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Ascension VIRTUOSO 5460P Series Maintenance And Repair Manual

Portable wheelchair lift
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ASCENSION VIRTUOSO
PORTABLE WHEELCHAIR LIFT
5460P MODEL SERIES
MAINTENANCE & REPAIR
MANUAL
Patented – see www.wheelchairlift.com/patents

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Summary of Contents for Ascension VIRTUOSO 5460P Series

  • Page 1 ASCENSION VIRTUOSO PORTABLE WHEELCHAIR LIFT 5460P MODEL SERIES MAINTENANCE & REPAIR MANUAL Patented – see www.wheelchairlift.com/patents...
  • Page 2 ASCENSION VIRTUOSO PORTABLE WHEELCHAIR LIFT 5460P MODEL SERIES MAINTENANCE & REPAIR MANUAL...
  • Page 3 Copyright © 2014 Ascension, A Division of AGM, Tucson, Arizona This document, or parts thereof, may not be reproduced in any form, by any method, for any purpose, without written permission of Ascension.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ......................1 About This Manual ....................... 1 Additional Information ....................2 Getting Help ......................... 2 Contacting Ascension ....................2 SECTION 1: Terminology ....................3 SECTION 2: Routine Maintenance................. 5 Hydraulic System ....................5 Cleaning ......................5 SECTION 3: Mechanical Disassembly and Repair............
  • Page 5 Testing the Power Supply ................42 Testing the Power Relay ................. 43 SECTION 5: Lift Compression/Expansion ..............44 Compressing the Lift ..................45 Expanding the Lift ................... 49 Verification of Operation ................. 55 SECTION 6: Troubleshooting ..................56...

  • Page 6: Introduction

    INTRODUCTION The purpose of this manual is to provide the necessary information to perform maintenance and repairs on the Ascension VIRTUOSO portable wheelchair lift. This manual is intended to be used by skilled technicians who have experience working on electro-mechanical systems and devices. Furthermore, these personnel should be well- versed in standard industrial safety practices and procedures.

  • Page 7: Additional Information

    Also, it is recommended that you contact Ascension while in the immediate vicinity of your lift, as this will reduce the time required to properly diagnose the problem.

  • Page 8: Section 1: Terminology

    Maintenance & Repair Manual SECTION 1 VIRTUOSO 5460P SECTION 1: Terminology To effectively use this manual, you need to be familiar with the following terms. Refer to the figure on the following page for identification of components. Not all components are shown in the figure.
  • Page 9 Maintenance & Repair Manual SECTION 1 VIRTUOSO 5460P 110057 REV K...

  • Page 10: Section 2: Routine Maintenance

    Maintenance & Repair Manual SECTION 2 VIRTUOSO 5460P SECTION 2: Routine Maintenance Hydraulic System The fluid level of the hydraulic system should be checked every six months. Before checking the fluid level, make sure the lift car is at ground level (i.e., at the lower landing) and off its casters.

  • Page 11: Section 3: Mechanical Disassembly And Repair

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P SECTION 3: Mechanical Disassembly and Repair Important Preliminary Information The repairs in this section are to be performed by a skilled technician who has experience working on electro-mechanical systems. Furthermore, the technician should be well-versed in standard industrial safety practices and procedures.
  • Page 12 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 2. Plug the power cord into a wall outlet with 120 VAC power. 3. Press "Reset" on the GFCI if necessary. 4. Turn the lift on. 110057 REV K...

  • Page 13: Opening The Machinery Cabinets From The Top

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Opening the Machinery Cabinets from the Top For some of the repairs described in this manual, it is necessary to gain access to a machinery cabinet from the top. The top of either machinery cabinet can be removed by performing the following steps: 1.

