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K-Series, Personal and Transit Use

1. Wabtec company MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 11 FOLDING PLATFORM ASSEMBLY K5005 K5510 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING ASSY RETROFIT left amp right 1 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19522 5 KIT LINK ASSY REAR FOLDING PLATFORM left amp right 1 29243 6 MAIN SHAFT 1 DIA X 39 13 1 1 49 6 1 KIT SHAFT MAIN 1 00 X 40 507 1 34887 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V2 SP 021 9 KIT ACTUATOR ROLLSTOP REPLACEMENT LH 1 22903 10 ROLLSTOP ASSY 6 X32 1 V2 PF 292 10 1 ROLLSTOP ASSY 6 X 34 W OUTBOARD 1 16626 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V2 SP 022 13 KIT ACTUATOR ROLLSTOP REPLACEMENT RH 1 22902 14 KIT LINK YEL amp BRKTS GREY HIGH MOUNT left amp right included in kit For serial numbers 169180 and above 1 31250 For serial numbers below 169180 1 23340 15 ROLLSTOP ASSY INNER 30 PLATFORM 1 V2 PF 141 15 1 BRIDGEPLATE ASSY 1 30869 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRACKETS GREY HIGH MOUNT W CAM FOLLOWER left amp right included in kit For serial numbers 169180 and above 1 31251 For serial numbers below 169180 1 23355 17 1 KIT BRACKETS GRAY HIGH MOUNT LH amp RH 2 23355 18 LINK ASSY FRONT PLATFORM 2 29223 19 WASHER DELRIN 1 ODX 38ID 03 THK BAG OF 10 8 25628 20 KIT COLLAR ROLLSTOP ACTUA
2. v 1 1 A Wabtec company INTRODUCTION K SERIES SERVICE MANUAL MARCH 2011 RICON CORPORATION FIVE YEAR LIMITED WARRANTY Ricon Corporation Ricon warrants to the original purchaser of this product that Ricon will repair or replace at its option any parts that fail because of defective material or workmanship as follows Repair or replace parts for a period of one year starting from the date of purchase A complete list of parts covered by this warranty can be obtained from an authorized Ricon dealer or qualified service technician Labor costs for specified parts replaced under this warranty for a period of one year from the date put into service A Ricon rate schedule determines parts covered and labor allowed Repair or replace lift power train parts for a period of five years from date of purchase A complete list of parts covered can be obtained from your authorized Ricon dealer or qualified service technician If You Need to Return a Product Return this Ricon product to your installing dealer or to Ricon Please give as much advance notice as possible and allow a reasonable amount of time for repairs If you are traveling All authorized Ricon dealers honor this warranty Consult the telephone directory or call our Product Support department for the name of the nearest authorized Ricon dealer This Warranty Does Not Cover e Malfunction or damage to p
3. O Ricon _ 4 21 A Wabtec company SPARE PARTS LO ei LL lt A 5 O LL LL K SERIES SERVICE MANUAL FIGURE 4 10 FOLDING PLATFORM ASSEMBLY K2005 O Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 10 FOLDING PLATFORM ASSEMBLY K2005 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING ASSY RETROFIT left amp right included in kit 1 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19522 5 KIT LINK ASSY REAR FOLDING PLATFORM left amp right included in kit 1 29243 6 MAIN SHAFT 1 DIA X 39 13 1 VT PI 49 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V2 SP 021 9 KIT ACTUATOR ROLLSTOP REPLACEMENT LH 1 22903 10 ROLLSTOP ASSY 6 X32 1 V2 PF 292 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V2 SP 022 13 KIT ACTUATOR ROLLSTOP REPLACEMENT RH 1 22902 14 KIT LINK YEL BRKTS GREY right amp left serial 5 169180 amp above 1 31246 KIT LINK RED BRKTS RED right left serial 5 169180 amp above 1 31246R KIT LINK YEL BRKTS YEL right amp left serial 5 169180 amp above 1 31246Y KIT LINK amp right left serial s below 169180 1 23338 15 ROLLSTOP ASSY INNER 1 V2 PF 142 16 CATCH BASE LATCH 1
4. ii CH Hicon 32DSS102 D 1 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL OF CONTENTS Chapter Page 1 INTRODUCTION rcc ELE PR 1 1 WARRANTY INFORMATION 1 2 A SERVICE TECHNICIAN INFORMATION 1 3 B GENERAL SAFETY 5 112 2 6000 enne inse sisse res 1 3 C PRODUCT TERMINOLOGY U U U 1 4 INSTAELEATION 2 1 A MECHANICAL INSTALLATION n 2 1 HIRT LOCATIONS ester 2 1 2 LIFT INSTALLATION GUIDELINES 2 2 1 3 LIFT INSTALLATION INTO VANS aan 2 2 4 LIFT INSTALLATION INTO BUSES sss nennen enenatis 2 4 ELEGTRICAE INSTAELATION 5 e Hed tesi ee e bed de IR ieee 2 6 1 INSTALL MAIN CIRCUIT BREAKER 2 2 7 2 ROUTE AND CONNECT MAIN POWER 2 7 35 GROUNDIGONNECTIONS eh et EE 2 9 4 RICON UNSUPPORTED INTERLOCK DEVICE INSTALLATION iii 2 10 Gi FINAL ADJUSTMENTS etat tinet tht 2 15 1 LIMIT SWITCH ADIUSTMENTe enne enne nenas saisis tras 2 15 2 ROLLSTOP PLATFORM TILT ADIUSTMENT enne enne nennen sinn 2 16
5. Hicon Wabtec company KlearVue K Series Folding Platform Personal and Transit Use Wheelchair Lift PRINT gt ERX N gt KER NG G RES 3 X lt KLIN SSK KE SR S OOK lt 2 LEE SIE gt IQ gt 4 lt gt lt gt lt 2 Service 03 31 10 32DSS102 D 1 1995 2011 RICON CORPORATION HOME Rights Reserv U S and foreign patents pending Printed in the United States of America MARCH 2011 K SERIES SERVICE MANUAL TABLE CONTENTS This Ricon service manual is for use by qualified service technicians and is not intended for use by non professionals do it yourselfers The manual provides essential instruc tions and reference information which supports qualified technicians in the correct installation and maintenance of Ricon products Qualified service technicians have the training and know ledge to perform maintenance work properly and safely For the location of a qualified service technician in your area call Ricon Product Support at 1 800 322 2884 Customer Name Installing Dealer Date Installed Serial Number 32056102 1 Wabtec company TABLE OF CONTENTS vs K SERIES SERVICE MANUAL MARCH 2011 REVISION RECORD Rev PAGES DESCRIPTION OF CHANGE OF CHANGE E Le ass eine Note added for installation to utilize Kit P N 43453 for Adjuster Link
6. Item not shown Part of the Articulating Pinch Point Set S20XX XXXXXXX1X 32DSS102 D 1 Ricon 4 29 A Wabtec company K SERIES SERVICE MANUAL MARCH 2011 SPARE PARTS q13IHS 3GIS100 GNVHLHOIY q13IHS 3GIS100 QNVHIJ3T 5 3GISNI GNVH LHOIY T13IHS H3100 GNVHLHOIY 200L00 LL G002M eui uo pesn Mun 479 3 QTAIHS 3GISNI GNVHI331 qTa3lHS H310n0 QNVH1431 INHV Wav 1331 SQT3IHS LNIOd HONId 531445 FIGURE 4 13 PINCH POINT SHIELDS 32DSS102 D 1 Ricon Wabtec company 4 30 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 13 PINCH POINT SHIELDS MODEL A B LEFT OUTER LEFT INSIDE RIGHT OUTER RIGHT INSIDE LEFT OUTSIDE RIGHT OUTSIDE SHIELD SHIELD SHIELD SHIELD SHIELD SHIELD K1132 29167 29183 29183 29167 N A N A K1200 29162 29165 29178 29181 N A N A K1203 K1205 K2003 29162 29178 29178 29162 N A N A K2005 K2010 K2005 29162 29178 29178 29162 29166 29182 710010024 K5005 29163 29179 29179 29163 N A N A K5010 K5511 32DSS102 D 1 O Ricon A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL MARCH 2011 FIGURE 4 14 HANDRAIL ASSEMBLIES Ricon Wabtec company 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 14 HANDRAIL ASSEMBLIES REF DESCRIPTION QTY PART NO 1 HANDRAIL ASSY 81200 W SWITCH RH 1 VS AC 161 1 1 HANDRAIL ASSY 52000 W SWITCH
7. WEIGHT d The pressure switch is correctly set if pump motor shuts off when attempting to stow the lift preventing inward movement of the platform The pressure switch is not correctly set if pump motor does NOT shut off and there is inward movement of the platform Adjustment of the pressure switch will be required NOTE f adjustment is necessary then pressure switch must be adjusted as shown in FIGURE 2 25 f Refer to Figure 2 25 Remove the 1 4 20 x 1 00 set screw with hex recess from end of pressure switch to gain access to adjustment screw Save screw for reinstallation PRESSURE SWITCH P N 39399 TURN CCW TO LOOSEN AND ADJUST PRESSURE TURN CW TO TIGHTEN AND ADJUST PRESSURE Sch RSM0005000 FIGURE 2 25 HYDRAULIC PUMP WITH PRESSURE SWITCH Turn the hydraulic pressure switch enclosure 1 8 of a turn counterclockwise CCW by hand to re duce the pressure NOTE Turn the hydraulic pressure switch enclosure clockwise CW to increase pressure and counterclockwise CCW to decrease pressure by hand h Stow platform and observe if the motor shuts off i If the motor does not shut off turn the hydraulic pressure switch enclosure 1 8 of a turn counterclock wise CCW by hand to reduce the pressure NOTE The lift should NOT stow or have inward movement with the weight on the platform Repeat pressure switch adjustment as necessary to achieve correct setting k Tighten the locking set screw when the correct pr
8. 3 ADJUSTMENT OF PLATFORM FOLDING LINKAGE esses nnns 2 17 4 PLATFORM PRESSURE SWITCH CHECK AND ADJUSTMENT eere 2 18 D VERIFY i n ceo ebe le 2 20 E CUSTOMER ORIENTATION rc carried Eed 2 20 Ill MAINTENANCE AND 3 1 Aza LEUBRIGATION EE 3 1 Bs CLEANING cect DIS 3 2 MAINTENANCE SCHEDULE initie eiit per es ehem bin pue ades Po Een 3 2 D TROUBLESHOOTING wir tcc eet ian otitis eating eter tete ts ecd 3 4 1 INTERLOCK INDICATOR DIAGNOSTICS 2 3 4 2 LIFT TROUBLESHOOTING 33 2 ree e eicit dde t e d d IAE 3 5 E HYDRAUEIC GIRGUIT DIAGRAM toit iota cente be ite ul uda 3 6 E ELECTRICAL WIRING DIAGRAM tei ttl hava ect de lie et tuat Asien dead 3 7 1 DIAGRAM LEGEND ei nee eat datae nte etes ras 3 7 2 K SERIES LIMIT SWITCH STATES esses tha 3 8 WIRING BIAGRAM enten n iate tere cite oae dte e be iis 3 9 IV SPARE PARTS 3 u ient oque Ro dua Ue Re cre ENN REENEN RAA 4 1 FIGURE 4 1 HYDRAULIC POWER UNITA 4 2 FIGURE 4 2 HYDRAULIC SYSTEM I I 4 6 FIGURE 4 3 ELECTRICAL GvGTEM U u 4 8 FIGURE IR RRE 4 10 FIGURE 4 5 FOLDING PLATFORM ASSY
9. Kin 4 12 FIGURE 4 6 FOLDING PLATFORM ASSY 1200 4 14 FIGURE 4 7 FOLDING PLATFORM ASSY kO 4 16 FIGURE 4 8 FOLDING PLATFORM ASSY ki 0p L L nennen nnns nnns 4 18 FIGURE 4 9 FOLDING PLATFORM ASSY K2003 L nsn 4 20 FIGURE 4 10 FOLDING PLATFORM ASSY K2005 1 0000000000000000000000 nnn enne 4 22 FIGURE 4 11 FOLDING PLATFORM ASSY koup 4 24 FIGURE 4 12 TRAVELLING FRAME e an dar lied eve a a de 4 26 FIGURE 4 13 SHIBEDS roce eee AA ea 4 30 FIGURE 4 14 HANDRAIL AGGEMDLIES sess eene eene enne 4 32 FIGURE 4 15 HANDRAIL ASSEMBLIES sss nennen enne 4 34 APPENDIX 1 K SERIES LIFT SPECIFICATIONS enne enne nnn nnne nnn nnns 4 36 32055102 1 Riec orn A Wabtec company TABLE OF CONTENTS K SERIES SERVICE MANUAL This page intentionally left blank D Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL INTRODUCTION L INTRODUCTION he RICON KlearVue Series wheelchair lift provides wheelchair access to vans and buses The patented movement provides smooth safe entry and exit and can lift up to 800 pounds 354 kilograms The platform is raised with a powerful electro hydraulic pump The pump has a built in manual backup pump so that it
10. RH 1 VT AC 281 2 HANDRAIL ASSY 81200 W SWITCH LH 1 VS AC 160 2 1 _ HANDRAIL ASSY 52000 W O SWITCH LH 1 VT AC 282 2 2 HANDRAIL ASSY 52000 W SWITCH LH 1 VT AC 284 3 BUMPER RUBBER BAG OF 10 2 20653 4 CAP ROUND BLACK 2 25550 5 HARNESS HANDRAIL SWITCH 1 V2 ES 012 6 HARNESS RIGHT HANDRAIL SWITCH 1 V2 ES 013 7 HANDRAIL ASSY W O SWITCH 1 VS AC 159 not shown 32DSS102 D 1 O Ricon 4 33 A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL K SERIES ADA HANDRAIL SERIAL NO s 32000 PRESENT FIGURE 4 15 ADA HANDRAIL ASSEMBLIES Ricon AWabtec company ITEM 9 DETAIL MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 15 ADA HANDRAIL ASSEMBLIES REF DESCRIPTION QTY PART NO 1 BUMPER RUBBER 2 V2 AC 86 2 CAP ROUND BLACK 2 25550 3 1 HANDRAIL ASSY ADA LH W BUCKLE P N VT AC 84 SUPERSEDED 1 11714 3 2 HANDRAIL 55 55000 LH P N V5 AC 84 SUPERSEDED 1 11714 3 3 HANDRAIL ASSY FMVSS LH W BUCKLE 1 32479 4 1 HANDRAIL ASSY ADA S2000 RH P N VT AC 85 SUPERSEDED 1 11715 4 2 HANDRAIL ASSY ADA S5000 RH P N V5 AC 85 SUPERSEDED 1 11715 4 4 HANDRAIL ASSY FMVSS RH 34 W 1 32485 5 KIT BUCKLE ASSY W SW amp HARDWARE 1 12160 6 1 KIT E BELT INTERLOCK 12VDC 1 13054 6 2 RESTRAINT BELT 34 ADA 1 16092 7 SCREW PAN HEAD 10 24 x 1 3 4 BAG OF 10 1 15957 8 SCREW HEX HEAD 5 16 18 X 1 75 SST BAG OF 10 2 14440 9 KIT ELECTRI
