with LOLER 98 call now on 01 21 552 5503 What equipment does LOLER cover All equip
56. ment used at work for lifting or lowering loads Who do the regulations affect Any person responsible for providing or having control over the provision of lifting equipment in the workplace the duty holder What should the duty holder be aware of The Health and Safety Executive HSE have produced a publication The Safe Use of Lifting Equipment lifting operations and lifting regulations 1998 approved code of practice and guidance APCPG How do obtain a copy of this publication By mail order from HSE Books PO Box 1999 Sudbury Suffolk CO10 6FS Tel 01787 881165 Fax 01787 313995 What do the regulations require me to do The regulations impose a number of requirements on the duty holder including ensuring that e lift operations are carried out and supervised in a safe manner by Competent People 1 03 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 10 What do the regulations require me to do The regulations impose a number of requirements on the duty holder including ensuring that e lift operations are carried out and supervised in a safe manner by Competent People e Where equipment is used for lifting people it is suitably marked and safe for the purpose Before the lifting equipment is used for the first time it is thoroughly examined by a Competent Person and thereafter at regular intervals Who Qualifies as a Competent Person A person who has appropriate practical and
57. n bolts washers and nylocks Note THE BOLT HEADS MUST BE ON THE INSIDE OF THE LIFT CASSETTE WITH THE WASHERS AND NYLOCKS ON THE OUTSIDE If fitted backwards the length of bolt will contact with lift innards and stop lift from functioning The kit is supplied with 2 M10 x 30mm turned down head bolts these are used on the front bracket at the near side of the vehicle They fit behind the umbilical cable and allow it to fit closely to the side of the box How to remove the lift innards If the box is to be fitted first lift innards added when box positioned the lifting section will need to be removed from the lift cassette box 1 Remove the stop blocks one fitted each side of the lift by removing the 8 bolts two bolts each 2 When removed mark up the stop blocks Left and Right These must be repositioned in the same manner If not the lift may power out too far Detach hydraulic QRC quick release coupling from rear for Carriage section Detach the electrical multiplug from rear of Carriage Remove cable ties holding umbilical to rear of Carriage The lift may now be removed from cassette QOIS AFTER REMOVAL PLACE A CABLE TIE AROUND THE ROLLER ARM OF THE OUT amp UP MICRO SWITCH LOCATED ON THE RIGHT SIDE TOP OF THE CARRIAGE THIS WILL AVOID DAMAGING THE SWITCH WHEN REPLACING THE LIFT INTO CASSETTE Note If the lift powers UP inside the cassette when re installed remember to cut off the cable tie that has
58. nally holes exist in the chassis ends which can be used The rear brackets MUST be mounted a minimum of 250mm from the mouth of the lift box This will allow clearance for the box lock mechanism The position of fitting brackets may also be determined via the body mounting points Always use the strongest parts of the chassis available 1 3 The lift is usually mounted as close to the underside of the vehicle chassis as possible for maximum ground clearance Normally however the rear valance of the vehicle protrudes downward lower than any of the chassis members e g position A on page 5 08 5 09 Position A can determine length of this is the drop from the underside of the chassis to the bottom lip of the tail lift box However on some coach built vehicles length B is determined by the type of lift fitted Remember to check lift build paperwork for a top of box to vehicle floor height measurement A top of box to underside of chassis dimension may also be included Remember to add box depth to measurements to extrapolate potential ground clearance In some cases it may be necessary to cut the rear valance to gain extra ground clearance 1 4 It should be clarified that the front of the tail lift is the end of the box closest towards the front of the vehicle on page 5 08 511 position Y The back of the tail lift is the open end of the box which is at the rear of the vehicle position X 5 01 e