  • Page 14: Retracting, Removing, And Reinstalling The Safety Skirt

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Retracting, Removing, and Reinstalling the Safety Skirt The safety skirt consists of two parts: the lift car skirt, which guards the lift car on three sides; and the gate skirt, which guards the area under the lower landing gate. For some of the repairs described in this manual, it is necessary to gain access to components normally hidden behind the skirt.
  • Page 15 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Use a Phillips screwdriver to remove the three (3) screws that secure the skirt to the lower landing gate. Use a 5/32" hex key to remove the two (2) button head cap screws and washers that secure the skirt guide tubes to the skirt base.
  • Page 16 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 6. Push the ball bearing slide releases toward the right side of the lift and then pull downward on the skirt guard to separate it from the lift car. 7. At the front of the skirt, use pliers or a similar tool to turn the skirt guide tubes counterclockwise until they release from the studs in the base.
  • Page 17 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P possible while moving it. A minimum of two (2) people is recommended for moving the skirt. To reinstall the lift car skirt, perform the following steps in the order indicated. necessary, refer to the figures in the skirt removal instructions above for identification of skirt components.
  • Page 18 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 5. Lift the skirt upward on both sides of the skirt guard until the skirt slips past the restraining tabs on the ball bearing slides as shown in the figure below. restraining tab must catch the skirt on the 5th panel down from the top of the skirt. 110057 REV K...
  • Page 19 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 6. Use a Phillips screwdriver to reinstall two (2) or three (3) pan head screws on each side of the lift car to secure the top of the skirt loosely to the lift car. 7.

  • Page 20: Lower Landing Gate Closer

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Lower Landing Gate Closer To make the lower landing gate close faster, turn the gate closer counterclockwise, 1/2 rotation at a time. To make the lower landing gate close slower, turn the gate closer clockwise, 1/2 rotation at a time. See the figure below.

  • Page 21: Upper Lock Rollers

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Upper Lock Rollers To adjust or replace the upper lock rollers, perform the following steps. Refer to the figure as necessary for identification of items referenced below. 1. With the lift car on the ground, retract the upper left corner of the lift car skirt until the upper lock rollers can be accessed.
  • Page 22 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P b. the locking rod is fully engaged between the rollers before the lift car has moved more than 2 inches away from the lower landing, and the sensing switch is actuated; c. when the locking rod is fully engaged, it cannot move vertically between the rollers more than 1/8";...

  • Page 23: Lower Lock Rollers

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Lower Lock Rollers To adjust or replace the lower lock rollers, perform the following steps. Refer to the figure as necessary for identification of items referenced below. CAUTION! Stay clear of the front edge of the lift car floor while operating the lift in the "TRANSPORT"...
  • Page 24 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P standard screwdriver to keep the roller from rotating while the nut is being turned. The rollers should be adjusted so that the following conditions are met: a. the locking rod is thrown smoothly between the rollers when the lift car rises off the ground, without jarring or hesitation;...

  • Page 25: Upper Stop Mechanism

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Upper Stop Mechanism The upper stop mechanism sets the height at which the lift car stops at the upper landing. This section describes the procedures for adjusting the upper stop mechanism in the case that it has come out of adjustment. If you are only looking for instructions on setting up the lift to stop at the correct height, refer to the section titled "Setup Instructions"...
  • Page 26 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P The upper stop mechanism has four (4) adjustable components: the transport switch, the stop switch, the two-inch switch, and the ball plunger. See the figure on the previous page for identification of these components. These four (4) components must be adjusted so that the following four (4) conditions are met: 1.

  • Page 27: Lower Landing Gate Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Lower Landing Gate Switch The lower landing gate switch senses whether the lower landing gate is open or closed. The switch is located on the lift car at the hinge side of the gate, about 12" from the lift car floor.
  • Page 28 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P You will need to access the back of the switch in order to adjust, test, or replace it. To do so, retract the right front corner of the lift car skirt away from the lift car. If necessary, see Section 3.4 for instructions on retracting the skirt.

  • Page 29: Upper Landing Gate Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.10 Upper Landing Gate Switch The upper landing gate switch senses whether the upper landing gate is open or closed. The switch is located on the lift car at the hinge side of the gate, about 12" from the lift car floor.

  • Page 30: Locking Rod Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.11 Locking Rod Switch The locking rod switch senses whether the lower landing gate has been locked by the locking rod; the locking rod must lock the gate before the lift car has moved 2" off the ground, or the lift car will stop.

  • Page 31: Operating Stations

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.12 Operating Stations The operating stations house the UP/DOWN rocker switches and, on the station inside the lift car, the emergency stop button. To test or remove either of these switches, use a Phillips screwdriver to remove the two (2) screws that secure the switch plate to the lift car and pull the plate away from the lift car.