11. amp right included in kit 1 29243 6 MAIN SHAFT 1 DIA X 39 13 1 VT PI 49 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V2 SP 021 9 KIT ACTUATOR ROLLSTOP REPLACEMENT LH 1 22903 10 ROLLSTOP ASSY 6 X32 1 V2 PF 292 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V2 SP 022 13 KIT ACTUATOR ROLLSTOP REPLACEMENT RH 1 22902 14 KIT LINK YEL BRKTS GREY RH amp LH serial 5 169180 amp above 1 31253 KIT LINK GREY BRKTS GREY RH amp LH serial 5 169180 amp above 1 31254 KIT LINK GREY BRKTS GREY RH amp LH serial s below 169180 1 23358 15 ROLLSTOP ASSY INNER 1 V2 PF 142 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRACKETS W ROLLER left and right included in kit For serial 5 169180 and above 1 31252 For serial 5 below 169180 1 23356 18 WASHER DELRIN 1 ODX 38IDX 03 THK BAG OF 10 8 25628 19 LINK ASSY FRONT PLATFORM 2 29222 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 WHDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18 17 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PAN HEAD 8TEK X 7 BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X 34 SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 28 X 625 X 065 BAG OF 10 2 17504 30 B
12. 10 2 14484 24 SCREW HEX HEAD 5 16 18X 1 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PAN HEAD 8TEK X BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X 34 SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 281 X 625 X 065 BAG OF 10 2 17504 30 BUSHING STEEL 25ID X 320D X 19L 2 V2 BU 003 31 SPACER 25ID X 4000 X 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32055102 1 O Ricon 4 17 Wabtec company SPARE PARTS A lt S a co LLI LL lt Q O LL LL j lt K SERIES SERVICE MANUAL FIGURE 4 8 FOLDING PLATFORM ASSEMBLY K1205 O Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 8 FOLDING PLATFORM ASSEMBLY K1205 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING ASSY RETROFIT left amp right included in kit 2 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19523 5 KIT LINK ASSY REAR FOLDING PLATFORM left
13. 4 N BREAKER CIRCUIT BREAKER gp TOP PUMP SOLENOID BUS BAR 0 a k 19 ng 8 AMP CIRCUIT 30 AMP CIRCUIT BREAKER eu BREAKER BUS BAR SIDE PUMP 18 AWG RED WIRE 2 JUMPER CONNECTED BETWEEN 30 AND 8 AMP CIRCUIT BREAKERS 10 AWG RED WIRE CONNECTED BETWEEN 30 AMP CIRCUIT BREAKER AND POSITIVE TERMINAL OF SOLENOID 4 RING TERMINAL FIGURE 2 9 ELECTRICAL INSTALLATION DIAGRAM 2 6 XD Ricon 3209910201 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL INSTALLATION 1 INSTALL MAIN CIRCUIT BREAKER a Disconnect battery Avoid heat sources b Mount main circuit breaker inside engine compartment as near to battery as possible within 12 inches to minimize exposure of unprotected cable 2 ROUTE CONNECT MAIN POWER CABLE N WARNING CHECK UNDERSIDE OF VEHICLE BEFORE DRILLING TO AVOID DAMAGE TO FUEL LINES VENT LINES BRAKE LINES OR ELECTRICAL WIRING NOTE For applications where power cable is to pass through sheet metal drill a 34 hole and use wire clamp pro vided For applications where cable is to pass through plywood drill a 1 hole and use black plastic grom met provided a Refer to Figure 2 10 Locate and drill hole through the vehicle floor near or under pump cover so power cable may reach positive pole of solenoid the side opposite to where the solenoid is connected to the pump motor The hole should be drilled so that it will be h
14. 87 2 SOLENOID ASSY 24V 1 V2 ES 128 88 CLIP SPRING BASE LATCH 1 V2 AC 009 89 SCREW FLAT HEAD 10 24 x 2 SST BAG OF 10 1 14426 90 NUT HEX NYLON INSERT 10 24 BAG OF 10 1 13382 91 PIN SPRING MOUNTING 1 2 1 095 92 1 KIT REPLACEMENT SOLENOID 12V S N s 32000 50516 1 01238 4 28 Ricon 32DSS102 D 1 AWabtec company 2011 K SERIES SERVICE MANUAL SPARE PARTS REF DESCRIPTION QTY PART NO 92 2 KIT REPLACEMENT SOLENOID 24V S N s 32000 50516 1 01239 93 SPRING DOOR HELPER 380DX3 5 1 V2 SP 093 94 BUSHING LATCH COVER 2 V2 BU 080 95 SCREW HEX HEAD 5 16 18 X 3 4 BAG OF 10 1 15901 96 SCREW FLAT HEAD 5 16 18X BAG OF 10 1 14499 97 SCREW BUTTON HEAD 4 20X7 SST BAG OF 10 1 15902 98 COVER BASE LATCH 1 V2 CV 123 99 SCREW HEX HEAD 5 16 18X 625 BAG OF 10 1 14495 100 WASHER FLAT 6900 x 34ID x 065 BAG OF 10 1 13350 101 SPRAY PAINT TOUCH UP CHARCOAL 1 25340 102 BUSHING E COVER MOUNT 2 V2 BU 081 103 SCREW HEX HEAD 4 20X1 GR5 BAG OF 10 1 14493 104 GROMMET 30ID x 88OD x 44 BAG OF 10 1 23391 105 PIN CONTROL CAM 1 2 1 091 106 RIVET BLIND 3 160DX5 8L STEEL BAG OF 10 4 34519 107 COVER PINCH POINT 7 X12 PVC 2 V3 AC 26 108 COVER PINCH POINT 3 X25 PVC 2 V3 AC 27 109 COVER PINCH POINT 3 X29 4 V3 AC 28 110 COVER PINCH POINT 3 X30 PVC 2 V3 AC 29 111 COVER PINCH POINT 3 X5 X8 PVC 2 V3 AC 31 not shown
15. Inspect electrical wiring for frayed wires chaffed wires loose connectors etc Vehicle Place vehicle in NON INTERLOCK mode and attempt to operate lift interlock Decals Verify that all lift decals are affixed properly clearly visible and legible Replace if necessary Verify that all handrail fasteners are properly tightened Lift mounting Verify that all lift mounting and support points in proper order and free from damage and support points Main lifting Verify all arm pins are installed properly free from damage and locked in position pivots Platform and Verify platform operates without binding during lift functions platform attachment points Bridgeplate Verify that bridgeplate operates without binding during lift functions Verify that bridgeplate deploys fully when platform stops at vehicle floor level Verify bridgeplate rests flat against baseplate Platform Verify that rollstop opens completely without binding when platform contacts ground rollstop Hydraulic power Check for visible hydraulic fluid leakage unit Verify backup pump manual release valve is lightly closed Verify that all mounting screws are sufficiently tight 3 2 CH Ricon M L 32055102 0 1 A Wabtec company MARCH 2011 K SERIES SERVICE MANUAL MAINTENANCE SIX MONTH SERVICE CHECK or 1750 cycles o
16. OF TABLE 32D S S102 DI gt Ricon O J 3 5 AWabtec company MAINTENANCE K SERIES SERVICE MANUAL MARCH 2011 E HYDRAULIC CIRCUIT DIAGRAM s e o 7 NI A FIGURE 3 2 K SERIES HYDRAULIC CIRCUIT DIAGRAM 3 6 CH Ricon nn 32055102 0 1 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL MAINTENANCE F ELECTRICAL WIRING DIAGRAMS 1 DIAGRAM LEGENDS a Wire Color Codes TABLE 3 4 WIRE COLOR CODES LETTER COLOR LETTER COLOR m R _ e om ov Gy _ oms Y vow b Electrical Connector Description Refer to Figure 3 3 The standard electrical connectors used by Ricon are Molex 062 Series These connec tors have terminal numbers molded onto the back use these numbers and colors to identify wires FIGURE 3 3 MOLEX CONNECTORS c Diagram Labels FIGURE 3 4 DIAGRAM LABEL CHART 32055102 1 svvvv oD D so s Ricon 3 7 Wabtec company MAINTENANCE K SERIES SERVICE MANUAL MARCH 2011 d Electrical Symbols gt 40 FIGURE 3 5 ELECTRICAL WIRING DIAGRAM SYMBOLS 2 K SERIES LIMIT SWITCH STATES Refer to Figure 3 6 The limit switch actuation diagram shows state of all limit switches as platform travels from ful ly closed to vehicle floor level and to ground le
17. SERVICE MANUAL DESCRIPTION Lift references when installation is viewed from outside of vehicle Pair of parallel links connecting vertical arm to base plate assembly Connects platform to top and bottom arms Provides a handhold for platform occupant INTRODUCTION 32DSS102 D 1 Occupant restraint belt K 2005 ADA model Front rollstop Front platform section Rear platform section Platform folding linkage Platform hinges Bridgeplate inboard rollstop Hydraulic cylinder left right Hydraulic power unit Control pendant Manual backup pump handle Baseplate assembly Electronically interlocked safety belt that helps to prevent a wheelchair from moving off of platform Lift will not operate unless belt is properly engaged Front barrier prevents wheelchair from slowly or inadvertently rolling off of platform during lift operation Portion of platform that unfolds during deploy operation and folds dur ing stow operation Fixed portion of platform with hinges along its front edge that front sec tion pivots on Folds front platform section as platform is stowed Three hinges welded to bottom side of platform join front and rear plat form sections together Plate that bridges gap between platform and lift baseplate when plat form is at floor level Also acts as a rear rollstop when platform is in motion Telescoping steel tube which converts hydraulic pressure into lifting for
18. SPACER KNUCKLE LINK 4 VT BU 42 12 SCREW BUTTON HEAD 1 4 20 X 1 SST BAG OF 10 6 19715 13 RETAINER CAM ROLLER 4 V2 AC 025 14 1 ROLLER INNER ROLLSTOP CAM K2000 amp K5000 2 V2 AC 124 14 2 ROLLER INNER ROLLSTOP CAM K1000 amp K1200 2 V2 AC 024 15 PIN CAM ROLLER 2 V2 PI 094 16 FLANGED BUSHING 75ID BAG OF 10 3 19576 18 RIVET BLIND 3 16 X 1 2 ALUM BAG OF 10 10 15918 19 CAP UPPER PARALLEL ARM 2 V2 AC 89 20 1 SCREW HEX HEAD 1 4 20 x 3 4 GR5 BAG OF 10 4 13308 20 2 SCREW FLAT HEAD 1 4 20 x BAG OF 10 1 15928 32DSS102 D 1 oO Ricon 4 27 AWabtec company MARCH 2011 SPARE PARTS K SERIES SERVICE MANUAL REF DESCRIPTION QTY PART NO 21 WASHER FLAT 63OD x 28ID x 065 BAG OF 10 2 17504 22 1 CABLE ASSY REPLACEMENT IRS K1100 1 13661 22 2 CABLE ASSY REPLACEMENT IRS K1200 1 16093 22 3 CABLE ASSY REPLACEMENT IRS 2000 1 16094 22 4 CABLE ASSY REPLACEMENT IRS K5000 1 16095 22 5 KIT CABLE ASSY W SLEEVE K55XX SERIES 2 34247 23 NUT HEX 14 20 W NYLON INSERT BAG OF TEN 1 15919 24 BEARING GROOVED 8 VS AH 06 25 WASHER FENDER 4 X1 OD BAG OF TEN 2 25623 26 STAND OFF 38LG 1 IDX1 OD 4 V2 AC 011 27 BLOCK PULLEY MOUNT INNER ROLLSTOP 2 V2 AC 112 28 BEARING 1 OD GROOVED 2510 51100 2 25374 29 SCREW BUTTON HEAD 1 4 20 x 2 1 4 SST BLK OXIDE BAG OF 10 1 19720 30 BUSHING 5 8 OD X 3 16L 2 VS AH 13 31 T NUT FLAT HEAD 10 24
19. V2 AC 103 17 KIT BRACKETS W CAM FOLLOWER left amp right included in kit For serial numbers 169180 and above 1 31247 For serial numbers below 169180 1 23339 18 LINK ASSY FRONT PLATFORM 2 29223 19 WASHER DELRIN 1 ODX 38ID 03 THK BAG OF 10 8 25628 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 W HDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18 11 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PAN HEAD 8TEK X 1 2 BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X 34 SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 28 X 625 X 065 BAG OF 10 2 17504 30 BUSHING STEEL 2510 X 320D X 19L 2 V2 BU 003 31 SPACER 2510 4000 X 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32055102 1 O Ricon A 23 Wabtec company SPARE PARTS LO gt lt LL lt e O IL LL SS gt lt K SERIES SERVICE MANUAL FIGURE 4 11 FOLDING PLATFORM ASSEMBLY K5005 Ricon AWabtec company MARCH 2011 32DSS102 D 1