59. ns In Out Pump Condition Overload Test Applied Up Down Pump Condition S W L Test Applied Description of Defects Identified and Remedial Work Required the undersigned confirm that the above Lift was examined in accordance with LOLER 98 regulations on Examining Company And that Certificate No was issued in confirmation of a satisfactory weight test Position Date Signed Qualifications 5 16 e PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 99 Welding Information Welding What is welding Welding is an industrial process used for joining metals It involves many processes in which two pieces of metal are joined together or separated by application of heat pressure or a combination of both Welding can be performed in a wide range of work environments Welding is a high risk and labour intensive activity It exposes workers to a number of hazards that may be detrimental to health and can have both acute and chronic effects Welding related accidents can also be fatal Hazards and risks associated with welding Welders are exposed to the following hazards Electric shock due to contact with electrically live components Radiation burns burns to the eyes or body due to large quantity of visible light ultraviolet and infrared from the welding arc Body burns burns due to weld spatt
60. on of a Powermatic lift is the same as a manual because all of the extra wiring is internal and factory set Note The change over switch mounted at the right side of centre of the carriage with roller attached will leave the factory with a cable tie over the switching mechanism This is to stop the switch from being damaged in transport Cable tie must be removed prior to first operation If not the system will think that the lift is not at end of travel and continue to power the carriage motor If the lift has not been removed from cassette during the installation process make sure that the hydraulic connection at the back of the carriage is connected correctly This is disconnected at the factory to avoid oil spillage and the lifting cylinders dropping 5 06 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 89 LOAD TESTING FITTED LIFT 1 S W L to vehicle floor a Load platform with 300Kgs and attach pressure gauge to test point on pump unit b Power the lift FULLY UP to vehicle floor height c Visually check mounting brackets for movement and strength d Leave lift for 10 minutes at full floor height and check for creep Should be NO more than 15mm down Lower lift to ground and add weight to 125 i e 375Kgs for 300Kgs badged lift The lift MUST NOT be able to power UP with this load on If lift rises turn the lifting pressure DOWN Turn valve fitted on pump face clockwise to increase
61. ould be clamped to the vehicle floor using the correct equipment The passenger utilises the static vehicle seats and seatbelts Please note The transportation of scooters and large powered wheelchairs may require NON STANDARD tail lift size or specification Where possible PLS can provide longer wider platforms higher roll off ramps Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 06 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 13 PLS A MOBILITY NETWORKS COMPANY ACCESS SEMI AUTOMATIC OPERATING PROCEDURE TO OPERATE 1 Pull the lift isolation switch if fitted in the drivers area to the position If not fitted in the drivers area power will be activated when doors adjacent to the lift are opened 2 Uncdlip safety chain located on r hand side if fitted 3 Briefly press the DOWN button 4 Holding the retaining catch up located on the left hand side of the lift pull the lift out from beneath the vehicle release the retaining catch 5 Ensuring that the lift has travelled fully out from beneath the vehicle press the UP button until the platform is at a comfortable working height 6 Raise the hand rail s check that they have located fully down into their
62. power and anti clockwise to decrease NOTE Valve must NEVER be fully tightened IN Minimum one full turn back f Remove overload weight and raise lift to vehicle floor height Check the full UP and DOWN stroke 5 times Check that the lift raises smoothly towards the top of stroke and does not struggle If lift is sluggish increase the relief valve pressure g Remove weight 2 Check hand pump operation and lowering DOWN valve 3 Check that all manual handling components are free and easy to operate i e handrails and platform 4 Check roll off ramp operates smoothly with NO trip hazards present 5 Check bridge plate operation With full S W L weight on the platform the bridge plate should land correctly flush with the vehicle floor If it does not lay flat the actuator rod should be adjusted see page 1 20 6 Fillin LOLER certificate page 5 15 7 in Weight Test certificate page 5 16 5 07 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 90 5 08 Hydraulic pipe View on left side of the box Bra Bupports Bracket rear section of the car ad Box section Box Si Bracket Chassis A Vehicle floor To fit box re Pump mounting bracket adjustable One cable can be two hydraulic pipes Hydraulic connection cover Nylon block Bolt Heod On Inside The Box Lift Direction Bolt Head Inside The Usua