  • Page 32: Override Keyswitch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.13 Override Keyswitch The override keyswitch is used in conjunction with an operating switch to raise or lower the lift car when installing or removing the casters. The switch is of the "OFF- Momentary ON"...

  • Page 33: Hydraulic Valves

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.14 Hydraulic Valves The hydraulic valves are located inside the right-hand machinery cabinet, and can be accessed through the outer access panel or through the top of the machinery cabinet. See Section 3.3 for instructions on opening the machinery cabinet from the top. Refer to the following instructions for adjusting or removing any of the four components located in the manifold.
  • Page 34 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P and pull the coil off the valve. Finally, use a 7/8" wrench to remove the valve from the manifold. When reinstalling the directional valve, torque it to 18.5-22.0 ft-lbs. • Hand Pump: The hand pump cannot be adjusted. The hand pump can be removed while the lift car is not at the lower landing provided that the counterbalance valve is working correctly.

  • Page 35: Windows

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.15 Windows The windows on the lift are pinched in the channel of a glazing strip which is attached to the lift frame with screws. See the figure below. To remove a window, remove each of the screws attaching the four glazing strips to the lift’s exterior.

  • Page 36: Skirt Guard

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.16 Skirt Guard The skirt guard is located on the upper landing side of the lift car, below the gate. The skirt guard blocks the dock plate from deploying when the lift car is at the lower landing, but slides out of the way as the lift car moves away from the lower landing.
  • Page 37 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 7. Use a 3/32 hex key to remove the two (2) 8-32 x 3/16 button head cap screws that secure the ball bearing slide rails to the skirt guard. The guard can now be freed from the safety skirt.
  • Page 38 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 6. Lift the skirt upward on both sides of the skirt guard until the skirt slips past the restraining tabs on the ball bearing slides as shown in the figure below. restraining tab must catch the skirt on the 5th panel down from the top of the skirt. 110057 REV K...
  • Page 39 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 7. Use a Phillips screwdriver to reinstall two (2) or three (3) pan head screws on each side of the lift car to secure the top of the skirt loosely to the lift car. 8.
  • Page 40 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3. Use a Phillips screwdriver to remove the two (2) 8-18 x 3/8 self-tapping pan head screws that are now accessible. You may need to shift the position of the movable portion of the ball bearing slide to expose the screws. Be sure to catch the screws as they are removed.

  • Page 41: Section 4: Electrical Testing

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P SECTION 4: Electrical Testing This section contains information that will enable a skilled and experienced electrician to service the lift. The logic diagram for the lift is shown on the following page. CAUTION! When working on any part of the electrical system, industrial electrical safety practices should be rigorously adhered to, including:...
  • Page 42 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P 110057 REV K...

  • Page 43: Access To The Electrical Panel

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Access to the Electrical Panel The electrical panel can be accessed through both access panels in the left-hand machinery cabinet. If additional access space is needed, the top of the left-hand machinery cabinet can be removed (refer to Section 3.3 for instructions). Refer to the figure below for identification of the major components on the electrical panel.

  • Page 44: Testing The Switches

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Switches Each of the lift's switches can be tested by locating the switch, removing the switch from the lift if necessary, and checking for continuity across the contacts on the back of the switch.
  • Page 45 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Component Relay Circuit is closed when: Circuit is open when: Module Contacts Transport Switch I6-L+ Height adjustment knob is Height adjustment knob is and Override in transport location and not in transport location Keyswitch override keyswitch is and override keyswitch is...

  • Page 46: Testing The Relay Module

    4. The power supply is not supplying 12 VDC. Refer to Section 4.4 to check it. 5. There has been a wiring harness or connector failure. See the Electrical Diagram on page 37 to continue troubleshooting, or contact Ascension. 110057 REV K...

  • Page 47: Testing The Power Supply

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Power Supply The power supply is located on the inner electrical panel. See Section 4.1. To gain access to the power supply, use a Phillips screwdriver to remove the four (4) #8 x 3/8 screws shown and then pull the outer electrical panel out of the way.

