III. MAINTENANCE AND REPAIR CAUTION CAUTION
Contents
1. FLOW CONTROL FLOW CONTROL ALVE LEFT ALVE RIGHT LOCATED AT LOCATED AT HYDRAULIC CYLINDER HYDRAULIC CYLINDER d PRESS RE at SWITCH e m ti ete ag e acis DECELERATION TX CONTROL VALVE MM OPTIONAL L _ o MANUAL BACK UI PUMP gt PRESSURE RELIEF rv S AL E JAL J e ELEASE e ALVE E all MA z m VN bec PEE EaR l FIGURE 3 5 K SERIES HYDRAULIC CIRCUIT DIAGRAM 32D S SK06 Bm Ricon AWabtec company MAINTENANCE F 1 ELECTRICAL WIRING DIAGRAM DIAGRAM LEGENDS a Wire Color Codes TABLE 3 3 WIRE COLOR CODES m Bax Re mm Om b Electrical Connector Description K SERIES PUBLIC USE SERVICE MANUAL AUGUST 2013 Refer to Figure 3 6 The standard electrical connectors used by Ricon are Molex 062 Series These con nectors have terminal numbers molded onto the back use these numbers and wire colors to identify wires 5 FIGURE 3 6 MOLEX CONNECTORS C Diagram Labels jjrcult current rating FIGURE 3 7 DIAGRAM LABELS Q Ricon AWabtec company 32DSSK06 B 3 K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE AUGUST 2013 d Electrical2. AUGUST 2013 VERTICAL AR INNER OLLSTC FIGURE 3 3 BRIDGEPLATE CABLE ROUTING 4 LIMIT SWITCH STATES Refer to Figure 3 4 The limit switch actuation chart shows the state of all limit switches as the platform travels from stowed to vehicle floor level and then to ground level The solid line segments represent current flow through the normally CLOSED switch contacts and the open line segments represent current flow through the normally OPEN switch contacts The heavy dashed lines m show switch states when platform is beyond normal travel boundaries This is useful in showing the operation of switches that change states at stowed or ground level positions For proper operation of lift the switch actuations must overlap as shown LT L E A TO T FL FL F E SWITCH v v v EPLOY enable A C 1 T ST nable 110 ey STOW door cl noble aaa Ib limit switch amp BSO 2 50 Ib limit switch actuate hen weight on platform exceeds lbs during IN platforr Yotior T FIGURE 3 4 LIMIT YATION CHART A Wabtec company AUGUST 2013 K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE E HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC HYDRAULIC CYLINDER CYLINDER LEFT RIGHT e 4 e
3. BK 4 lt 128A P3 J3 0 GN 2 16 J16 e 3 W O 3 BL SLOW BLOCK DIODES Ska J4 1 P140__ x o e T UP enable N STOW enable LIFT p CONTROL NC stow SN STOW LOCK No STATUS 13 Ec SOLENOID 0 Nu gt CUTOFF e GN DOWN enable SWITCHES 2EA BK DEPLOY enable 50A zr 5 ume z 9 z E UL EE a S INTERLOCK N 2 a a s ad z 6 zo 2 4 6 1 2 3 4 5 6 7 8 9 J22 J23 PENDANT VEHICLE INTERFACE FIGURE 3 9 K SERIES DOT PUBLIC USE LIFT SCHEMATIC SHEET 1 32DSSK06 B 3 Ricon 3 11 A Wabtec company MAINTENANCE K SERIES PUBLIC USE SERVICE MANUAL AUGUST 2013 e BL BR 8 HANDRAIL LIGHTS e e 8A P20 J20 R CYCLE COUNTER A g ME FLASHING LIGHT Y RED 4 RX TX z BRIDGEPLATE Y E d 7 orem 1 2 3 4 5 6 P19 RX TX J19 2 3 5 6 EN r amp amp 4
4. w a S gt m m 2 3 4 1 2 E o RE TT s J13 12 L1 12 L1 ud i 3E 3j Wa J J9 B T SET2 SET 1 BL 3 E PRINTED a O4 CIRCUIT Rsa BOARD DO NOT SERVICE wo 6 gt 2 9 o x T1 BK 7 T3 ii n J18 pope d 2 3 m P12 p RED ro BLU f SAFETY BELT SWITCH HANDRAIL All wire is 18 gauge unless noted otherwise DSHIS FIGURE 3 10 K SERIES DOT PUBLIC USE LIFT SCHEMATIC SHEET 2 BACK TO TOP NEXT CHAPTER 12 OY Riec orn z sskoe 8 3 A Wabtec company
5. 1 Study the routing of the cable before removing it 2 Deploy the lift platform to vehicle floor level Be certain that bridgeplate is resting against baseplate as sembly 3 Remove pinch point shields from the left and right vertical arm assemblies 4 Assemble and secure one end of an IRS cable to the IRS pulley mount block 1 located inside the left ver tical arm assembly using a hex screw bushing and washer OY Ricon L szesskoe B 3 A Wabtec company AUGUST 2013 9 K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE Route the cable around the IRS pulley mount block bushing 2 Verify that cable is routed between the bushing tab and the point where the cable makes contact with the bushing Install washer and hex nut over bushing and cable assembly Continue to route the cable around grooved bearings 3 4 and 5 Route the cable down the length of the vertical arm assembly and around grooved bearing 6 Assemble and secure the end of the IRS cable to the left side of the bridgeplate 7 using a hex screw washer bushing and he nut Be sure to install a hex nut on the inside of the inner rollstop Repeat for right side 10 Reinstall pinch point shields removed in step 2 32DSSK06 B 3 0 Ricon AWabtec company MAINTENANCE K SERIES PUBLIC USE SERVICE MANUAL