20. is present in both linkages If either linkage is under tension repeat steps a and b 4 PLATFORM PRESSURE SWITCH CHECK AND ADJUSTMENT SERIAL NUMBERS 104 000 TO PRESENT Correct adjustment of this pressure switch is required to prevent platform from folding into vehicle when there is a load of 50 Ibs or more on the platform a Refer to Figure 2 21 Deploy and lower platform to ground Place a 23Kg 50 Ib load in center of platform and then raise platform to floor level Press and hold STOW switch NOTE HANDRAILS NOT SHOWN FOR CLARITY APPLY 23KG 50 LB LOAD KNUCKLE LINK RSM0003601 FIGURE 2 21 PRESSURE SWITCH TEST AT FLOOR LEVEL NOTE Weight must be 23kg 50 lbs and placed 152mm 6 inches from rear edge of platform mesh as shown Figure 2 23 CENTER OF 23 KG 50 LBS WEIGHT FIGURE 2 23 23KG 50 LBS WEIGHT PLACEMENT ON PLATFORM b Place a 152mm 6 in x 152mm 6 in x 305mm 12 in 23kg 50 105 load on the rear center portion of platform then stow platform by pressing and holding the STOW switch C Refer to Figure 2 24 If an alternate weight is to be used the center of the weight must be 152mm 6 in from the rear edge of the platform mesh 2 18 Ricon 7 3209910201 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL INSTALLATION CENTER OF WEIGH EDGE OF MESH FIGURE 2 24 ALTERNATE 23KG 50 LB
21. states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply Important The warranty registration card must be completed and returned to Ricon within twenty days after installation of this Ricon product for the warranty to be valid The warranty is not trans ferable The warranty gives specific legal rights There may be other rights that vary from state to state 1 2 Q Ricon Oe 3209910201 AWabtec company MARCH 2011 K SERIES SERVICE MANUAL INTRODUCTION A SERVICE TECHNICIAN INFORMATION Because of the specialized nature of this product Ricon does not sell directly to the user Instead the product is distributed through the woldwide network of authorized Ricon dealer or qualified Service Technicians who perform the actual installation When the product is received unpack the product and check for freight damage Claims for any damage should be made to the carrier immediately sure the installation kit contains all the items listed on the kit packing list Please report any missing items Immediately to the Ricon Product Support Document The warranty and owner s registration cards must be completed and returned to Ricon within 20 days to validate the warranty NOTE The Sales or Service Personnel must review the Warranty and the Operator Manual with the user to be ce
22. 0 7 HEX ROD PUMP STANDOFF 2 V2 CV 015 8 1 HYDRAULIC PUMP 12V NOTOP UV RES 2KPSI 1 PM212002007 8 2 HYDRAULIC PUMP 12V W INTLK amp ANTIDRIFT DISCONTINUED 1 PM212090110 8 3 HYDRAULIC PUMP 12V COMMON BRKT S N s 31000 31999 amp 35000 present 1 PM212090100 8 4 HYDRAULIC PUMP 24V COMMON BRKT S N s 31000 31999 amp 35000 present 1 PM224110100 8 5 HYDRAULIC PUMP 12V COMMON BRKT S N s 32000 34999 1 PM212090100 8 6 HYDRAULIC PUMP 24V COMMON BRKT S N s 32000 34999 1 PM224110100 8 7 HYDRAULIC PUMP 12V COM BRKT w o INTLK RH DCL 1 PM212090308 8 8 HYDRAULIC PUMP 24V COM BRKT w o INTLK RH DCL 1 PM224100108 9 PLATE PUMP COVER MOUNT 1 V2 AC 71 10 PLATE PUMP MOUNTING 1 V2 AC 70 11 SCREW FLAT HEAD 5 16 18 X 3 4 BAG OF 10 2 14499 12 STUD THREADED 5 16 18 X 1 75 BAG OF 10 2 14500 13 CABLE TIE 5 5 BLACK BAG OF 10 2 25697 14 TUBE POLYURETHANE 6MM x 4MM BLACK 9 22 02 230 15 1 ADAPTOR STRAIGHT 1 4 NPT MALE 5 5 32000 63999 2 V2 SH 84 15 2 ADAPTOR 6 SAE MALE X 4 JIC MALE S N s 64000 present 2 26591 16 FITTING L MALE 10 32 X 1 4 BARB 2 V2 SH 16 17 KIT CYLINDER REPAIR W PISTON ASSY GLAND NUT AND SEAL 2 21829 18 KIT FLOW CNTRL VALVE PRESSURE COMPENSATED FIXED RATE 2 KIT 1 30968 19 SCREW HEX RECESS HEAD 1 4 20 X 1 BAG OF 10 4 14491 20 HOSE ASSY 61 X 1 4 JIC X 1 4 JIC 1 V2 SH 009 21 HOSE ASSY 26 X 1 4 JIC X 1 4 JIC 1 V2 SH 008 22 FITTING RUN TEE 1 4 JIC M M F 1 V2 SH 012 23
23. 3 8 carriage screws 4 x 3 8 screws on Ford vans into holes to secure position 3 Refer to Figure 2 6 Align the top bracket holes 5 6 7 and 8 with baseplate assembly holes 5 6 7 and 8 Mark bracket assembly mounting holes 9 10 11 and 12 onto vehicle step FIGURE 2 6 BRACKET HOLES 32055102 Ricon 2 3 Wabtec company INSTALLATION n sL K SERIES SERVICE MANUAL s 2011 4 Remove carriage screws installed in step 2 and carefully push lift back into vehicle interior 5 Drill 14 dia holes through marked locations 9 10 11 and 12 Fasten Bracket Assemblies Lift 1 Using 1 1 2 x 5 16 sheet metal screws with 5 16 lock washers secure lower brackets to vehicle step holes 9 through 12 NOTE Do not install screw in position 12 if it interferes with proper door operation 2 Reposition lift on brackets Verify that surface supporting lift is free of debris 3 Reinsert four 8 x 3 8 carriage screws through mounting holes at rear of baseplate assembly and in sert four 1 1 2 x 3 8 carriage screws through baseplate and bracket assemblies Place 3 8 washers lock washers and nuts under bracket assemblies and finger tighten nuts 4 On Dodge and GM vans place four 4 x 4 plates 3 8 washers lock washers and hex nuts on 8 x 3 8 carriage screws under van and finger tighten On Ford models reinforce vehicle floor with clamping bars They are
24. 31246 KIT LINK RED BRKTS RED right left serial 5 169180 amp above 1 31246R KIT LINK YEL BRKTS YEL right amp left serial 5 169180 amp above 1 31246Y KIT LINK amp right left serial 5 below 169180 1 23338 15 ROLLSTOP ASSY INNER 30 PLATFORM 1 V2 PF 141 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRACKET W CAM FOLLOWER left and right included in kit For serial 5 169180 and above 1 31247 For serial 5 below 169180 1 23339 18 LINK ASSY FRONT PLATFORM 2 29223 19 WASHER DELRIN 1 ODX 38IDX 03 THK BAG OF 10 8 25628 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 WHDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18X 1 1 2 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PAN HEAD 8TEK X 7 BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X 34 SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 28 X 625 X 065 BAG OF 10 2 17504 30 BUSHING STEEL 25ID X 320D X 19L 2 V2 BU 003 31 SPACER 2510 X 4000 X 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32055102 1
25. BACK UP PUMP 3 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ricon AWabtec company 28111T 20668 26449 V2 ES 100 10069 V2 ES 150 10335 13382 20670 20669 V2 ES 034 10807 UV ES 040 13087 14345 14346 14332 14345 14333 14346 18235 V2 SH 279 V2 SH 001 42050 V2 SH 182 35739 V2 SH 105 V2 SH 136 30938 V2 SH 106 V2 SH 109 01176 01177 V2 SH 220 V2 SH 210 VS SH 06 18660 19798 19772 19774 V2 SH 005 26510 V2 SH 127 10507 V2 SH 111 MARCH 2011 SPARE PARTS K SERIES SERVICE MANUAL REF DESCRIPTION QTY PART NO 31 JUMPER DPDT SOLENOID BLK 10GA 5 0 1 ELJ00121 32 JUMPER DPDT SOLENOID w ISOLATED GROUND BLK 10GA 5 5 1 ELJ00122 33 JUMPER DPDT SOLENOID RED 10GA 5 5 1 ELJ02055 34 JUMPER DPDT SOLENOID ORG 18GA 5 0 1 ELJ03061 35 DIODE BLOCK ASSEMBLY 1 08232 36 PIN amp RETAINING RING 2 V2 SH 017 37 1 KIT PUMP MOTOR BRUSH SET S N s 32000 95999 DISCONTINUED 1 V2 SH 115B 37 2 PUMP MOTOR BRUSH SET S N s 96000 present 1 14334 38 DECAL 8 AMP CIRCUIT BREAKER DISCONTINUED 1 26290 39 ADAPTER 625 D HOLE TO 484 ROUND 1 V2 ES 059 40 WASHER FLAT 7 16 S N s 61878 present BAG OF 10 1 19716 41 BRACKET TENSION LINK MONARCH PUMP 1 V2 SH 149 42 1 JUMPER SWITCH PRESSURE RH PUMP 1 15860 42 2 JUMPER SWITCH PRESSURE LH PUMP 1 15861 43 DECAL OIL LEVEL WARNING 1 32 10 154 44 SCREW HE
26. BRICANT GRAPHITE HANDRAILS AND PLATFORM LUBRICATE WITH COPPER BASED ANTISEIZE LUBRICANT MAY DIFFER FROM ILLUSTRATION FIGURE 3 1 LIFT LUBRICATION POINTS 1 2 3 Ricon 32055102 0 1 Wabtec company MAINTENANCE K SERIES SERVICE MANUAL MARCH 2011 B CLEANING Regular cleaning 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 ACTION TO PERFORM POINT DAILY SAFETY CHECK Overall Listen for any abnormal noises as lift operates i e grinding or binding noises condition Control pendant Check that control pendant is not damaged and cable connectors are tight TWO WEEK SAFETY CHECK Overall Listen for any abnormal noises as lift operates i e grinding or binding noises condition Inspect underside of vehicle to be certain nothing is out of the ordinary Electrical wiring
27. CAL HARNESS RESTRAINT BELT 1 01274 10 SCREW HEX HEAD 5 16 18 X 34 SST BAG OF 10 1 17508 11 SCREW 5 16 18 X 3 8 SST 1 28373 12 NUT NYLON INSERT 1 4 20 THIN SST BAG OF 10 1 13339 14 SPACER TRANSIT HANDRAIL 1 V2 AC 063 15 TERMINAL SLIP MALE 18 22 FULLINSUL BAG OF 10 2 13315 16 TERMINAL SLIP MALE 14 16 FULLINSUL BAG OF 10 1 13317 17 TERMINAL SLIP MALE 14 16 FULLINSUL BAG OF 10 1 13318 18 BUSHING SNAP IN 1 28 26 077 20 CABLE TIE STD X 1 5 DIA BLACK BAG OF 10 1 25697 21 WASHER FLAT 344X 688X 065 BAG OF 10 2 13350 32DSS102 D 1 O Ricon 4 35 A Wabtec company 5 K SERIES SERVICE MANUAL MARCH 2011 APPENDIX 1 K SERIES KLEARVUE LIFT SPECIFICATIONS Power electro hydraulic power up gravity down Rated load 800 lbs Pump rating 12 volts DC 65A avg cycle 1250 psi Manual backup hand pump 24 volts DC 32 5A avg cycle 1250 psi Manual backup lower pressure release valve Hydraulic cylinders 2 ea 1 5 dia Lift weight 310 325 Ibs p DN i 1 Y i T DIMENSIONS inches A B D E F G H Stationary Height Installation Usable Usable Floo
28. D CUTOFF S N s 62560 present 1 V2 AC 089 12 SWITCH LIMIT FLOOR LEVEL POWER CUTOFF UP amp DOWN 2 V2 ES 110 13 SOLENOID BRACKET COMPONENTS for replacement parts refer to hydraulic power unit parts list drawing 13 1 CIRCUIT BREAKER 8 AMP BR8 1908 2 26401 14 KIT LIMIT SWITCH BLOCK REPLACEMENT 2 V2 ES 61 18 SCREW PAN HEAD 4 40 X 1 25 BAG OF 10 2 15908 19 SCREW PAN HEAD 4 40 X 75 BAG OF 10 4 15909 20 NUT HEX 4 40 BAG OF 10 4 15903 21 ELECTRICAL HARNESS MAIN wDOOR OPERATOR INTERCONNECT 1 V2 ES 051 22 ELECTRICAL HARNESS MAIN w o DOOR OPERATOR INTERCONNECT 1 V2 ES 050 31 KIT CIRCUIT BREAKER MAIN 90a 1 01010K 41 CLAMP CABLE 11 16 S N s 53168 present 1 255161 42 MS 10 24 X 1 2 PHIL PAN BAG OF 10 1 13304 43 PIN EXTENSION FOLD CUTOFF S N s 62560 present BAG OF 10 1 15914 44 MS 10 24 X 1 3 4 PHIL PAN S N s 62560 present BAG OF 10 2 15915 45 MS 8 32 X 1 1 4 PHIL PAN S N s 62560 present BAG OF 10 1 15906 46 NUT HEX 8 32 NYLON INSERT S N s 62560 present BAG OF 10 1 15907 47 COVER ELEC SYSTEM 1 V2 CV 110 32DSS102 D 1 O Ricon 4 9 A Wabtec company SPARE PARTS 2 lt 2 LU D K SERIES SERVICE MANUAL FIGURE 4 4 PENDANT O Ricon A Wabtec company MARCH 2011 32DSS102 D 1 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 4 PENDANT REF DESCRIPTION QTY PART NO 1 SPARE PARTS STOW DEPLOY BUTTON K SERIES 1 14731 2 SPARE PART
29. E 4 9 FOLDING PLATFORM ASSEMBLY 2003 nennen nnne nnns 4 20 FIGURE 4 10 FOLDING PLATFORM ASSEMBLY 2005 aa qO sq 4 22 FIGURE 4 11 FOLDING PLATFORM ASSEMBLY 5005 4 24 FIGURE 4 12 TRAVELLING FRAME testa hi tr ae toti het Ha ed ce repe qd ce 4 26 FIGURE 4 13 PINGH POINT SHIELDS inte dta n cake da e x Fh Rad da 4 30 FIGURE 4 14 HANDRAIL ASSEMBLIES 4 32 FIGURE 4 15 ADA HANDRAIL ASSEMBPLIES e ath eer a ee 4 34 APPENDIX 1 K SERIES LIFT SPECIFICATIONS 4 36 32D S S102 D1 mm O Ricon 4 1 Wabtec company SPARE PARTS DATE 05 05 04 DWG SSX00001 REVK K SERIES SERVICE MANUAL FIGURE 4 1 MONARCH HYDRAULIC POWER UNIT 1 O Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 REF 32DSS102 D 1 K SERIES SERVICE MANUAL FIGURE 4 1 MONARCH HYDRAULIC POWER UNIT SPARE PARTS DESCRIPTION QTY PART NO SCREW PAN HEAD 10 24 X v SELF THREAD KIT SOLENOID 12V DPST CONT DUTY SOLENOID SPST 24V HARNESS PUMP w DOOR INTERLOCK S N s 32000 95999 HARNESS PUMP w DOOR INTERLOCK SN s 96000 present HARNESS PUMP w o DOOR INTERLOCK S N s 32000 95999 HARNESS PUMP w o DOOR INTERLOCK SN s 96000 present NUT NYLON INSERT 10 24 BAG OF 10 KIT SOLENOID 12V DBL POLE wHDWR KIT SOLENOID 24V DBL POLE w