63. rm camber or uneven ground Their handbrakes are applied Ensure that the vehicle handbrake is Electric wheelchairs engage neutral firmly applied Ensure that the platform is properly stowed after loading INSIDE THE VEHICLE ENSURE Do not move the vehicle with the platform lowered near the ground Wheelchairs are clamped to the floor Do not move the vehicle with a person load on the platform Seatbelts are used PLS 216 Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 05 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 12 Safety Instructions for Scooters and Large Powered Wheelchairs Before operating tail lift Fully familiarize yourself with lift controls relevant safety procedures and possible hazards signified by warning labels or highlighted in your Operators Risk Assessment Tail lift safety Only an authorised fully trained operator must control the lift Secure vehicle doors fully open well clear of the lift platform Keep within the stated maximum safe working load SWL Keep people away from the operating area inside and outside of vehicle Ensure that the platform is always level horizontal not more than 59 NEVER leave th
64. screw 79 Bridge Plate Spiggot 99 Split Pin 80 Torsion Spring 2 105 8 Spring Washer 81 Standard Push rod 121 Bridge Plate Rocker Bor 82 Twin Push Rod 176 Exten Plat Com Follower Return Spring Extension Platform Stop 77 Roller Fastener Bolt E 2 17 PLS Access amp Main Manual 2014 12 06 2014 13 31 EM 49 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 50 STANDARD PLATFORM FRAMES HYDRAULIC BRIDGE PLATE PART DESCRIPTION Upper Left Arm Lowerr Left Arm Arms Pin Plain Std Arms Pin Threoted Std Platform Frame Platform Alloy Dummy Pin Roller Ex Platform Roller Bearings Bearing s Inner Bush Extension Platform Roller Fastener Bolt Bridge Plate Spiggot Bridge P Torsion Spring Box Lock Pin 8 8 C sunk Socket Screw M8x10 Grubscrew M5x6 Grubscrew 176 Exten Plat Cam Follower Plotform Loom 1 177 Extension Platform Stop PLS Access amp Main Manual 2014 12 06 2014 13 31 ase 51 FOR HYDRAULIC ELEMENT DETAILs SEE NEXT PAGE PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 52 PART DESCRIPTION B4 MB Nyloc Nut 193 ese Cylinder MB Standard Washer 107 M8x45 C sunk Socket Setscrew 108 Tube Spacer 124 Roll Pin 94x12 142 MBx45 Standard Setscrew 143 0 25 Step Ho
65. se 144 0 25 Platform Hose 145 0 25 Microbore Hose 146 0 25 Microbore Hose 147 0 25 Microbore Hose 148 0 25 Microbore Hose 149 0 25 Barrel Tube L120mm 150 0 25 Seal Dowty Washer 151 0 25 Locknut 152 0 25 Mole Female Mcle Tee 153 Male Male Connector Hex Head Banjo Beli 159 Bridge Plate Coil 154 M12 Washer 160 Relay Box 155 0 25 0 25 Bulkhead 161 0 25 Male Allen Key Plug 156 Adjuster Check Valve 162 Bridge Plate Valve 157 Inline Check Valve Coll C Lcd feel fet 163 3 Pin Plug HYDRAULIC ELEMENTS HYDRAULIC BRIDGE PLATE 2 21 PLS Access amp Main Manual 2014 12 06 2014 13 31 STANDARD HANDRAIL 53 PART DESCRIPTION Platform Frame Platform Alloy M8x10 Grubscrew Pivot Pin Standard Handrai Guard Top Hat Std Handrail Side Std Handrail Side E P Clip gt 2 22 PLS Access amp Main Manual 2014 12 06 2014 13 31 2 23 age 54 PART DESCRIPTION FOR rel PART DESCRIPTION FOR PART DESCRIPTION FOR ry SINGLE MECHANICAL DOUBLE MECHANICAL HYDRAULIC 70 Platform Frame 1 70 Platform Frame 1 Platform Frame 1 71 Platform Alloy 2 71 P