  • Page 48: Testing The Power Relay

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Power Relay The power relay is located on the outer electrical panel. See Section 4.1. Visually inspect the power relay for black scorch marks, particularly near the motor wires at contacts "1" and "2." If there are any such marks, replace the power relay. The lift must be plugged in and turned on to perform the following tests.

  • Page 49: Section 5: Lift Compression/Expansion

    This section describes the procedures for compressing the lift and then expanding it again. A toolkit is available for purchase from Ascension that contains several of the tools required for the process; however, the owning facility may use its own tools in place of the kit if desired.

  • Page 50: Compressing The Lift

    Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Compressing the Lift To compress the lift, complete the following steps in the order listed. Boxed step numbers correspond to boxed numbers in the referenced figures. WARNING! NEVER place your head or torso under any part of the lift car. CAUTION! Wear safety glasses at all times while performing the following procedures.
  • Page 51 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.1 (Upper Landing Gate View) Fold both floor sections up and secure them together in the raised position using duct tape or a similar method. CAUTION! In the following step, stay clear of the lift car when it is moving to avoid any pinching and/or crushing hazards.
  • Page 52 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.2 (Lower Landing Gate View) (Refer to Figure 5.2) Install two (2) welding clamps or C-clamps in the location shown. These clamps should hold the vertical rails together securely. (Refer to Figures 5.1 & 5.2) Use a 3/16" hex key to remove the eight (8) button head screws from the back base cross members.
  • Page 53 Or, if necessary, the straps provided with the Ascension Toolkit can be used, installed in the holes at the locations shown and routed underneath the lift car. See Figure 5.6 on page 54 for instructions on operating the strap buckle.

  • Page 54: Expanding The Lift

    Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Expanding the Lift To expand the lift, complete the following steps in the order listed. Boxed step numbers correspond to boxed numbers in the referenced figures. WARNING! NEVER place your head or torso under any part of the lift car. CAUTION! Wear safety glasses at all times while performing the following procedures.
  • Page 55 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.3 (Lower Landing Gate View) (Refer to Figure 5.3) Tighten the ten (10) 3/8-16 x 3/4" hex cap screws which fasten the floor members together. Take special care to align the scored lines on the top of the smaller lift car floor members with the edges of the larger lift car floor members before tightening these screws.
  • Page 56 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.4 (Upper Landing Gate View) (Refer to Figure 5.4) Thread the following fasteners into the back base cross members in the locations shown: 9.1 one (1) 5/16-18 x 5/8 button head screw 9.2 two (2) 5/16-18 x 1/2 button head screws Tighten the screws and then back them off one (1) full turn counterclockwise.
  • Page 57 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Tighten the screws and then back them off one (1) full turn counterclockwise. You may need to use a hammer or pry bar to align the holes in the cross members (refer to figure 5.5). Figure 5.5 (Upper Landing Gate View) 11.
  • Page 58 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P 14. (Refer to Figure 5.4) Use a 3/16" hex key to turn the four (4) adjustment screws (two (2) on each side) at the back of the lift car exactly three (3) full rotations clockwise.
  • Page 59 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Ratchet buckle instructions for the straps supplied with the Ascension Toolkit Figure 5.6 110057 REV K...

  • Page 60: Verification Of Operation

    If any of the above conditions is not met, and the problem cannot be corrected by reviewing or repeating the reassembly steps, contact Ascension immediately. 110057 REV K...

  • Page 61: Section 6: Troubleshooting

    Maintenance & Repair Manual SECTION 6 VIRTUOSO 5460P SECTION 6: Troubleshooting The table below presents the necessary information to perform basic troubleshooting on the lift. The numbers in the Section column refer to sections within this manual. For the sake of completeness, many of the items in this table are of a setup and operational nature and are not specifically addressed in this manual.
  • Page 62 Maintenance & Repair Manual SECTION 6 VIRTUOSO 5460P Basic Troubleshooting Steps Problem Possible Cause Remedy Section Two-inch switch out of Adjust two-inch switch adjustment Lift car will not go Lift is in transport mode Set the upper height more than 10" off knob properly per the the ground Operating Manual...
  • Page 63 Printed in the U.S.A. 110057 REV K...

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