30. EW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X 2 GR5 BAG OF 10 2 34518 32DSS102 D 1 O Ricon 4 13 SPARE PARTS K SERIES SERVICE MANUAL MARCH 2011 A NC gt d LLI 42 lt LL lt A 5 LL LL M FIGURE 4 6 FOLDING PLATFORM ASSEMBLY K1200 Ricon A Wabtec company 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL 9 9 SPARE PARTS FIGURE 4 6 FOLDING PLATFORM ASSEMBLY K1200 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING RETROFIT left amp right included in kit 2 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19507 5 KIT LINK ASSY REAR FOLDING PLATFORM left amp right included in kit 1 29242 6 MAIN SHAFT 1 DIA X 36 50 1 VT PI 43 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V3 SP 21 9 ACTUATOR ROLLSTOP LH 1 V2 FL 95 10 ROLLSTOP ASSY 4 X30 1 V2 PF 160 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V3 SP 22 13 ACTUATOR ROLLSTOP RH 1 V2 FL 94 14 KIT LINK YEL amp BRKTS GRAY HIGH MOUNT left amp right included in kit For serial numbers 169180 and above 1 31250 For serial numbers below 169180 1 23360 15 ROLLSTOP ASSY INNER 30 1 V2 PF 141 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRKTS GRAY HIGH MOUNT left amp right included in kit F
31. F ADJUSTMENT SCREW clockwise until plat form jogs up to vehicle floor level Verify that clearance between knuckle actuator saddle and parallel arm is 1 8 minimum distance may be 1 2 maximum and unequal from left or right arm stop turning screw and release UP switch If lift does not operate after 1 2 full turns of adjustment screw cycle platform UP and DOWN The UP CUTOFF SWITCH is less sensitive than OUT CUTOFF SWITCH Cycle platform through all functions DEPLOY DOWN UP and STOW to verify correct adjustment Refer to Table 2 1 if necessary TABLE 2 1 LIMIT SWITCH ADJUSTMENT CHART COMPONENT SYMPTOM CORRECTIVE ADJUSTMENT PROCEDURE ACTION Fold cutoff Lift does not Rotate collar With lift fully folded handrails should be folded actuator fold tightly counter tight against arms rotate actuator so clockwise that fold cutoff leg barely trips fold cutoff Switch Pump runs con Rotate collar Test lift Pump should cutoff when lift is tinuously clockwise folded tight Up cutoff Lift stops low Adjust screw Adjust up cutoff switch so that lift stops just be adjustment clockwise fore first knuckle actuator or roller screw touches underside of lower parallel arm Saddle or roller should be about 1 8 from lower parallel arm Lift stops high Adjust screw counter clockwise Out cutoff Lift stops low Adjust screw Adjust lower limit switch so that lift stops just adjustment counter be
32. FITTING L 1 4 JIC M F SWIVEL 3 VS SH 06 24 OIL HYDRAULIC TEXACO 15 MEETS MIL H 5606G 1GAL 20 16 051 25 1 CYLINDER ASSY K 1100 1200 2 VS SH 105 25 2 CYLINDER ASSY K 2000 2 VT SH 105 25 5 CYLINDER ASSY K 5000 2 V5 SH 105 25 4 CYLINDER ASSY K 55XX 2 30836 28 DECAL MANUAL OPERATION TOP w CB 1 26214 29 GROMMET CATERPILLAR 3 16 8 5 26647 30 SPACER CABLE AND HOSE 2 25557 31 BUSHING 3 4 ID X 3 8W 4 25381 32 GLAND NUT AND SEAL 2 13009 32DSS102 D 1 O Ricon 4 7 A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL FIGURE 4 3 ELECTRICAL SYSTEM Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 3 ELECTRICAL SYSTEM REF DESCRIPTION QTY PART NO 1 1 CAM LIFT CONTROL w SET SCREW S N s 32000 62559 1 V2 ES 99 1 2 CAM LIFT CONTROL S N s 62560 present 1 V2 AC 107 2 SWITCH LIMIT FOLD POWER CUTOFF 1 V2 ES 111 3 BLOCK FOLD CUTOFF SWITCH OFFSET 1 4 THICK 1 V2 ES 78 4 BLOCK FOLD CUTOFF SWITCH OFFSET 3 8 THICK 1 V2 ES 79 5 SPRING RETAINING UPPER AND LOWER SWITCH BLOCKS 1 V2 ES 95 6 SCREW ROUND HEAD 10 24 X 2 ADJUSTING BAG OF 10 2 14497 7 SPRING COMPRESSION 30 OD X 2 06L 2 V2 ES 93 8 ROLL PIN 94 X 1 0 TIMING PIN BAG OF 10 1 14498 9 ROLL PIN 94 X 50 SWITCH BLOCK MOUNT BAG OF 10 2 14496 10 SWITCH BLOCK ASSY UPPER amp LOWER 2 V2 ES 82 11 1 KIT RETRO CAM V2 BU 89 SUPERSEDED 1 01287 11 2 ACTUATOR FOL
33. FOLDING PLATFORM ASSEMBLY K1203 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING ASSY RETROFIT left amp right included in kit 2 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19522 5 KIT LINK ASSY REAR FOLDING PLATFORM left amp right included in kit 1 29243 6 MAIN SHAFT 1 DIA X 36 50 1 1 43 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V2 SP 021 9 KIT ACTUATOR ROLLSTOP REPLACEMENT LH 1 22903 10 ROLLSTOP ASSY 6 X30 1 V2 PF 291 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V2 SP 022 13 KIT ACTUATOR ROLLSTOP REPLACEMENT RH 1 22902 14 KIT LINK YEL BRKTS GREY RH amp LH serial 169180 amp above 1 31253 KIT LINK GREY amp BRKTS GREY RH amp LH serial 4 169180 amp above 1 31254 KIT LINK amp BRACKETS W ROLLER RH amp LH serial s below 169180 1 23357 15 ROLLSTOP ASSY INNER 30 PLATFORM 1 V2 PF 141 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRKTS W ROLLER left and right included in kit For serial numbers 169180 amp above 1 31252 For serials numbers below 169180 1 23356 18 WASHER DELRIN 1 ODX 388ID 0 03 THK BAG OF 10 8 25628 19 LINK ASSY FRONT PLATFORM 2 29223 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 W HDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF
34. HDWR BUS BAR MOTOR SP SOLENOID S N s 52456 95999 DISCONTINUED BUS BAR SN 96000 present BUS BAR MOTOR DP SOLENOID S N s 32000 95999 DISCONTINUED BUS BAR S Ns 96000 present MOTOR ASSY 12V 3 MONARCH PUMP P N V2 SH 115 DISCONTINUED MOTOR ASSY 24V 3 MONARCH PUMP P N V2 SH 116 DISCONTINUED MOTOR ASSY 12V ISKRA SN s 96000 present DISCONTINUED MOTOR ASSY w BRACKET 12V ISKRA MOTOR ASSY 24V ISKRA SN s 96000 present DISCONTINUED MOTOR ASSY w BRACKET 24V ISKRA FITTING ASSY ELBOW 4 STD THD X 4 JIC w HDWR DECELERATION VALVE ASSY PLUG 3 4 16 CAVITY w O RING DISCONTINUED KIT PRESSURE SWITCH W INSTRUCTIONS P N 16640 SUPERSEDED PLUG w O RING LIGHT ASSY INDICATOR 12V P N 15207 DISCONTINUED VALVE ASSY POPPET DELTROL 12V VALVE ASSY POPPET DELTROL 24V DISCONTINUED RESERVOIR PUMP PLASTIC w DECAL amp PLUG PLUG BREATHER RESERVOIR HOSE CLAMP SPOOL VALVE ASSY 12V ADA APPLICATIONS SPOOL VALVE ASSY 24V ADA APPLICATIONS SEAL KIT MANUAL BACK UP PUMP BACK UP PUMP MANUAL FITTING ASSY SNL 1 4 X 1 4J STEEL CABLE CLAMP 3 8 NYLON BAG OF 10 CABLE CLAMP 3 16 NYLON BAG OF 10 CABLE CLAMP 5 16 NYLON BAG OF 10 CABLE CLAMP 1 2 NYLON BAG OF 10 CIRCUIT BREAKER 8 AMP w HDWR amp DECAL CIRCUIT BREAKER 30 AMP w HDWR BRACKET SOLENOID MOUNTING S N s 32000 95999 BRACKET SOLENOID ISKRA S N s 96000 present HANDLE MANUAL
35. PUT side of interlock circuit to OUTPUT side of circuit protector using 16 AWG or larger wire 4 If an optional 30 amp circuit breaker has been installed next to 8 amp breaker completely remove 18 AWG wire connecting INPUT sides of 30 amp and 8 amp circuit breakers To do this the spade nector must be removed from 8 amp INPUT and 18 AWG wire must be cut as close as possible to 30 amp INPUT connector since it is crimped to that connector along with a 10 AWG wire 5 Connect OUTPUT side of interlock circuit to INPUT side of lif s 8 amp circuit breaker using 16 AWG or larger wire 2 10 Ricon 3209910201 Wabtec company MARCH 2011 32DSS102 D 1 6 K SERIES SERVICE MANUAL o gt INSTALLATION Re connect battery c Interlock Method 3 Power interrupt preferred method Refer to Figure 2 16 This method interrupts power between interlock s solenoid and battery This cuts all power to lift It requires circuit protection to be supplied by installer 1 5 Disconnect battery Disconnect 4 AWG power cable from main breaker at pump solenoid Connect cable to one of terminal posts of interlock solenoid Connect other terminal post of interlock solenoid to empty terminal post of pump solenoid using 4 AWG wire Connect circuit protector provided by installer should be 8 amp maximum to main power cable com ing from battery which should b
36. RM ACTUATOR Y SADDLE 2 1 8 y s INBOARD ROLLSTOP FIGURE 2 18 KNUCKLE ACTUATOR SADDLE MINIMUM CLEARANCE a Fully DEPLOY platform b Adjust UP CUTOFF ADJUSTMENT SCREW and OUT CUTOFF ADJUSTMENT SCREW 6 8 turns coun ter clockwise and then push screws FORWARD Cycle platform to STOW and DEPLOY d When in DEPLOY position platform should stop at an angle and NOT even with vehicle floor If not turn OUT CUTOFF ADJUSTMENT SCREW an additional 2 3 turns counter clockwise push screw forward STOW and DEPLOY platform then repeat this step e Cycle platform to UP position 320551020 2 15 Wabtec company INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 f When in UP position platform should stop short of vehicle floor level If not turn UP CUTOFF ADJUSTMENT SCREW an additional 2 3 turns counter clockwise push screw forward cycle platform DOWN then UP then repeat this step Cycle platform to STOW and DEPLOY Push and hold control pendant DEPLOY switch Slowly turn UP CUTOFF ADJUSTMENT SCREW clock wise until platform jogs down to vehicle floor level Make sure that clearance between knuckle actuator saddle and parallel arm is 1 8 minimum distance may be 12 maximum and unequal from left or right arm stop turning screw and release DEPLOY switch Cycle platform DOWN to ground level then UP until it stops Push and hold pendant UP switch Slowly turn UP CUTOF
37. S UP DOWN BUTTON K SERIES 1 14732 3 SPARE PARTS V BRACKET PLASTIC 1 14733 4 KIT WALL MOUNT BRACKET UNIVERSAL PENDANT 1 14709 5 KIT CONTROL HARNESS STRAIN RELIEF K SERIES 1 01007 6 1 KIT PENDANT S SERIES 7 FT 1 14727 6 2 KIT PENDANT S SERIES COILED CORD 1 14728 6 3 KIT PENDANT S SERIES 10 FT 1 14729 6 4 KIT PENDANT S SERIES STEEL JACKETED CORD 1 14730 6 5 KIT PENDANT COIL CORD FMVSS 33436 SUPERSEDED 1 42968 7 KIT PENDANT OLD STYLE W ROCKER SWITCH 1 01008 8 KIT CLIP PENDANT MALE W RIVETS 1 28781 9 KIT INSTL PENDANT MTG CLIP 1 01118 10 FACEPLATE ASSY PENDANT SWITCH GD 1 V2 ES 035 11 SWITCH SP ROCKER ON OFF ON BLK 2 26455 12 HARNESS REPLACEMENT 7FT CORD for 01008 old style pendant only 1 V2 ES 024 32DSS102 D 1 O Ricon 4 11 A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL FIGURE 4 5 FOLDING PLATFORM ASSEMBLY K1132 Ricon A Wabtec company MARCH 2011 TI g Z O v gt 2 A N 32DSS102 D 1 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 5 FOLDING PLATFORM ASSEMBLY K1132 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING W BRACKETS amp HDWR 2 21647 2 SAFETREAD 25 5 X 2 75 BLK 1 23047 3 ROD END ASSY W HDWR 1 29224 4 LINK ASSY 2 21645 5 KIT LINK REAR 6 75 W HDWR left right included in kit 1 29244 6 SHAFT MAIN 1 X 32 50 1 VS PI 14 7 T NU
38. S AND PART NUMBERS 32DSS102 D 1 Ricon A Wabtec company K SERIES SERVICE MANUAL MAINTENANCE MARCH 2011 Ill MAINTENANCE AND REPAIR egular maintenance of the Ricon KlearVue Series platform wheelchair lift is required to help optimize its perfor mance and reduce the need for repairs This chapter contains lubrication and cleaning instructions a mainten ance schedule troubleshooting section and maintenance diagrams N CAUTION This Ricon product is highly specialized Maintenance and repairs must be performed by an authorized Ricon dealer or qualified service technician using Ricon replacement parts A LUBRICATION A 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 1 BOTH SIDES Ld me EN c 1 gt 56 GREASE DETAIL A FITTING J 1 BOTH SIDES KNUCKLE LINKS H LG EON 1 BOTHSIDES lt gt HINGES UNDERSIDE 3 27 2 2 TORSIONSPRINGS BOTH SIDES 55 gt gt DETAIL B HINGE 1 LUBRICATE WITH PENETRATING OIL NOTE LUBRICATE WITH DRY LU