66. sidered alongside other Health and Safety Law in particular the Management of Health and Safety at Work regulations which contain important duties regarding the preparation of a risk assessment How are the regulations enforced Health and Safety Officers enforce the regulations The Duty Holder must be able to produce a valid examination certificate when requested by a Health and Safety Officer 1 04 e PLS Access amp Main Manual 2014 12 06 2014 13 31 11 PLS A MOBILITY NETWORKS COMPANY SAFETY INSTRUCTIONS IMPORTANT FAMILIARISE YOURSELF WITH CONTROLS AND SAFETY PROCEDURES BEFORE USING LIFT TAIL LIFT SAFETY T PEDESTRIAN PASSENGERS Only an authorised operator must ENSURE THAT control the lift Passengers keep clear of the Secure the vehicle doors in the open platform edges position well clear of the platform They hold onto the hand rails within the maximum safe working They do not climb onto the platform oad They do not leave the platform Keep people away from the operating before it reaches the floor or ground area inside and outside the vehicle Ensure that the platform is level n WHEELCHAIR PASSENGERS Switch off the isolator if fitted before A leaving the lift unattended ENSURE Operator is behind wheelchair VEHICLE SAFETY They are stable Do not operate the lift on a steep hill e They do not overhang the platfo
67. sockets 7 Pull the rear platform extension out until the platform surface drops flush TO STOW 1 Press the UP button until the lift is at a comfortable working height Do NOT attempt to stow the lift from a low position 2 Briefly lift the rear platform surface and push the rear platform extension fully home 3 Liftthe hand rail s out of its socket and fold across the platform surface 4 Pressthe DOWN button until the lift stops and then push the lift underneath the vehicle CHECK that the lift is stowed correctly by attempting to pull the lift out again without releasing the retaining catch 5 SAFETY CHAIN ONTO HOLE PROVIDED IN ROLL OFF RAMP 6 Push the lift isolation switch to the OFF position if fitted Otherwise closing doors will isolate lift PLS 211A Passenger Lift Services Limited Unit 2 Summit Crescent Ind Est Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 Fax 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 07 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 14 PLS A MOBILITY NETWORKS COMPANY ACCESS PASSENGER LIFT POWERMATIC OPERATING PROCEDURE EXTERNAL CABLE BOX LOCK TO OPERATE 1 Open the vehicle door s where the lift is located 2 Unclip safety chain located r hand side if fitted 3 Pull the external box lock handle loc
68. st Off Roebuck Lane Smethwick West Midlands B66 1BT U K Tel 44 0 121 552 0660 Fax 44 0 121 552 0200 E mail enquiries pls access co uk Web Site www passengerliftservices co uk 1 11 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 18 PLS A MOBILITY NETWORKS COMPANY ACCESS PASSENGER LIFT AUXILIARY HAND PUMP OPERATION PROCEDURE MONARCH POWERPACK A hand pump allows the lift to be used in the event of any electrical fault The unit which is integral with the power pack comprises a single acting piston pump with removable operating lever This is found either under the rear of the vehicle on the nearside or internally on the nearside Remove the black plastic cover to gain access to the pump To use the pump proceed as follows PREPARATION 1 Take the operating lever from its stowage Note The notched end is also used as a spanner for operating the relief valve TO LOWER THE PLATFORM 2 Open the relief valve anti clockwise TO RAISE THE PLATFORM 3 Close the relief valve clockwise 4 Connect operating lever to hand pump 5 Operate lever until platform is at required height STOWAGE PROCEDURE 6 Using the hand pump stow the platform in the normal way When power is restored to the lift check that the relief valve is firmly closed clockwise 7 Stow the operating lever N B Should the power IN amp OUT system fail the lift can be pulled and pushed into the box by hand P
69. tents Section Information Warranty terms amp conditions Access Lift technical data LOLER information Safety instructions Safety instructions for scooters and large Powered wheelchairs Access Semi Auto operating procedure Access Powermatic operating procedure Mega coach lift operating procedure Hydraulic bridge plate manual override Savery hand pump operating procedure Monarch hand pump operating procedure PLS Lift daily check sheet Service record sheet Monthly safety checks 6 monthly safety checks Lift trouble shooting Floor height adjustment How to set the bridge plate mechanism Lubrication diagram Decal sticker diagram Hand set layout Ordering spare parts drawings Spare parts order form Lift assembly drawing Flatback box drawing Stepback box drawing Standard carriage assembly Mega carriage assembly Standard box lock In out motor assembly Standard arm assembly Mega arm assembly Standard platform assembly Double bridge plate mechanism platform Hydraulic bridge plate mechanism platform Hydraulic elements for bridge plate mechanism Standard handrail assembly Bridge plate assembly e Page 1 01 1 02 1 03 1 04 1 05 1 06 1 07 1 08 1 09 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 2 01 2 02 2 03 2 04 2 05 2 06 2 07 2 08 2 09 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 18 2 19 2 20 2 2
