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® ™ PRINT SERVICE MANUAL 32DF9T02.C 07/26/04 1995-2001 RICON CORPORATION All Rights Reserved U.S and Foreign Patent(s) Pending Printed in the United States of America...
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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 es- sential instructions and reference information, which sup- ports qualified technicians in the correct installation and maintenance of Ricon products.
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Revision Record DATE PAGES DESCRIPTION OF CHANGE ECR/ECO 32DF9T02. 07/08/03 3-9 - 3-12 Redrew physical outline of Lifting Frame 12/04/03 5-24 Added item 20C 12/17/03 5-15 Added item 10 01/30/04 Added Troubleshooting Table 06/22/04 Added item 21 06/30/04 5-24 Changed item 12 from 19583, item 29 from UV-SP-001 TO 20123. Changed items 5 &...
F9T INTRODUCTION afe and easy access to mass-transit vehicles is provided by the RICON Mirage F9T Transit Use Wheelchair and Standee Lift. Refer to Figures 1-1 and 1-2. This manual covers both Dedicated Entry (DE) and Stepwell (SW) models. The Dedicated Entry model is intended for installation in a vehicle baggage bay, or similar com- partment.
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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 de- sign of this Ricon product without written authorization by Ricon.
Inspect lift before each use. Do not operate lift if an unsafe condition is present, or if there are un- usual noises or movements. Keep others clear during lift operation. Maintain the lift at its highest level of performance by doing the required maintenance. Ricon recom- mends a thorough inspection every six months. 32DF9T02.C...
MAJOR LIFT COMPONENTS DEDICATED ENTRY MODEL Major components of the Mirage F9T Transit Use Dedicated Entry Wheelchair and Standee Lift are in Figure 1-3. A description of each component is in Table 1-1. 32DF9T02.C 1 - 4...
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TABLE 1-1: LIFT COMPONENTS FOR DEDICATED ENTRY MODEL NAME DESCRIPTION Left, Right, Front, Rear Reference points from outside vehicle looking inward at lift. Pump Enclosure Contains lift electrical and hydraulic control components. Electric Circuit Breakers Prevent over-current damage to lift electrical components. Hydraulic Pump Assy.
STEPWELL MODEL Major components of the Mirage F9T Transit Use Stepwell Model Wheelchair and Standee Lift are in Figure 1-4. A description of each component is in Table 1-2. 32DF9T02.C 1 - 6...
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TABLE 1-2: LIFT COMPONENTS FOR STEPWELL MODEL NAME DESCRIPTION Left, Right, Front, Rear Reference points from outside of vehicle looking inward at installed lift. Pump enclosure Contains lift electrical and hydraulic control components. Pump Handle Used to manually operate hydraulic pump or to release platform. Electric Circuit Breakers Prevent over-current damage to lift electrical components.
F9T INSTALLATION he RICON Mirage F9T Transit Use Wheelchair and Standee Lift is contained in an enclosure, which can be mounted in several possible vehicle locations. Specific information for every possible installation is not provided due to the wide range of applications.
CAUTION! It is important that fasteners used for lift mounting do not protrude into the lift interior. Fasteners that are too long can interfere with movement of carriage. Threaded fasteners for mounting lift are 5/16-18, and must be grade 5, or higher. Their length must provide at least 5/16”...
ELECTRICAL Electrical installation is similar for both 12 and 24 VDC electrical systems, whether they are insulated return, or chassis return. Use the following procedure to connect power to lift. NOTE: A dedicated, insulated 4 AWG return (ground) wire is recommended. In either case, be certain all connections are clean and strong.
FINAL ADJUSTMENTS This section contains procedures that might be needed after lift is installed in vehicle. It is not a requirement to perform all procedures after lift installation, but only those that are necessary. Additional adjustment procedures, that would normally be needed after maintenance or repair, are in Chapter IV. WARNING! FAILURE TO PROPERLY ADJUST EQUIPMENT MAY RESULT IN UNSAFE OPERATING CONDITIONS FOR THE LIFT USER.