6. PRINT AUGUST 2013 TABLE OF CONTENTS K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE 11 MAINTENANCE AND REPAIR R egular maintenance of the Ricon K Series Public Use wheelchair lift will optimize its performance and reduce the need for repairs This chapter contains lubrication and cleaning instructions a maintenance schedule trouble shooting section and maintenance diagrams N CAUTION This Ricon product is highly specialized Maintenance and repairs must be per formed by an authorized Ricon service technician using Ricon replacement parts A LUBRICATION N CAUTION Do not lubricate motor or other electrical components Lubrication of electrical components may collect dirt and debris causing short circuits Lubrication should be performed at least every six months or sooner depending on usage Refer to Figure 3 1 and the following Maintenance Schedule Lubricate lift at points indicated with lubricants specified TORSION SPRINGS BOTH SIDES DETAIL A KNUCKLE LINKS BOTH SIDES 1 NS TORSION SPRINGS BOTH SIDES A HINGE 1 LUBRICATE WITH PENETRATING OIL DETAIL B LUBRICATE WITH DRY LUBRICANT GRAPHITE 2 FIGURE 3 1 LIFT LUBRICATION POINTS 32DSSK06 B 3 Q Ricon AWabtec company MAINTENANCE B CLEANING K SERIES PUBLIC USE SERVICE MANUAL Regular clea
7. Symbols Figure 3 8 defines the symbols used on the electrical wiring diagram ra e CUIT LE ACTUATO T F ALVE OR LATCH TACT a e e LIMIT SWITCH LE er EHE ee ES ESISTO CONNECTO ITCH E e _ ALLY LOSED A 6 ALLY THRESHOL OPEN NC CONNECTORS EX URT FIGURE 3 8 ELECTRICAL WIRING DIAGRAM SYMBOLS 0 Ricon 32DSSK06 B 3 A Wabtec company MAINTENANCE PUBLIC USE SERVICE MANUAL 2 WIRING DIAGRAM Refer to Figures 3 9 and 3 10 on the following two pages The diagram is divided into two sheets 8 19 Ricon A Wabtec company AUGUST 2013 32DSSK06 B 3 K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE AUGUST 2013 gt MOTOR CONTACTOR TOP z N e SIDE 7 3 A PUMP GRN SIDE lt Lith 44 gt S gt el E nl 9 cas PLATFORM us z PRESSURE 8 Ge 212 SWITCH e P lt N C R1 R FAST P15 J15 PUMPON W3 DOWN C VALVE
8. 2 PUMP SOLENOID LED STATUS INDICATOR K SERIES PUBLIC USE SERVICE MANUAL AUGUST 2013 While platform is at GROUND LEVEL be certain that pump hydraulic fluid level is maintained at required FULL level Add only Texaco 01554 Aircraft Hydraulic Oil or equivalent U S mil spec H5606G fluid Purge hydraulic system by operating lift through its max imum range of travel for at least four complete cycles For some vehicles the maximum range of travel is ac complished by raising vehicle on a service hoist or ramp Refer to Figure 3 2 Two solenoids provide a margin of safety if one of the solenoids fails with its contacts closed A status two color indicator LED is located between the two 8A circuit breakers to monitor the condition of the two solenoids The LED is normally off when the pump is not operating and becomes green when the pump operates When the pump is not operating and the top solenoid has failed the LED will be red The LED will be green when the side solenoid has failed LED STATUS INDICATOR TOP PUMP SOLENOID SIDE PUMP SOLENOID FIGURE 3 2 STATUS INDICATOR FOR PUMP SOLENOIDS 3 BRIDGEPLATE CABLE ASSEMBLY REPLACEMENT The following steps provide instructions for replacing the bridgeplate also known as inner rollstop or IRS cable as sembly Refer to Figure 3 3 on following page Please follow these instructions carefully Contact Ricon Product Support if you need assistance
9. ify that link pins on arms are properly installed free from damage and locked in position Platform pivot points Verify that platform moves freely without binding and does not wobble Bridgeplate Verify that bridgeplate operates without binding during lift functions Verify that bridgeplate deploys fully when platform stops at floor level Verify bridgeplate rests flat against baseplate Front rollstop Verify that rollstop is opened completely when platform is at ground level Verify that rollstop closes and locks when platform leaves ground Hydraulic power unit N CAUTION Check and add fluid when platform is at ground level Fluid that is added when platform is raised will overflow when platform is lowered Verify that pump hydraulic fluid level is at FULL mark when platform is at ground level Add Texaco 01554 Aircraft Hydraulic Oil or equivalent U S mil spec H5606G fluid Verify there are no hydraulic fluid leaks Verify that manual backup pump operates properly Cleaning and 1800 CYCLES 1 Clean lift with mild soap and water and wipe dry Prevent rust by coating all surfaces with lubrication a light weight oil Remove excess oil 2 Spray penetrating oil Curtisol Red Grease 88167 or WD 40 where specified follow ing directions on container Remove excess grease from surrounding areas A CAUTION A Ricon authorized dealer must