39. T 14 20X1 4 SST BAG OF 10 2 14485 8 TORSION BAR LH 1 V3 SP 21 9 ROLLSTOP ACTUATOR LH 1 V1 PF 003 10 ROLLSTOP 1 22280 11 PIN CLEVIS 5 16 1 114 BAG OF 10 2 19513 12 TORSION BAR RH 1 V3 SP 22 13 ROLLSTOP ACTUATOR RH 1 V1 PF 002 14 KIT LINK ASSY GREY amp BRKTS GREY SHORTARM left amp right included in kit For serial numbers 169180 and above 1 32824 For serial numbers below 169180 1 23359 15 ROLLSTOP ASSY INBOARD 1 V1 PF 212 16 CATCH BASE LATCH 1 V2 AC 103 17 KIT BRKTS W CAM FOLLOWER left amp right included in kit For serial numbers 169180 and above 1 31247 For serial numbers below 169180 1 23386 18 LINK ASSY FRONT PLATFORM 2 29222 19 WASHER DELRIN 1 ODX 38 ID 0 031 THK BAG OF 10 8 25628 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 W HDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18X 1 v GR5 BAG OF 10 2 14403 25 SETSCREW 12 20 1 14 W NYLON INSERT BAG OF 10 2 19704 26 KIT HINGE W HDWR 3 14352 27 BUSHING 392 ID BRONZE 2 V2 BU 195 28 SCREW BUTTON HEAD 5 16 18X 34 SST BLK OX BAG OF 10 6 15983 29 WASHER FLAT 28X 62X 06 BAG OF 10 2 17504 30 BUSHING STEEL 25 ID X 32 OD X 19L 2 V2 BU 003 31 SPACER 25ID X 40 ODX 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 9 14415 34 SCR
40. TALLER J553 CIRCUIT BREAKERS BATTERY J1292 SEC 2 9 WIRE ASSEMBLY M re J1292 SEC 2 10 PARAGRAPH 2 10 1 CIRCUIT PROTECTION e CIRCUIT 8 AMP CIRCUIT PROTECTION 90 TA INTERLOCK N SOLENOID 4 AWG POWER WIRE TO PUMP SOLENOID NOTE VERIFY THAT ALL w 7 ELECTRICAL CONNECTIONS ARE INSULATED AND THAT WIRING IS PROPERLY SECURED PROVIDED BY INSTALLER BATTERY bn S P ez Ki L 4 ANG POWER CABLE 8 AMP CIRCUIT E PROTECTION 16 AWG MINIMUM SIZE WIRE INTERLOCK CIRCUIT 90 4 MAIN BREAKER 4 AWG POWER CABLE CONNECTED BETWEEN NS MAIN CIRCUIT BREAKER AND POSITIVE TERMINAL OF SOLENOID 16 AWG MINIMUM SIZE WIRE ow pt INTERLOCK SOLENOID FIGURE 2 16 INTERLOCK METHOD 3 CH Ricon 32055102 1 Wabtec company MARCH 2011 K SERIES SERVICE MANUAL INSTALLATION C FINAL ADJUSTMENTS 1 LIMIT SWITCH ADJUSTMENT For lift limit switch adjustment refer to Figures 2 17 2 18 and the following procedure Contact the Ricon Product Support Department for assistance if needed FIGURE 2 17 LIMIT SWITCH ADJUSTMENT DIAGRAM NOTE To avoid operational dead spots adjust OUT CUTOFF SWITCH before UP cutoff switch NOTE When loosening adjustment screws apply enough pressure to screw to move block instead of screw The block might stick if insufficient pressure is applied to screw PARALLEL ud KNUCKLE A
41. TE WLDT 1 16618 2 1 VERTICAL ARM ASSY RH K1100 1 21604 VERTICAL ARM ASSY LH K1100 1 21605 2 1 VERTICAL ARM ASSY RH K1200 1 15167 VERTICAL ARM ASSY LH K1200 1 15166 2 2 VERTICAL ARM ASSY K2000 RH 1 19328 VERTICAL ARM ASSY K2000 LH 1 19327 2 3 VERTICAL ARM ASSY K5000 RH 1 22292 VERTICAL ARM ASSY K5000 LH 1 22293 2 4 VERTICAL ARM ASSY K55XX RH 1 30850 VERTICAL ARM ASSY K55XX LH 1 30854 3 1 TOP ARM ASSY K1100 K1200 2 VS AC 250 3 2 TOP ARM ASSY K2000 2 VT AC 250 3 3 ARM ASSY K5000 2 V5 AC 250 3 4 TOP ARM ASSY K55XX 2 30858 4 1 BOTTOM ARM ASSY K1200 2 VS AC 252 4 2 BOTTOM ARM ASSY K2000 2 VT AC 252 4 3 BOTTOM ARM ASSY K5000 2 V5 AC 252 4 4 BOTTOM ARM ASSY K55XX 2 30835 5 SADDLE ASSEMBLY 2 VT AC 046 6 LINK UPPER KNUCKLE LEVER ASSY 2 VT AC 070 7 1 LINK VERTICAL KNUCKLE ASSY W LOAD SENSOR K1200 1 VS AC 058 7 2 LINK VERTICAL KNUCKLE ASSY W LOAD SENSOR K2000 1 VT AC 058 7 3 LINK VERTICAL KNUCKLE ASSY W LOAD SENSOR K5000 1 V5 AC 058 7 4 LINK VERTICAL KNUCKLE ASSY K1100 W O LOAD SENSOR 1 V1 AC 069 7 5 LINK VERTICAL KNUCKLE ASSY K1200 W O LOAD SENSOR 2 VS AC 069 7 6 LINK VERTICAL KNUCKLE ASSY K2000 W O LOAD SENSOR 2 VT AC 069 7 7 LINK VERTICAL KNUCKLE ASSY K5000 W O LOAD SENSOR 2 V5 AC 069 7 8 KIT KNUCKLE LEVER ASSY K55XX W O LOAD SENSOR 2 34894 8 SPRING KNUCKLE ACTUATOR 2 VT SP 42 9 RETAINING RING 75 EXT BAG OF 10 1 11796 10 PIN SNAP RING 75 OD X 2 15L 2 VT PI 41 11
42. TOR 6 25 WHHDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 21 1 KIT FLANGED BEARING 34 ID KIT OF 10 2 19576 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18 1 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PAN HEAD 8TEK X 7 BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 28 X 625 X 065 BAG OF 10 2 17504 30 BUSHING STEEL 2510 X 320D X 19L 2 V2 BU 003 31 SPACER 2510 X 4000 X 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32DSS102 D 1 O Ricon 4 25 SPARE PARTS K SERIES SERVICE MANUAL FIGURE 4 12 TRAVELING FRAME Ricon AWabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 12 TRAVELING FRAME REF DESCRIPTION QTY PART NO 1 1 BASEPLATE ASSY 30 w o INTERLOCK 1 14452 BASEPLATE ASSY 30 w o INTERLOCK RH 1 14452R BASEPLATE ASSY 30 wINTERLOCK 1 14453 1 2 BASEPLATE ASSY 32 w o INTERLOCK 1 14454 BASEPLATE ASSY 32 w o INTERLOCK 1 14454R BASEPLATE ASSY 32 w INTERLOCK 1 14455 1 3 BASEPLA
43. USHING STEEL 25ID X 320D X 19L 2 V2 BU 003 31 SPACER 2510 X 4000 X 2 2 UV PF 839 32 NUT W NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT W NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32055102 1 O Ricon 4 19 A Wabtec company SPARE PARTS E lt LL lt zx A 6 LL lt K SERIES SERVICE MANUAL FIGURE 4 9 FOLDING PLATFORM ASSEMBLY K2003 Ricon AWabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL o SPARE PARTS FIGURE 4 9 FOLDING PLATFORM ASSEMBLY K2003 REF DESCRIPTION QTY PART NO 1 KIT PNEUMATIC SPRING ASSY RETROFIT left amp right 2 19318 2 SPRING PNEUMATIC ASSIST 2 R5 SP 502 3 ROD END ASSY W HDWR 2 29224 4 KIT LINK ASSY 2 19522 5 KIT LINK ASSY REAR FOLDING PLATFORM left amp right 1 29243 6 MAIN SHAFT 1 DIA X 36 50 1 VT PI 43 7 T NUT 14 20 SST BAG OF 10 2 14485 8 TORSION SPRING LH 1 V2 SP 021 9 KIT ACTUATOR ROLLSTOP REPLACEMENT LH 1 22903 10 ROLLSTOP ASSY 6 X30 1 V2 PF 291 11 PIN CLEVIS 5 16X1 1 4 BAG OF 10 2 19513 12 TORSION SPRING RH 1 V2 SP 022 13 KIT ACTUATOR ROLLSTOP REPLACEMENT RH 1 22902 14 KIT LINK YEL BRKTS GREY right amp left serial 5 169180 amp above 1
44. X 25 OD X 44L 2 V2 AC 015 32 SCREW FLAT HEAD 10 24 x 1 2 BAG OF 10 1 13303 33 CAM ASSY INNER ROLLSTOP ACTUATOR 2 V2 AC 190 34 KIT SPACER RUBBER INNER ROLLSTOP CAM KIT OF 4 4 01224 35 PIN SNAP RING 3800 3 09L 2 5 1 09 36 RETAINING RING 3810 BAG OF 10 1 11795 45 BUSHING STEEL 251D X 320D X 19L 2 V2 BU 003 52 KIT RETROFIT PIN LINK ARM ASSY 3 16679 53 WASHER FENDER 5 16 SST BAG OF TEN 1 15921 54 SCREW BUTTON HEAD 5 16 18X1 SST BAG OF 1 14494 56 SET SCREW 3 8 16X3 8 CUP POINT 4 11797 57 SEE FIGURE 4 13 PINCH POINT SHIELDS 58 SPRING NUT 10 24 U TYPE BAG OF 10 1 11799 59 SCREW PAN HEAD 10 24 x 2 BAG OF 10 1 13304 60 PLUG 1 LOW PROFILE BLK NYLON 2 25563 61 BEARING NYLINER 3 8 IDX11 16 LONG 2 25562 62 BUMPER BUTTON IRS CAM BAG OF 10 1 19783 63 BUMPER IRS CAM ANTI RATTLE 2 V2 BU 090 71 SCREW HEX HEAD 1 4 20 X 1 3 4 GR5 BAG OF 10 1 25696 73 SPRING UPPER PARALLEL ARM 2 V2 SP 97 80 SETSCREW 5 16 18 x 1 CUP PT BAG OF 10 1 15830 81 WASHER KEYED 2 20258 82 1 KIT LATCH RELEASE 26 w BLOCKS HDWR 1 28767 82 2 LATCH RELEASE 30 w BLOCKS HDWR 1 28768 82 3 KIT LATCH RELEASE 32 w BLOCKS HDWR 1 28769 83 BLOCK CENTER MOUNTING BASE LATCH 1 V2 AC 102 84 DOWEL PIN 094 DIA X 38 L BAG OF 10 1 25615 85 BLOCK MOUNTING BASE LATCH 1 V2 AC 001 86 BRACKET STOW LOCK SOLENOID 1 V2 AC 108 87 1 SOLENOID ASSY 12V 1 V2 ES 127
45. X RECESS HEAD 1 4 20X2 3 28490 45 FITTING SRT 1 4J STEEL 1 V2 SH 012 46 RETROFIT 2nd SOLENOID 12V 1 19068 47 RETROFIT 2nd SOLENOID 24V 1 19843 48 HARNESS EXT RH PUMP 1 V2 ES 155 49 1 LIGHT LIFT ARMED INDICATOR 12V S N s 61878 present 1 UL ES 034 49 2 LIGHT LIFT ARMED INDICATOR 24V S N s 61878 present 1 V2 ES 016 Item not shown Ricon AWabtec company 32DSS102 D 1 2011 32DSS102 D 1 K SERIES SERVICE MANUAL This page intentionally left blank O Ricon A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL MARCH 2011 SPARE PARTS TWAS 08 F LAN ONV TO 31vu q31VSN3dWOO 5 TOHLNOD MOTA dO4 J3ON3H3H3H 81 JON3H3H3H IN3SdHd 0002 SON 1VIH3S IN31SAS Sald3S 3 HYIANITAD 41 803 J3ON3H3H3H guva v L X 26 01 JTW ONILU 91 401 JON3H3H3H FIGURE 4 2 HYDRAULIC SYSTEM 32DSS102 D 1 Ricon Wabtec company 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 2 HYDRAULIC SYSTEM REF DESCRIPTION QTY PART NO 1 HANDLE MANUAL BACKUP PUMP 1 V2 SH 111 2 KIT TOOL CLIP W HDWR 2 19557 4 1 COVER PUMP RH 1 V2 CV 121 4 2 COVER PUMP LH S N s 31000 31999 amp 35000 present 1 V2 CV 220 5 SCREW HEX HEAD 5 16 18 X 625 BAG OF 10 3 14495 6 WASHER FLAT 5 16 SAE BAG OF 10 1 1335
46. Y THAT ALL I N ELECTRICAL CONNECTIONS LX ARE INSULATED AND THAT S WIRING IS PROPERLY SECURED P CIRCUIT Se 2 4 BATTERY PROVIDED BY INSTALLER FIGURE 2 14 INTERLOCK METHOD 1 2 12 Q Ricon O m P 7 3209910201 Wabtec company K SERIES SERVICE MANUAL INSTALLATION MARCH 2011 PROVIDED BY INSTALLER INSTALLATION MUST CONFORM TO SAE SPECIFICATIONS J553 CIRCUIT BREAKERS BATTERY J1292 SEC 2 9 WIRE ASSEMBLY J1292 SEC 2 10 PARAGRAPH 2 10 1 CIRCUIT PROTECTION 4 AWG POWER WIRE TO SIDE SOLENOID 9 i 2 90 AMP 8 AMP CIRCUIT MAIN BREAKER PROTECTION INTERLOCK CIRCUIT NOTE VERIFY THAT ALL ELECTRICAL CONNECTIONS ARE INSULATED AND THAT WIRING 15 PROPERLY SECURED EE 8 AMP CIRCUIT BREAKER NOTE REMOVE EXISTING 18 AWG JUMPER CONNECTED BETWEEN 8 AMP AND 30 AMP CIRCUIT BREAKERS 8 AMP CIRCUIT BREAKER SIDE SOLENOID 16 AWG WIRE MINIMUM SIZE p J Z em INTERLOCK 2 ON CIRCUIT lt _ Z r 8A CIRCUIT PROTECTION BATTERY PROVIDED BY INSTALLER FIGURE 2 15 INTERLOCK METHOD 2 320551020 2 13 Wabtec company INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 INSTALLATION MUST CONFORM TO SAE SPECIFICATIONS PROVIDED BY INS
47. and on the platform until the installation is complete Upon completion of installation test load the lift mounting integrity at 125 of its rated load capacity e Stand clear of doors and platform and keep others clear during operation The product requires regular maintenance A thorough inspection is recommended at least every six months The lift must always be maintained at the highest level of performance 32055102 01 n o _ yg gt c O Ricon 1 3 A Wabtec company K SERIES SERVICE MANUAL MARCH 2011 INTRODUCTION PRODUCT TERMINOLOGY The references used throughout this manual are illustrated in Figure 1 1 and defined in Table 1 1 Refer to Chap ter IV for more details C 32DSS102 D 1 BASEPLATE ASSEMBLY TOP AND BOTTOM ARMS RIGHT MANUAL BACKUP DS I PUMP HANDLE Roc REAR nr a VERTICAL ARM HANDRAIL HYDRAULIC lt x POWER UNIT PLATFORM 1 s Gs P FOLDING P LINKAGE Sr NM 2 HYDRAULIC 3 CYLINDER x OCCUPANT RESTRAINT C BELT CONTROL PLATFORM HINGES LEFT FRONT BRIDGEPLATE ROLLSTOP REAR PLATFORM SECTION FRONT ge C PLATFORM SECTION E FIGURE 1 1 KLEARVUE LIFT REFERENCES 2011 TABLE 1 1 KLEARVUE SERIES WHEELCHAIR LIFT TERMINOLOGY NAME Left Right Front Rear Top and bottom arms left right Vertical arm left right Handrail left right K SERIES
48. ber The flange of a subframe member must be used to sup port clamping bar YS wa FIGURE 2 7 BUS CLAMPING BAR ARRANGEMENT 2 4 Hicon 32D88102 D 1 Wabtec company MARCH 2011 cs K SERIES SERVICE MANUAL INSTALLATION LIFT WEIGHT IS APPROXIMATELY 350 375 LBS USE GREAT CARE WHEN POSITIONING DO NOT POSITION ALONE a Open doors fully Position lift so that it is centered in vehicle doorway and setback 17 2 from edge of doorsill The lift baseplate must be parallel to side of bus b Turn manual pump release CCW and allow folded platform to fully settle on lift baseplate Close doors and verify that no interference is present between lift and doors Reposition lift if necessary Close pump release valve c Refer to Figure 2 8 Mark and drill eight 25 64 baseplate assembly mounting holes 1 thru 8 through ve hicle floor N CAUTION WW Check vehicle before drilling Do not drill into factory wiring hydraulic lines fuel lines fuel tank etc FIGURE 2 8 BUS BASEPLATE HOLES d Fasten Lift 1 Insert eight 4 x 3 8 carriage screws through baseplate and vehicle floor 2 Install support tubes 4 ea to screws underneath vehicle floor across baseplate i e from 1 to 5 2 to 6 etc and secure lift to vehicle floor with 3 8 washers lock washers and hex nuts 3 Tightening carriage screws requires specia