Remove plug on the top of hydraulic pump tank (reservoir). Make sure that hydraulic fluid in tank is at FULL level. Add only Texaco 01554 Aircraft Hydraulic Oil, or equivalent U.S. mil spec H5606G fluid and reinstall plug. Repeat previous five steps until fluid coming out of bleeder valve is free of air. Verify that air bleeder valve is fully closed.
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WARNING! •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BATTERIES CONTAIN ACID THAT CAN BURN. IF ACID COMES INTO CONTACT WITH SKIN, IM- MEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP. •• ALWAYS WORK IN A PROPERLY VENTILATED AREA. DO NOT SMOKE OR USE OPEN FLAME IN THE VICINITY OF BATTERY.
An optional programming switch kit is available to program the stow and intermediate heights into the controller memory. It is Ricon part number 17885. NOTE: The stow and intermediate height values are stored indefinitely in the controller memory. Programming the controller will clear the present value and store a new value.
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Repeat steps nine and ten. Program the Intermediate Height (Dedicated Entry model, only) CAUTION Ricon recommends that stow height be programmed before intermediate height. NOTE: This procedure may require use of manual back-up pump to raise platform because the /UP button (on pendant) may be disabled. The /DOWN button can be used to lower platform.
NOTE: After the OUT switch is pressed three times, there is a time period of 5 minutes during which the programming switch is enabled. Programming will be disabled if any other switch is used during this period. Verify that programmed intermediate position is correct by stowing platform, then deploying and raising it to intermediate height.
Lifts that are installed for the first time in a new application, or installations carried out by technicians with limited experience, must be checked by a representative of Ricon Applications Engineering. The check is based on the items listed on Ricon document 32EIVF9T (Equipment Installation Verification checklist for F9T).
Ricon Mirage F9T Transit Use Wheelchair and Standee Lift is essential for optimum performance, and will reduce the need for repairs. This chapter contains a maintenance schedule, plus electrical and hydraulic diagrams. This Ricon product is highly specialized. maintenance and repair work must be performed by a Ricon authorized service technician, using Ricon replacement parts.
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Dedicated Entry – Stepwell Dedicated Entry touring (exposed to environment) (protected from environment) (high mileage; low usage) Normal Normal Normal usage usage usage (0 – 115 (116 – 230 (116 – 230 (0 – 115 (116 – 230 (0 – 115 cycles) cycles per month) cycles per month)
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Dedicated Entry – Stepwell Dedicated Entry touring (exposed to environment) (protected from environment) (high mileage; low usage) Normal High Normal High Normal High usage usage usage usage usage usage (116 – 230 (231+ cycles (116 – 230 (231+ cycles (116 – 230 (231+ cycles cycles) per month)
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Checked safety issues require repairing before vehicle is returned to service. Zep Formula 50 R.T.U, part #599A or equivalent; (use to clean decals and platform) Zep I.D. Red, part #399C or equivalent; (use to clean carriage assembly) Zep PLS, part #497C or equivalent; (use to lubricate carriage assembly) Platform is clean.
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Inspect four guide rollers, and lube with Zep PLS. Inspect primary and secondary drive chains. Adjust, if needed. Lube with Zep PLS lubricating spray. Check hydraulic cylinder for leaks; spray trunnion and center pivot pin with Zep PLS lubricating spray. Spray eight pins on lifting frame with Zep PLS lubricating spray.
Reference is made in the troubleshooting chart to connector pins located on harness connectors and components. Re- fer to the Wheelchair Lift Electrical Wiring Diagram in Figures 2-11 and 2-12 for identification and location of these com- ponents and connectors. Figures referenced in the troubleshooting chart are located either in this chapter or other chapters in this man- ual.
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Controller Check for 24 vdc at pin 18 of P2 with If voltage is present, replace control- failure. Down button pressed. ler. Debris in hydraulic Open manual release valve. If platform lowers with valve open, system. flush hydraulic system. Platform Hydraulic quick- Verify that quick-disconnect connector If loose, remake connection.