70. theoretical knowledge and experience for the lifting equipment to be examined to enable them too detect actual or potential defects or weaknesses and to asses their importance in relation to the equipment and it s installation i e A person holding a service training certificate by the manufacturer It is essential that the competent person is sufficiently independent and impartial to allow objective decisions to be made Does this mean the competent person must be employed by an outside company No BUT if in house examiners are used you must ensure that their total impartiality to carry out the examination s without fear or favour Are the regular intervals specified YES but you have a choice you can follow the specified period intervals of at least six months for equipment used for lifting people or You can have a examination scheme drawn up and have the equipment examined in accor dance with this scheme Are there other criteria requiring a thorough examination 1 After installation and before putting into service Installation and Weight Test Certificate If re installed on a different vehicle Following exceptional circumstances which may jeopardise the safety of the lift Following an accident or dangerous occurrance After significant changes in conditions of use After long periods out of use wh How do the regulations relate other HSE legislation The requirements of the regulations need to be con
71. troke requires adjustment the following steps should be taken 1 Remove the plastic top and bottom arm cover retained with cap headed bolts 2 Undo the 24mm lock nut at cylinder ends 3 With the lift powered down to the floor i e pressure off the hydraulic system turn the pistons anti clockwise to increase the lift height or clockwise to decrease the lift height 4 Power the lift up to floor height and put the platform in it s vertical position Final adjustment to correct a cylinder imbalance is carried out in the same manner 5 Re tighten lock nuts and refit plastic arm guards N B Under no circumstances should the thread be unscrewed more than 30mm as insufficient thread portion will be left in the cylinder end resulting in possible dam age to cylinder lift and personnel Should it be necessary to extend beyond this point please refer to our technical department CYLINDER MUST NOT EXCEED 30mm 1 19 PLS Access amp Main Manual 2014 12 06 2014 13 31 Page 26 How to set or re set the mechanical bridging plate system 1 2 10 Power lift to MAXIMUM UP position Fold bridge plate I over to vehicle to its maximum position With the bridge plate in this position the plunger bar B should be 2 to 3mm away from the roller or cam H the bridge plate hinge 1 Lock plunger bar B into position with mole grips Set TOGGLE F length there must be a minimum of 20mm of thread show
72. will be two zinc plated solid metal blocks usually located with a cable tie to the handrails These are the lift STOP BLOCKS they should be bolted into the lift box just underneath the side tracks at position W on page 5 08 5 11 The bolts used should be M8 x 25mm a spring retaining washer is also required With the blocks in place the lift can not come out of the box 3 3 The next operation is to connect the inner box hose to the back of the lift carriage via the quick release coupling QRC see page 3 11 The MALE section of the coupling is located at the back of the carriage the collar of this coupling should be pulled back away from the open end The FEMALE end to the inner box hose umbilical can then be inserted It is important to make sure that this connection snaps fully home because the lift will not power correctly otherwise The multiplug on the umbilical can be connected to the plug on the carriage A large cable tie should be used to reattach the umbilical into position on the back of the carriage see page 5 12 Finally the cable tie used to hold the micro switch on the carriage can be cut off failure to do this will result in the lift trying to power UP instead of OUT on Powermatic lifts 4 ADJUSTING THE LIFT TO SUIT THE VEHICLE FLOOR HEIGHT 4 1 The lift can now be powered up to the vehicle floor height The floor height of the lift is set at the manufacturers however in some instances it may be necessary to make

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