49. can be raised or lowered manually By using the lift control switches the platform is unfolded from the vehicle deployed The passenger boards the large non skid platform and the operator uses the control switches to gently lower the platform to the ground After the pas senger departs the platform is raised and folded into the vehicle stowed The lift platform splits and folds horizontally when stowed This manual contains operation and maintenance instructions and a troubleshooting guide for the lift It is important to user safety that the lift operators be completely familiar with the Operating Instructions chapter of the operator manual 32055101 Once the lift is installed it is very important that the lift be properly maintained by following the Ricon rec ommended cleaning lubrication and inspection instructions If there are questions about this manual or additional copies are needed please contact Ricon Product Support at one of the following locations Ricon Corporation 7900 Nelson Road Panorama City CA EC EE 818 267 3000 Outside 818 Area Code ENEE SEO 800 322 2884 World Wide www riconcorp com Ricon U K Ltd Littlemoss Business Park Littlemoss Road Droylsden Manchester United Kingdom M43 7 EF creer ec cias taie te u Ca a ad aria 444 161 301 6000 32DS5102 D 1 O Ric on
50. ce Contains electric motor driven pump that produces hydraulic pressure to raise and fold lift and a pressure release valve to unfold and lower it Hand held device used to control the lift operating functions Used to operate manual back up pump Assembly that is securely bolted to the vehicle floor END OF TABLE O Ricon AWabtec company INTRODUCTION K SERIES SERVICE MANUAL This page intentionally left blank 9 Ricon AWabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL INSTALLATION ll INSTALLATION his chapter contains information for installing the RICON KlearVue Series platform wheelchair lift into most vans and buses although custom installations are also possible in other types of vehicles Due to the wide range of applications of lift specific information for every possible application is not available The following general proce dures will apply to most installations Contact Ricon Product Support for instruction about installations not covered To install lift refer to following sections and perform procedures carefully and in the order they are presented Be certain that installation instructions are followed exactly and do not eliminate any steps or modify product A MECHANICAL INSTALLATION 1 LIFT LOCATION The installation surface must be flat and level It is recommended that the lift be installed on a 12 minimum high g
51. e disconnected at this time using wire at least 16 AWG or larger not to exceed 12 in length Be sure that wiring cannot pinch or chafe Connect OUTPUT side of circuit protector to INPUT side of interlock circuit provided by installer using 16 AWG or larger wire Connect OUTPUT side of interlock circuit to coil terminal of solenoid using 16 AWG or larger wire Be sure that interlock is properly grounded If a separate grounding post is provided connect a 16 AWG wire from ground post to a suitable chassis ground If coil is grounded through body of solenoid be sure that solenoid is mounted to a suitable chassis ground Reconnect the battery Ricon 2 11 Wabtec company INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 OUTPUT SIDE INSTALLATION MUST CONFORM TO SAE SPECIFICATIONS OF 8 AMP BREAKER J553 CIRCUIT BREAKERS J1292 SEC 2 9 WIRE ASSEMBLY INTERLOCK ASSEMBLY J1292 SEC 2 10 PARAGRAPH 2 10 1 CIRCUIT PROTECTION PROVIDED BY INSTALLER FROM POSITIVE TERMINAL FEMALE SPADE OF SIDE SOLENOID INTERLOCK TO CONTROL CIRCUIT 4 PENDANT 4 TO INTERLOCK 4 MALE SPADE 7 INDICATOR LIGHT CONNECTOR FEMALE SPADE CONNECTOR PREVIOUSLY CONNECTED TO OUTPUT SIDE OF 8 AMP BREAKER 8 AMP BREAKER ALL INTERLOCK WIRING MUST BE 16 AWG OR LARGER SIDE SOLENOID 16 AWG WIRE MINIMUM SIZE OW NOTE VERIF
52. ecal Locations and Part Numbers figure at the end of Chapter II of this manual NOTE To order a part locate the part or assembly on an exploded view note its reference number find this number on the associated parts list following page and order the part number in the far right column Most kits con tain a single part plus hardware Therefore you may need to order more than one kit if the part is used more than once on a major assembly NOTE Some major lift components that are typically painted gray may also be produced in other colors such as red yellow blue black and white These components include the platform assembly handrails vertical arms top and bottom arms and baseplate assembly These colored components are available from Ricon as spare parts DIAGRAM PAGE FIGURE 4 1 HYDRAUEIG POWER UNIT ennt ette t ed edente ent 4 2 FIGURE 4 2 FYDRAULIC SYSTEM rete ee ee eec t eene ee tak Pe enda e 4 6 FIGURE 4 3 ELECTRICAL SYSTEM uum m da ico dice Tee ege a su a ege Ue dede de die vd du 4 8 FIGURE 4 4 PENDAN up nigel oe Era e Ee e ep e nitive 4 10 FIGURE 4 5 FOLDING PLATFORM ASSEMBLY 1132 7 4 12 FIGURE 4 6 FOLDING PLATFORM ASSEMBLY 1200 nnns 4 14 FIGURE 4 7 FOLDING PLATFORM ASSEMBLY 1203 kapani eks 4 16 FIGURE 4 8 FOLDING PLATFORM ASSEMBLY 1205 nnne 4 18 FIGUR
53. essure setting is achieved g 32DSS102 D 1 ls Ricon U Y 2 19 Wabtec company INSTALLATION _s K SERIES SERVICE MANUAL MARCH 2011 D VERIFY INSTALLATION Verify there is no interference with operation of the lift by interior or exterior components The lift is designed to carry the weight of a wheelchair and its passenger The vehicle structure must be ade quate to support all loads produced during lift operation as well as forces incurred by motion of vehicle when driven The lift must be test loaded to 12596 of its rated 800 pound load capacity to verify integrity of installation N CAUTION Do not operate lift during load test The load test is intended to test lift installation mount ing points not lifting capacity Remove test weight immediately after test When test weight is placed on platform the vehicle suspension will compress and vehicle will lean If weighted platform touches ground remove weight raise platform and retest 1 Raise lift plattorm 2 6 above ground place 1000 pounds in center of platform then inspect lift mounting points REMOVE TEST WEIGHT 2 Run lift through several complete cycles while checking for proper operation CUSTOMER ORIENTATION IMPORTANT Customer Orientation Ricon Sales or Service personnel must review the warranty and operator ma nua
54. evenly CORRECT BOWED UP BOWED DOWN ESE pese l PROSESS SE RSS 2 22 Kx x SE X e 5555 Ke G Im 52 x SR BIS lt lt 555 2 XX Ka Sg NNN cm 22 gt x amp Ke d o CG x LOOSEN HERE R 2 Ve LOOSEN ap E TIGHTEN FIGURE 2 1 BASEPLATE WARPAGE XS 222222 A gt Q XX 5 x x x x 5 gt X SS x xx XX 4 gt X LL XX 4 IGHTEN HERE lt lt KS px KK RS MES EH 32DSS102 D 1 Ricon 2 1 Wabtec company INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 Refer to Figure 2 2 On Ford van installations clamping bars must be used to help distribute floor loading and should only be cut if needed to clear a subframe member Use the flange of the subframe member as a port for the clamping bar FIGURE 2 2 FORD VAN CLAMPING BAR ARRANGEMENT 3 LIFT INSTALLATION INTO VANS a Referto Figure 2 3 Using four 1 x 3 8 screws 3 8 washers 3 8 lock washers and 3 8 hex nuts as semble two bracket assembly kits NOTE The top bracket must overlap bottom bracket and both slots must face outward FIGURE 2 3 STEPWELL BRACKET b Position and adjust height of both bracket assemblies so that top bracket i
55. f conducting an additional 90 amps to the negative battery terminal b 24VDC Systems 1 Ricon recommends that a dedicated ground cable be used in 24 VDC installations cable heavier must be used 2 Refer to Figure 2 13 The ground cable is routed from the negative stud on pump motor to the neg ative battery terminal 24V TOP SOLENOID a SEE SC GROUND hrr CONNECTION 24V SIDE SOLENOID IQ SEE 4GA GROUND CABLE M NOTE TO NS GROUND BATTERY TERMINAL CONNECTION 4GA POWER CABLE FROM NOTE CONNECT THESE TERMINALS TO CIRCUIT BREAKER PIN 3 WHITE OF PUMP CONNECTOR FIGURE 2 13 24VDC WIRING 320 55102 0 1 a a n Ricon 2 9 A Wabtec company INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 4 RICON UNSUPPORTED INTERLOCK DEVICE INSTALLATION An interlock device can be installed that prevents operation of lift or vehicle when it is unsafe to do so The interlock is supplied by the installing Ricon service technician and is not a Ricon product Some interlock devices lock vehicle transmission in PARK when lift is deployed or do not allow lift to be deployed unless vehicle transmission is in PARK and emergency brake is set Other devices will stall vehicle s engine if lift is deployed and emergency brake is released or transmission is shifted from PARK There may be other types of in terlock devices that disable lift or vehicle and prevent unsafe lif
56. f operation Verify that all handrail fasteners are properly tightened Cleaning and Clean lift with a mild soap and wipe dry Rub down all surfaces with a light oil using a soft lubrication cloth to avoid rusting of material Wipe away excess oil Following directions on container spray lubricants specified in Lift Lubrication Points figure at points prescribed Wipe excess lubricant from surrounding areas Hydraulic power CAUTION unit Do not add fluid until platform is lowered to ground level Adding fluid while platform is ele vated will cause reservoir to overflow when platform is lowered With platform at ground level be certain that pump hydraulic fluid level is at FULL level Add only Texaco hydraulic fluid or equivalent U S mil spec H5606G fluid as necessary N CAUTION This safety check must be performed by an authorized Ricon dealer or qualified service technician ANNUAL SAFETY CHECK or 2 3500 cycles of operation Check hydraulic clinder for evidence of leaks Inspect hydraulic hoses for damage Verify that all fittings are tightly secured END OF TABLE 32055102 0 1_ _ _ 77 77 O O Ricon err 3 3 AWabtec company MAINTENANCE K SERIES SERVICE MANUAL MARCH 2011 D TROUBLESHOOTING The troubleshooting guides are designed to provide logical starting points to locate general problems that could occur with lif
57. idden by pump cover A 75 DIA FOR FLOOR METAL 1 00 DIA FOR OTHER MATERIAL B 32 PLATFORM WIDTH 2 25 30 PLATFORM WIDTH 1 25 FIGURE 2 10 POWER CABLE ACCESS HOLE NOTE Two circuit breakers one 30 amp and one 90 amp are provided for lift as circuit protection devices What ever circuit interface is supplied by the OEM it should be capable of carrying the additional current used by lift b Install ring terminals supplied to each end of 12 power cable and also one ring terminal to one end only of long power cable using an appropriate crimp tool such as Ricon P N 26553 c Connect end of the long 4 AWG power cable with ring terminal to main circuit breaker then route power cable underneath vehicle floor and up through hole in floor N WARNING VERIFY THAT VEHICLE PARTS DO NOT INTERFERE WITH POWER CABLE OR ASSOCIATED WIRES IN ANY WAY d Becertain that power cable is secure Secure power cable to pump assembly harness and to pump motor using cable ties Avoid pinch points exhaust system moving parts and brake lines 32DSS102 D 1 Q Ricon 2 7 Wabtec company MARCH 2011 INSTALLATION K SERIES SERVICE MANUAL Refer to Figure 2 11 Cut any excess wire from long cable install remaining heavy ring terminal to unter minated end of long cable and to connect it to live side of solenoid Be certain that red wire from main cir cuit b