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Down valve failure. Check for 24 vdc at terminal 4 on TS1 If voltage is not present, replace (located in pump enclosure). down valve (or replace entire hydraulic pump assembly). Debris in hydraulic Look for fluid returning to pump reser- If fluid is seen, flush hydraulic system.
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Black Blue Violet Brown Gray Green White Orange Yellow Word logic signal to bus BIT 0 BIT 1 Word logic signal to bus Stow switch #2 normally open Stow switch #2 common Cycle counter signal Door open signal from bus Door closed signal from bus DWNA Signal from control pendant requesting a DOWN operation...
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MOMENTARY PUSH-BUTTON SWITCH CONTACTOR RELAY SWITCH CONTACTS: CIRCUIT - COMMON BREAKER - NORMALLY CLOSED - NORMALLY OPEN SPDT TOGGLE SWITCH DIODE HARNESS CONNECTOR SPDT LIMIT SWITCH L E D ELECTRIC MOTOR HYDRAULIC VALVE CRIMP SPLICE Refer to the following four pages for Dedicated Entry and Stepwell model electrical schematics. The schematic for each model is divided across two pages.
RICON Mirage F9T Series Transit Use Wheelchair and Standee Lift. Maintain the lift at its highest level of performance by doing the required maintenance. Ricon recommends a thorough inspection every six months.
LIFT ACCESS FOR SERVICE Access to internal lift components is from beneath the enclosure. A hinged access panel is located on the bottom of the enclosure, near the front. Deploy platform using control pendant ( /OUT), and support. WARNING •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BATTERIES CONTAIN ACID THAT CAN BURN.
TRAVELLING FRAME AND ROLLSTOP The carriage, lifting frame, and platform are referred to as a “travelling frame” when assembled together. PLATFORM LIFTING FRAME CARRIAGE FIGURE 4-2: TRAVELLING FRAME ROLLSTOP MAINTENANCE Rollstop Lubrication Deploy platform using control pendant ( /OUT), and then support. WARNING! ••...
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CAUTION! The manual rollstop control knob is made from a brittle material. Handle accordingly. Use a 1/8" punch to remove retaining pin from manual rollstop control knob. Remove con- trol knob. Remove right rollstop actuator bracket and left rollstop release bracket. Refer to Figure 4-4.
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Refer to Figure 4-6. Loosen jam-nut and adjust the link length by turning the center sec- tion. Adjust link so that rollstop closes to within 1/32" of rubber bumper (that rollstop con- tacts). Rotating the center section counterclockwise (viewed from rollstop) shortens the link, and turning it clockwise lengthens it.
BRIDGEPLATE MAINTENANCE Bridgeplate Lubrication Deploy platform using control pendant ( /OUT), and support. WARNING! •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BAT- TERIES CONTAIN ACID THAT CAN BURN. IF ACID COMES INTO CONTACT WITH SKIN, IMMEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP.
CARRIAGE MAINTENANCE Refer to Figure 4-10. There are two large carriage rollers on each side of the carriage, and four small guide rollers on the top. These rollers require lubrication on a periodic basis, dependant upon usage and climate. Refer to the appropriate Mechanic Maintenance Checklist in the Maintenance chapter. The large side rollers carry the weight of the travelling frame.
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Raise platform to vehicle floor height using control pendant ( /UP), and then support. WARNING! •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BAT- TERIES CONTAIN ACID THAT CAN BURN. IF ACID COMES INTO CONTACT WITH SKIN, IMMEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP.
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Refer to Figure 4-13. Remove bottom platform mounting pins from platform mounting brackets, and drop lower parallel arms. NOTE: The platform mounting pins can be removed by placing a small pry bar between the outside of platform and inner end of pin. Push pin outward until it is flush with bracket, and then grasp other end of pin and pull it out.