10. ning with mild soap i e hand soap car wash liquid and drying thoroughly will protect lift painted surfaces Cleaning is especially important in areas where roads are salted in winter Make sure that lift pivot points remain clear and clean prior to lubrication C MAINTENANCE SCHEDULE Under normal operating conditions maintenance inspections are required at least every six months 1750 cycles and a thorough inspection should be performed at service intervals referenced in Table 3 1 Service should be increased un der conditions of heavy use more than 10 cycles per day TABLE 3 1 MAINTENANCE SCHEDULE SERVICE POINT ACTION TO PERFORM 10 CYCLES Overall condition Listen for abnormal noises as lift operates i e grinding or binding noises Control pendant Verify that control pendant is undamaged and cable connector is tight 150 CYCLES Electrical wiring Inspect electrical wiring for frayed wires loose connectors etc Vehicle interlock Place vehicle in non interlock mode and verify that lift does not operate Decals Verify that lift decals are properly affixed clearly visible and legible Replace if necessary Handrails Verify that handrail fasteners are properly tightened Lift mounting points Verify that vehicle mounting and support points are undamaged Verify that mounting bolts are sufficiently tight and free of corrosion Main lifting pivots Ver
11. perform the following safety check 3600 CYCLES O Ricon 32DSSK06 B 3 A Wabtec company AUGUST 2013 AUGUST 2013 K SERIES PUBLIC USE SERVICE MANUAL MAINTENANCE TABLE 3 1 MAINTENANCE SCHEDULE SERVICE POINT ACTION TO PERFORM Hydraulic cylinder Check hydraulic cylinder for evidence of leaks hoses and fittings Inspect hydraulic hoses for damage Verify that all fittings are tight END OF TABLE D TROUBLESHOOTING The troubleshooting guides are designed to provide logical starting points to locate general problems that could occur with lift However not all possible problems or combinations of problems are listed For troubleshooting lift refer to Table 3 2 The guide does not incorporate routine safety precautions or preliminary procedures and assumes that ve hicle battery is fully charged and battery terminals connectors are clean and tight THE TROUBLESHOOTING GUIDES DO NOT INCORPORATE ROUTINE SAFETY PRECAUTIONS OR PRELIMINARY PROCEDURES DURING THE RICON WARRANTY PERIOD ONLY A TRAINED AUTHORIZED RICON SERVICE TECHNICIAN CAN PERFORM TROUBLESHOOTING AFTER THE WARRANTY PERIOD IT IS RECOMMENDED THAT TROUBLESHOOTING CONTINUE TO BE PERFORMED BY AN AUTHORIZED RICON SERVICE TECHNICIAN 1 LIFT TROUBLESHOOTING TABLE 3 2 LIFT OPERATIONAL TROUBLESHOOTING GUIDE POSSIBLE CAUSE REMEDY Hydraulic fluid leaks Make sure fit
12. ting is PROPERLY tightened Hydraulic component Do not use lift until repairs are made by an authorized defective Ricon service technician Rollstop does not open Obstruction of rollstop Raise lift and remove obstruction release latch Lift functions Abnormal Obstruction in lifting Remove obstruction and check for any damage operation frame Backup pump manual Turn manual release valve CLOCKWISE until slightly release valve OPEN snug Hydraulic fluid may be While platform is at GROUND LEVEL be certain that low pump hydraulic fluid level is maintained at required FULL level Add only Texaco 01554 Aircraft Hydraulic Oil or equivalent U S mil spec H5606G fluid Air may be trapped in Purge hydraulic system by operating lift through its max hydraulic system imum range of travel for at least four complete cycles For vehicles that do not use full travel of lift the maxi mum range of travel is accomplished by raising vehicle on a service hoist or ramp No operation Control system circuit Reset circuit breaker breaker tripped Backup pump manual Turn manual release valve CLOCKWISE until slightly release valve OPEN snug Hydraulic hose or fitting Contact an authorized Ricon service technician for re leak pair 32DSSK06 B 3 _ 0 Ricon 3 3 A Wabtec company MAINTENANCE END OF TABLE Hydraulic fluid may be low Air may be trapped in hydraulic system
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