58. ional circuit protection but does require a modification to lift harness 1 Disconnect battery 2 Remove piggyback spade connector wire from OUTPUT side of 8 amp circuit breaker refer to decal on circuit breaker NOTE The OUTPUT side of breaker must be used to avoid possibility of an electrical short 3 Connect female spade connector of interlock circuit provided by installer to OUTPUT side of 8 amp breaker using 16 AWG or larger wire NOTE connectors provided on interlock circuit must be fully insulated type 4 Cut piggyback connector from light assembly and female spade connector from signal power wire Strip both wires about 2 being careful not to nick connector Crimp both wires in a single 14 fully insu lated female spade connector designed for use on 14 16 AWG wire 5 Connect male spade connector of interlock circuit to female spade connector added to harness in above step 6 Dress wires in such a way as to not allow rubbing or chafing of insulation and so there is no strain at any terminals or body of light b Interlock Method 2 Signal interrupt feed from vehicle Refer to Figure 2 15 This method interrupts power between lift s 8 amp breaker and vehicle s battery It re quires circuit protection to be provided by installer 1 Disconnect battery 2 The cable leading to applicable circuit protection from battery must be at least 16 AWG or larger and must not exceed 12 in length 3 Connect IN
59. l care to keep baseplate assembly from warping when se cured to vehicle floor If baseplate assembly warps vertical arms will not be parallel Corrections can be made by shimming at appropriate locations To help prevent warping tighten the eight carriage screws to 28 ft lbs in following sequence 2 3 6 7 1 4 5 8 NOTE Vertical Arms must be parallel for proper operation Adjust screws as required Best results are ob tained when lift is mounted on plywood Shims although best avoided may be used if required 320 55102 0 1 a Ricon 2 5 A Wabtec company INSTALLATION F x K SERIES SERVICE MANUAL MARCH 2011 B ELECTRICAL INSTALLATION N CAUTION e Do not route a wire while it is connected to the battery e Route wires clear of moving parts brake lines and the exhaust system Secure to the vehicle e When routing an electrical wire through vehicle floor or walls use a grommet to protect wires from chafing e Check underside of vehicle before drilling to avoid damage to fuel lines vent lines brake lines or wires M is BATTERY p 4 AWG POWER CABLE de A LONG CABLE CONNECTED BETWEEN p 4 AWG POWER CABLE _ MAIN CIRCUIT BREAKER AND POSITIVE 6 90 SHORT CABLE NOT EXCEED 12 TERMINAL OF SOLENOID CONNECTED BETWEEN BATTERY OR MAIN POWER SOURCE AND MAIN
60. l with the customer to be certain customer understands how to safely oper ate lift Instruct customer to follow operating instructions without exception Refer to Figure 2 23 on next page and be certain that all decals are secure and located as shown NOTE The installing dealer must affix the Operating Instructions decal to vehicle in a location that is clearly visi ble to the lift operator 2 20 n An sI Q Ricon U oli tq s shsa s bx Wabtec company 2011 32DSS102 D 1 K SERIES SERVICE MANUAL This page intentionally left blank Ricon Wabtec company INSTALLATION INSTALLATION K SERIES SERVICE MANUAL MARCH 2011 MANUAL OPERATION OPERATION MANUELLE OPERACION MANUAL LUN ANNY SAN ANDBEDIENUNG N 2 4 s 3 N 32 1 166 QUNLY RIG LOAD 2 ACEAR N 27 1 BE 800 Lb 364 Kg MAINTENANCE REQUIRED IF CONTINUOUSLY ILLUMINATED MAINTENANCE DOIT ETRE FAITE SI CETTE LUMIERE RESTE ALLUMEE EN PERMANENCE MANTENIMIENTO ES REQUERIDO SI PERMANECE CONTINUAMENTE ILUMINADO BEI UNUNTERBROCHENER WARNLICHT ANZEIGE IST WARTUNG ERFORDERLICH K SERIES WHEELCHAIR amp STANDEE LIFTS FASTEN OCCUPANT RESTRAINT BELT BEFORE OPERATING LIFT FE D ADA STANDARDS NATIONAL SCHOOL BUS STANDARDS WARNING FIGURE 2 23 DECAL LOCATION
61. low Up cutoff described in above step screw clockwise This will give the necessary overlap to avoid dead spots Lift stops high Adjust screw clockwise END OF TABLE Ricon 32055102 1 Wabtec company 2011 2 K SERIES SERVICE MANUAL INSTALLATION PLATFORM TILT ADJUSTMENT The platform tilt adjustment is crucial for proper rollstop operation but cannot be adjusted at the factory Factors such as vehicle floor height lift tilt angle and stiffness of vehicle springs will vary installation geometry a b NOTE C d Deploy and lower the lift platform to a position halfway between vehicle floor level and ground level Refer to Figure 2 19 Adjust the left and right platform setscrews to level platform Turn setscrews clock wise to angle front end of platform upward or counterclockwise to angle front end downward Evenly adjust set screws at both sides of platform to maintain platform level SET SCREW PLATFORM FIGURE 2 19 PLATFORM SET SCREWS Lower the platform towards ground level Stop lowering at the moment when the rollstop is fully open The distance between the rear of platform and the ground should be 37 to 1 Repeat steps a and b as required to achieve proper platform tilt 3 ADJUSTMENT OF PLATFORM FOLDING LINKAGE The front portion of the platform is connected to the rear portion with a hinge The front portion is folded with lin kages located at the right a
62. ly be mounted on all lift assemblies without optional door operator The light indicates power is supplied to signal portion of electrical system and will aid in diagnosing electrical problems TABLE 3 2 INTERLOCK INDICATOR TROUBLESHOOTING GUIDE POSSIBLE CAUSE Light is not lit lift does Control system circuit breaker is tripped not operate Interlock system is not allowing power to lift due to an unsafe condition or a faulty interlock Light is not lit lift Light needs to be replaced operates Light is lit lift works in Interlock is not functioning an unsafe condition Light is lit lift does not There is a problem with electrical system either with power operate signal side Both will have to be checked but start with power side since it is less complicated END OF TABLE 3 4 Ricon P 2055102 0 1 A Wabtec company MARCH 2011 K SERIES SERVICE MANUAL MAINTENANCE 2 LIFT TROUBLESHOOTING TABLE 3 3 LIFT OPERATIONAL TROUBLESHOOTING GUIDE Hydraulic component Discontinue use of lift until repairs are made by defective an authorized Ricon dealer or qualified 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 p
63. nd left sides of the platform The length of the linkage might require adjustment after in stallation of the lift or after disassembly of the platform NOTE Perform the PLATFORM TILT ADJUSTMENT procedure before adjusting the linkage a b Referto Figure 2 20 Loosen the jam nuts right and left sides and use the adjusters to set the length of 32DSS102 D 1 Deploy and lower the platform to a position about halfway between floor level and ground level the linkages so that the front and rear portions are in the same plane the two surfaces of the platform por tions must be flat without any apparent folding along the hinge Verify that the tension of both linkages is the same by sighting along the outer edge of the platform arrow in figure Tighten jam nuts Le F JAM NUT 5 NK K Jy LES Es 55 FOLDING LINKAGE gt x e 55255555026 0606 SN ADJUSTER 55 St SE OUS DQ Oe 2 amp Z Coe ER RR LK 9 FIGURE 2 20 ADJUSTMENT HARDWARE FOR PLATFORM FOLDING LINKAGE N CAUTION Adjuster link of platform folding linkage must be replaced with Kit P N 45453 if the wheel chair lift baseplate is installed with a shim that will tilt the lift back more than 1 4 Inch Q Ricon Wabtec company INSTALLATION K SERIES SERVICE MANUAL _ MARCH 2011 Lower platform until it settles on the ground Verify that a slight amount of slack
64. or serial numbers 169180 and above 1 31251 For serial numbers below 169180 1 23339 18 LINK ASSY FRONT PLATFORM 1 29222 19 WASHER DELRIN 1 0DX 381DX 03 BAG OF 10 8 25628 20 KIT COLLAR ROLLSTOP ACTUATOR 6 25 W HDWR 1 28775 21 KIT FLANGED BEARING 1 ID KIT OF 10 2 19579 22 BLOCK PLATFORM LEVEL ADJ 2 VT AH 142 23 SCREW BUTTON HEAD 5 16 18X1 2 SST BLK OX BAG OF 10 2 14484 24 SCREW HEX HEAD 5 16 18X 11 GR5 BAG OF 10 2 14403 25 SETSCREW 1 20 1 4 W NYLON INSERT BAG OF 10 2 19704 26 BUMPER VHMW 75DX 38T 2 V2 AC 027 27 SCREW PANHEAD 8TEK X 7 BAG OF 10 2 15961 28 SCREW BUTTON HEAD 5 16 18 X 34 SST BLK OX BAG OF 10 7 15983 29 WASHER FLAT 281 X 625 X 065 BAG OF 10 2 17504 30 BUSHING STEEL 25ID X 320D X 19L 2 V2 BU 003 31 SPACER 25ID X 4000 X 2 2 UV PF 839 32 NUT NYLON INSERT 14 20 BAG OF 10 2 15919 33 NUT NYLON INSERT 5 16 18 SST BAG OF 10 7 14415 34 SCREW HEX HEAD 14 20 X 34 GR5 BAG OF 10 2 13308 35 SCREW HEX HEAD 14 20 X ve GR5 BAG OF 10 2 34518 32055102 1 O Ricon 4 15 A Wabtec company SPARE PARTS K SERIES SERVICE MANUAL K LIFT FOLDING PLATFORM ASSEMBLY K1203 MARCH 2011 FIGURE 4 7 FOLDING PLATFORM ASSEMBLY K1203 4 15 O Ricon A Wabtec company 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL SPARE PARTS FIGURE 4 7
65. r to Traveling Clear entry frame width folded depth platform platform ground frame width width Model folded width length travel K1101 47 38 6 15 5 30 38 24 37 5 29 25 K1132 43 38 6 15 5 26 38 24 33 5 25 25 K1200 47 43 5 15 5 30 44 28 37 5 29 25 K1203 47 43 5 15 5 30 51 28 37 5 29 25 K1205 49 43 5 15 5 32 51 28 39 5 31 25 K2003 47 47 15 5 30 51 37 37 5 29 25 K2005 49 47 15 5 32 51 37 39 5 31 25 K2005 ADA 49 55 15 5 32 51 37 39 5 31 25 K2010 50 5 47 15 5 34 54 37 41 5 33 25 K5005 49 60 15 5 32 51 43 39 5 31 25 K5010 50 5 60 15 5 34 54 43 41 5 33 25 K5503 45 60 15 5 30 51 48 37 5 29 25 K5505 49 60 15 5 32 51 48 39 5 31 25 K5510 50 5 60 15 5 34 54 48 41 5 33 25 K5511 50 5 60 15 5 34 51 48 41 5 33 25 Q Ricon AWabtec company 32DSS102 D 1 2011 5 32DSS102 D 1 K SERIES SERVICE MANUAL O Ricon A Wabtec company SPARE PARTS SPARE PARTS K SERIES SERVICE MANUAL This page intentionally left blank Ricon AWabtec company MARCH 2011 32DSS102 D 1
66. rade plywood sub floor However this additional installation height may not be acceptable in cases where over head clearance is limited Be certain to check for proper travel clearance through the doorway a With doors fully open place position lift in vehicle doorway as close as possible to door with lift s baseplate assembly parallel to side of vehicle b Be sure to allow a distance of 34 if possible between door and the part of lift closest to it Adjust lift s left and right side locations to accommodate subframe members c Verify proper clearance of door frame passenger seats and outer edge of vehicle floor and possible inter ference with wires fluid lines subframe members etc 2 LIFT INSTALLATION GUIDELINES The mounting of lift is a very important step Lift performance can be greatly affected by improper mounting and or fastening of lift Although fastening details may vary from one vehicle to the next some general principals always apply Be certain that all mounting screws are properly installed and tightened Screws used to fasten baseplate as sembly to vehicle floor must be SAE Grade 5 or greater and torqued to 28 ft lbs dry Keep in mind that the most important screws are those at the rear of the lift since they retain most of the load N CAUTION Refer to Figure 2 1 Improper fastening sequence or torquing of screws can result in a warped or bowed baseplate which would cause platform to operate un