LIFTING FRAME REMOVAL Refer to end of this section for re-installation notes. Refer to the Platform Removal section and remove platform. Raise lifting frame as far as possible with manual backup pump. Refer to Figure 4-14. Remove four setscrews securing lifting frame pivot pins. Remove two setscrews securing center pivot pin.
CARRIAGE REMOVAL The following procedure describes removal of carriage after platform and lifting frame have been re- moved. The carriage, lifting frame, and platform are referred to as a “travelling frame”, when assembled to- gether (Refer to Figure 4-2). The travelling frame can be removed from enclosure as a unit. Be pre- pared to handle the combined weight of the carriage, lifting frame, and platform when removing and in- stalling.
Disconnect main electrical harness connector from electronic controller. Position a support stand in front of enclosure to place carriage on. WARNING! THE CARRIAGE ASSEMBLY IS HEAVY AND REQUIRES TWO PEOPLE TO REMOVE. Pull carriage out of enclosure, supporting each side, and place on support stand. NOTE: Care is required while extracting carriage to avoid damage.
IN/OUT MOTOR AND GEARBOX The in/out motor drives the deployment system. The motor receives electric power from the on-board electronic controller; voltage polarity determines the direction of motor rotation (which determines whether platform is deployed or stowed). The motor drives the gearbox, reducing the motor speed and increasing torque.
Raise service access panel, and install two retaining screws and lock-nuts at front edge of panel. Reconnect positive battery cable at vehicle battery compartment. DRIVE CHAINS The drive chains transfer power from gearmotor to final driveshaft. Power is transferred through pri- mary drive chain to torque limiting clutch (mounted on an intermediate shaft), and then to secondary drive chain.
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WARNING! •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BAT- TERIES CONTAIN ACID THAT CAN BURN. IF ACID COMES INTO CONTACT WITH SKIN, IMMEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP. •• WORK IN A PROPERLY VENTILATED AREA. DO NOT SMOKE OR USE AN OPEN FLAME IN THE VICINITY OF BATTERY.
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DRIVE CHAIN ADJUSTMENT NOTE: Adjust final drive chain first when adjusting both drive chains. The primary drive chain ad- justment is dependent on setting of final drive chain. Final Drive Chain Refer to LIFT SERVICE ACCESS section to deploy platform and open service access panel.
Raise service access panel, and install two retaining screws and lock-nuts at front edge of panel. Reconnect positive battery cable at vehicle battery compartment. TORQUE LIMITING CLUTCH The torque limiting clutch prevents stalling of deployment motor when traveling frame reaches either end of its movement.
Rotate intermediate shaft until clutch slips. Maximum torque occurs at point where clutch first begins to slip. Breakaway must occur between 24–28 ft-lbs. ADJUST: Refer to Figure 4-19. Do the following, if clutch adjustment is necessary: JAM NUT INCREASE ADJUSTING NUT FIGURE 4-19: TORQUE LIMITING CLUTCH ADJUSTMENT Loosen 15/16"...
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Intermediate Shaft and Final Driveshaft Installation INTERMEDIATE SHAFT– NOTE: Refer to Intermediate Shaft Removal section if an intermediate shaft is present. Press new bushings into intermediate shaft support, if necessary. Bearing flange is on out- side of support. Slide intermediate shaft sprocket onto intermediate shaft. Align hole in sprocket hub with corresponding hole in intermediate shaft.
MANUAL PLATFORM RELEASE MECHANISM Refer to Figure 4-20. The travelling frame (carriage, lifting frame, and platform) can be manually dis- engaged from the enclosure by rotating either platform release shaft. Each release shaft has an ec- centric cam that bears against a roller on the driveshaft. Rotating a release shaft pushes the final driveshaft downward (against the force of an engagement spring), disengaging each driveshaft pinion gear from its gear rack (mounted to the inside of the enclosure).
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Release Switch Adjustment A limit switch is mounted below one driveshaft support arm, and detects the position of the arm. It is adjusted to change states when the pinion gears disengage. NOTE: Refer to Electrical Controls section if replacement of switch is necessary. CHECK: Refer to LIFT SERVICE ACCESS section to deploy platform and open service access panel.
HYDRAULIC POWER SYSTEM Refer to Figure 4-22. The major components of hydraulic system are an electric motor, a gear pump, a hy- draulic cylinder, control valves, and a manual back-up pump. ELECTRIC MOTOR BACK-UP PUMP GEAR PUMP CYLINDER (removed) FIGURE 4-22: HYDRAULIC SYSTEM COMPONENTS SYSTEM FLUID RENEWAL Deploy platform using control pendant ( /OUT).
ELECTRIC PUMP MOTOR Electric Pump Motor Removal Deploy platform using control pendant ( /OUT), and then support. WARNING! •• WEAR PROTECTIVE CLOTHING AND EYE PROTECTION AT ALL TIMES. BAT- TERIES CONTAIN ACID THAT CAN BURN. IF ACID COMES INTO CONTACT WITH SKIN, IMMEDIATELY FLUSH AFFECTED AREA WITH WATER AND WASH WITH SOAP.
HYDRAULIC CYLINDER Hydraulic Cylinder Removal Deploy platform using control pendant ( /OUT). Raise platform to a comfortable working height and then support. WARNING! THE SERVICE ACCESS PANEL IS HINGED ALONG THE REAR EDGE AND SHOULD BE HELD UP WHILE REMOVING THE RETAINING SCREWS AT THE FRONT EDGE. THIS WILL PREVENT PANEL FROM FALLING AND CAUSING INJURY OR DAMAGE To gain access to underside of lift, hold service access panel up, remove two retaining screws and lock-nuts from front edge of panel, and lower panel.
Remove pivot plug from left-side of cylinder; this will release cylinder from carriage. Carefully remove cylinder and trunnion assembly from carriage. Remove two bushings from carriage frame. Loosen jam nut (located behind trunnion), and remove trunnion. Hydraulic Cylinder Installation NOTE: This procedure assumes that hydraulic cylinder has been removed.
HYDRAULIC HOSE AND MAIN ELECTRICAL HARNESS A single flexible conduit, containing both a hydraulic hose and an electrical harness, is routed inside the enclosure. It is routed between the pull box and carriage. The hydraulic hose is part of a line that con- nects the hydraulic pump (located in pump box) to the hydraulic cylinder (platform lifting cylinder).
Place a 1" length of ¼” shrinkable tubing around each switch wire if you are going to solder the new connections. Slide tubing away from end of wire. Connect each harness lead to appropriate lead on replacement switch. [Contact Ricon Product Support if replacement switch leads are a different color than switch being replaced.] The leads can be joined with crimp-on butt connectors, or soldered.
Slide controller mounting loop off of other bracket and remove controller from carriage. Position replacement controller inside carriage. Slide loop on top of housing onto mounting bracket tab. Re-install two Phillips screws. Connect three harness connectors to controller; tighten connectors securely. NOTE: Each connector is uniquely keyed, and cannot be intermixed.
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-This page intentionally left blank- -BACK TO PREVIOUS CHAPTER- -GO TO NEXT CHAPTER- 4 - 30 32DF9T02.C...
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RICON Mirage F9T Transit Use Wheelchair Lift. Spare parts for both the Dedicated Entry model (DE) and the Stepwell model (SW) are included. Each exploded view of a major lift assembly shows smaller assemblies, components, and kits referenced with numbers. The ac- companying parts list has the part reference number, a part description, the quantity required for one major assembly, and the Ricon part number.
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HANDRAIL ASSY (F9T-SG001 left & right) 22530 HANDRAIL ASSY, LEFT HAND (F9T-SG002, F9T-SG004) 23065 HANDRAIL ASSY, SLOPED, LEFT HAND (F9T-SG005) F9-0459 Handrail styles are continually developing. Contact Ricon Product Support to verify the correct handrail for your ap- plication. 32DF9T02.C...
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