67. reaker if applicable is connected to positive solenoid pole e 4 AWG POWER CABLE VERTICAL SUPPORT CABLE TIES RIT GROMMET OR CABLE CLAMP FIGURE 2 11 CABLE ROUTING Refer to Figure 2 12 Connect supplied RICON lift control pendant to lift and secure with supplied bracket and cable clamps f PENDANT INTERFACE INSTALL DOOR OPERATOR INTERFACE JUMPER IF DOOR OPERATOR IS NOT USED STRAIN RELIEF BRACKET CABLE CLAMP FIGURE 2 12 CONTROL INTERFACE AND STRAIN RELIEF NOTE For applications where a hand held control pendant is used it is essential that strain relief be installed N CAUTION Be sure that harness does not interfere with any moving parts or binds against any parts or is pinched in any way Connect 12 cable from battery positive terminal to main breaker terminal closest to battery h Install wall portion of pendant dovetail clip in a convenient location near the lift Q Ricon 2 8 Wabtec company 32DSS102 D 1 MARCH 2011 ns SERIES SERVICE MANUAL INSTALLATION 3 GROUND CONNECTIONS a 12VDC Systems 12VDC powered lifts can be chassis grounded and therefore do not require a separate ground cable connec tion to battery NOTE If lift electrical system is grounded to chassis the ground cable must be attached in a manner that provides a reliable electrical connection If cable is attached to an existing ground circuit the circuit must be capable o
68. roduct parts caused by accident misuse lack of proper maintenance neglect improper adjustment modification alteration the mechanical condition of the vehicle road hazards over loading failure to follow operating instructions or acts of nature i e weather lightning flood NOTE Ricon recommends this product be inspected by an authorized Ricon dealer or qualified service techni cian once every six months or sooner if necessary Any required maintenance or repair should be performed at that time This Warranty Is Void If N WARNING THIS PRODUCT HAS BEEN DESIGNED AND MANUFACTURED TO EXACT SPECIFICATIONS ANY MODIFICATION OF THIS PRODUCT CAN BE DANGEROUS The product has been installed or maintained by someone other than a Ricon dealer or a qualified service technician The product has been modified or altered in any respect from its original design without written authorization by Ricon Ricon disclaims liability for any personal injury or property damage that results from operation of a Ricon product that has been modified from the original Ricon design No person or company is authorized to change the design of this Ricon product without written authorization by Ricon Ricon s obligation under this warranty is exclusively limited to the repair or exchange of parts that fail within the applicable warranty period Ricon assumes no responsibility for expenses or damages including incidental or consequential damages Some
69. rtain that they understand how to safely operate the product Instruct the user to follow the operating instructions without exception B GENERAL SAFETY PRECAUTIONS The following general safety precautions must be followed during installation operation service and maintenance Under no circumstances should installation maintenance repair and adjustments be attempted without the immediate presence of a person capable of rendering aid An injury no matter how slight must be attended to Administer first aid or seek medical attention immediately e Protective eyeshields and appropriate clothing should be worn at all times To avoid injury exercise caution when operating lift and be certain that hands feet legs and clothing are not in the path of platform movement e Batteries contain acid that can burn If acid comes in contact with skin immediately flush affected area with wa ter and wash with soap e Always work in a properly ventilated area Do not smoke or use an open flame near battery e Donotlay anything metallic on top of battery Check under vehicle before drilling to avoid drilling into frame subframe members wiring hydraulic lines fuel lines fuel tank etc e Read and thoroughly understand the operating instructions before operating lift e Inspect the lift before each use If an unsafe condition unusual noises or movements exist do not use lift until the problem is corrected Never load or st
70. s level with vehicle floor Tighten bracket assembly screws c Becertain that lift is fully closed with handrails folded tight against vertical arms If necessary use manual pump N WARNING LIFT WEIGHT IS APPROXIMATELY 350 375 LBS USE GREAT CARE WHEN POSITIONING DO NOT POSITION ALONE d Referto Figure 2 4 on following page With doors fully open position lift in vehicle doorway so that the back is supported by vehicle floor and front is supported by both bracket assemblies 2 2 Ricon 7 9 3209910201 Wabtec company MARCH 2011 ns K SEHRIES SERVICE MANUAL INSTALLATION FIGURE 2 4 BRACKET ASSEMBLY e Adjust Base Assembly NOTE If Ricon power door operators are used install them first They can influence the location of the lift Becertain baseplate assembly is parallel with vehicle floor The baseplate assembly may be slightly offset in door opening to provide proper clearance for passenger seats N CAUTION Check vehicle before drilling Do not drill into factory wiring hydraulic lines fuel lines fuel tank etc f Mark and drill holes 1 Refer to Figure 2 5 Mark and drill four 25 64 dia baseplate assembly mounting holes 1 2 3 and 4 through vehicle floor On Dodge and GM vans you must drill through vehicle floor and subframe FIGURE 2 5 VAN BASEPLATE HOLES 2 Place four 8 x
71. t However not all possible problems or combinations of problems are listed For troubleshooting lift refer to Tables 3 2 and 3 3 The guides do not incorporate routine safety precautions or preliminary procedures and assume that vehicle 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 DEALER OR QUALIFIED SERVICE TECHNICIAN CAN PERFORM TROUBLESHOOTING AFTER THE WARRANTY PERIOD IT IS RECOMMENDED THAT TROUBLESHOOTING CONTINUE TO BE PERFORMED BY AN AUTHORIZED RICON DEALER OR QUALIFIED SERVICE TECHNICIAN 1 INTERLOCK INDICATOR DIAGNOSTICS The purpose of a vehicle interlock system is to prevent operation of lift if an unsafe condition is present When vehicle interlock systems are interfaced with lift circuitry the interlock indicator shows whether or not interlock is providing power to lift or not It does not indicate proper operation of the interlock The light is in terfaced with the electrical system so that no matter which interlock system method is used the light will be ON when interlock allows electrical power to lift and OFF when interlock has disabled power to lift When there is no interlock system installed the light stays illuminated at all times A light assembly is installed in the position where door operator circuit breaker would normal
72. t operating conditions Because these devices are non Ricon products Ricon is not aware of all that are available For this reason it is very important that interlock device be properly installed such that it does not interfere with safe operation of lift or create an electrical or fire hazard The installer should always be certain that none of the original equipment electrical circuit breakers fuses or sole noids are bypassed removed or altered Be sure no wires are left frayed or hanging loose after installation of the interlock device If you have any questions about proper installation of these interlock devices please contact our Product Support Department immediately DO NOT OPERATE LIFT UNLESS YOU ARE CERTAIN THAT INTEGRITY OF LIFT S ELECTRICAL CIRCUITS AS DESIGNED HAS BEEN MAINTAINED N CAUTION Wiring attached directly to a battery s positive terminal is not protected against short circuits Wiring attached directly to a battery must be kept as short as possible 12 or less and must be routed so that there is no risk of pinching Wires for interlock circuit should be routed from an appropriately protected power source such as a dedicated accessory on an existing fuse panel Ricon recommends using one of three possible installation methods a Interlock Method 1 Signal interrupt feed from lift Refer to Figure 2 14 This method interrupts power to lift s hand control pendant It does not require addit
73. to be bolted in positions 1 2 3 and 4 and run across width of baseplate towards center of van 5 Before tightening carriage screws verify that lift is level with vehicle floor Adjust bracket assembly screws if necessary Tilting lift towards inside of van may hinder its initial unfolding Install lift with its baseplate assembly as level as possible 7 Tightening carriage screws requires special care to keep baseplate assembly from warping when se cured to vehicle floor If baseplate assembly warps the vertical arms will not be parallel Corrections can be made by shimming at appropriate locations Refer to Figure 2 5 To help prevent warping tigh ten the eight carriage screws six on Dodge van with sliding door to 28 ft Ibs in the following sequence DODGE WITH SWING DOORS ALL FORD AND GM VANS 2 3 6 7 1 4 5 8 DODGE WITH SLIDING DOORS 2 3 5 8 1 4 NOTE Vertical Arms must be parallel for proper operation Adjust screws as required Best results are ob tained when lift is mounted on plywood Shims although best avoided may be used if required 8 Refer to Figure 2 6 Make certain that holes 13 and 14 on front of each bracket assembly are drilled through and 5 16 screws are inserted to lock position of bracket assemblies 4 LIFT INSTALLATION INTO BUSES Refer to Figure 2 7 Since clamping bars are used on most bus installations they help distribute floor loading and should only be cut if needed to clear a subframe mem
74. ump manual Turn manual release valve CLOCKWISE until release valve OPEN lightly snug Hydraulic fluid may be While platform is at GROUND LEVEL be cer low tain 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 Air may be trapped in Purge hydraulic system by operating lift through hydraulic system its maximum range of travel for at least four complete cycles For vehicles that do not use full travel of lift the maximum range of travel is accomplished by raising vehicle on a service hoist or ramp No Control System Circuit Reset circuit breaker operation Breaker tripped Backup pump manual Turn manual release valve CLOCKWISE until release valve OPEN lightly snug Hydraulic hose or fit Contact an authorized Ricon dealer or qualified ting leak service technician for repair Hydraulic fluid may be While platform is at GROUND LEVEL be cer low tain 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 Air may be trapped in Purge hydraulic system by operating lift through hydraulic system its maximum range of travel for at least four complete cycles For vehicles that do not use full travel of lift the maximum range of travel is accomplished by raising vehicle on a service hoist or ramp END
75. vel The solid indicates normally CLOSED portion of Switch is operational while the two thin lines 2 indicates normally OPEN portion of switch is operational The dot ted lines mmm are used to show switch states beyond normal travel boundaries of platform This is useful in show ing the operation of switches which change states at folded or ground level positions For proper operation of lift the switch actuations must overlap as shown HUT LE FIGURE 3 6 LIMIT SWITCH ACTUATION DIAGRAM 3 WIRING DIAGRAMS Refer to following pages 8 8 Ricon 32055102 0 1 Wabtec company MARCH 2011 32DSS102 D 1 K SERIES SERVICE MANUAL FIGURE 3 7 WIRING DIAGRAM FOR LIFT WITH DOOR OPERATOR 0 Ricon AWabtec company MAINTENANCE K SERIES SERVICE MANUAL FIGURE 3 8 WIRING DIAGRAM FOR LIFT WITHOUT DOOR OPERATOR Ricon A Wabtec company MARCH 2011 32DSS102 D 1 MARCH 2011 K SERIES SERVICE MANUAL 9 SPARE PARTS IV SPARE PARTS his chapter contains parts diagrams and parts list for the Ricon K series KlearVue Wheelchair Lift The ex ploded views of major lift assemblies show individual or kit components referenced by numbers On the asso ciated lists are the reference numbers part descriptions quantities used and Ricon part numbers For part num bers of lift decals refer to the D

K-Series, Personal and Transit Use

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