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Ascension VIRTUOSO 5460P Series Maintenance & Repair Manual

Portable wheelchair lift
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ASCENSION VIRTUOSO
PORTABLE WHEELCHAIR LIFT
5460P MODEL SERIES
MAINTENANCE & REPAIR
MANUAL
Patented – see www.ascension-lift.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.ascension-lift.com/patents...
  • Page 3 ASCENSION VIRTUOSO PORTABLE WHEELCHAIR LIFT 5460P MODEL SERIES MAINTENANCE & REPAIR MANUAL...
  • Page 4 Copyright © 2023 Ascension, a Division of AGM, Tucson, Arizona http://ascension-lift.com 1-800-459-0400 This document, or parts thereof, may not be reproduced in any form, by any method, for any purpose, without written permission from Ascension.

  • Page 5: 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 SECTION 3 Mechanical Disassembly and Repair ............
  • Page 6 3.21 Electrical Cord ....................39 SECTION 4 Electrical Testing ..................40 Control Panel ....................44 Testing the Switches ..................45 Testing the Relay Module ................47 Testing the Power Supply ................48 Testing the Power Relays ................49 SECTION 5 Lift Compression/Expansion ..............

  • Page 7: 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 8: 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 9: 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 10 Maintenance & Repair Manual SECTION 1 VIRTUOSO 5460P 110057 REV N...

  • Page 11: 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. Verify that the hydraulic fluid in the reservoir (behind right-side access panels) is between the minimum and maximum levels when the platform is at the lower landing.

  • Page 12: 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 in working on electro-mechanical systems. Furthermore, the technician should be well-versed in standard industrial safety practices and procedures.

  • 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 platform skirt, which guards the platform on three sides; and the gate skirt, which guards the area under the lower platform 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 Platform Skirt: To remove the platform skirt, perform the following steps. Also see Virtuoso Compression Video from the Ascension website which includes skirt removal. Performing steps 2 & 3 will provide access behind the skirt without fully removing it. 1. With the platform about 15" [380 mm] off the ground, remove the (32) T25 Torx tamper-resistant head screws that secure the sides of the skirt to the platform at the top and to the lift base at the bottom.
  • Page 16 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 6. Push the ball bearing slide release levers toward the right side of the lift and then pull downward on the skirt guard to separate it from the platform. 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 To reinstall the platform skirt, perform the following steps. Also see Virtuoso Compression Video from the Ascension website which includes skirt reinstallation. If necessary, refer to the figures in the skirt removal instructions above for identification of skirt components. CAUTION! In the following step, stay clear of the platform when it is moving to avoid any pinching and/or crushing hazards.
  • Page 18 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 4. 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 7th panel down from the top of the skirt. 110057 REV N...
  • Page 19 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 5. Reinstall two (2) or three (3) T25 Torx tamper-resistant head screws on each side of the platform to secure the top of the skirt loosely to the platform. 6. Use a 5/16" combination wrench to reinstall the four (4) hex head screws that secure the top of the skirt to the platform, one (1) at each corner.

  • Page 20: Platform Gate Closers

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Platform Gate Closers To make a platform gate close faster, turn the gate closer counterclockwise, 1/2 rotation at a time. To make a platform gate close slower, turn the gate closer clockwise, 1/2 rotation at a time.

  • Page 21: Upper And Lower Terminal Switches & Transport Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Upper and Lower Terminal Switches & Transport Switch The upper stop mechanism serves a few different functions, but gets its name since its main purpose is to stop the platform at the upper landing. The upper stop mechanism is located in the left-hand machinery cabinet and contains the upper terminal switch, the ball plunger, the lower terminal switch, and the transport switch.
  • Page 22 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Lower Terminal Switch: When this normally open (NO) switch is actuated, it allows the motor to fully engage/disengage the lower platform gate lock, functioning as a bypass to the locking rod switch (Section 3.9). Accordingly, the lower terminal switch is factory-set to be actuated when the platform is within 2”...

  • Page 23: Lower Platform Gate Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Lower Platform Gate Switch The lower platform gate switch senses whether the lower platform gate is open or closed. The switch is located on the platform at the hinge side of the gate, about 12" [305 mm] from the floor.
  • Page 24 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 upper front corner of the platform skirt away from the platform. If necessary, see Section 3.4 for instructions on retracting the skirt.

  • Page 25: Upper Platform Gate Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Upper Platform Gate Switch The upper platform gate switch senses whether the upper platform gate is open or closed. The switch is a refrigerator-style switch located on the hinge-side of the gate. The switch is of the normally open (NO) type.

  • Page 26: Locking Rods And Locking Rod Switch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Locking Rods and Locking Rod Switch The two hydraulically driven locking rods (interlock) extend from the lower platform gate into the platform sides to physically lock the gate during travel. The locking rod switch senses if the top locking rod has successfully engaged and locked the gate.

  • Page 27: Operating Stations

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.10 Operating Stations Operating stations are the controls for raising and lowering the platform. There is an operating station for the lower landing, the platform, and the upper landing. operating station inside the platform has an emergency stop switch. The emergency stop switch immediately stops the lift until it is manually reset.

  • Page 28: Override Keyswitch

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.12 Override Keyswitch The override keyswitch is used in conjunction with the transport switch (Section 3.6) and an operating switch to raise or lower the platform with the lower platform gate open when installing or removing the casters.

  • Page 29: Alarm

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.14 Alarm The lift is equipped with a battery-powered audible alarm that sounds when the emergency stop button is pressed. To test, press the emergency stop button. Reset the emergency stop button to turn off the alarm. If the alarm does not sound when the emergency stop button is pressed, the alarm battery may need to be replaced.

  • Page 30: Skirt Sensor System

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.15 Skirt Sensor System The skirt sensor system halts the motion of the platform when an object or person pushes the safety skirt on the long sides of the lift inward more than 3" [76 mm]. One sensor assembly is located on each of the two hydraulic cylinders and consists of two extension springs that run the length of the hydraulic cylinder and two sensor switches that are actuated by the movement of the springs.
  • Page 31 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P • To shift the position of a sensor switch, loosen the hose clamp that holds it in place, shift the clamp, and then retighten it. • To remove a switch: o Mark the location of the hose clamp on the hydraulic cylinder so it can be put back in the same place.
  • Page 32 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 110057 REV N...

  • Page 33: Hydraulic Valves

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.16 Hydraulic Valves The various hydraulic valves are located inside the right-hand machinery cabinet behind the access panels. For additional access, the top of the machinery cabinet may be removed (see Section 3.3). Refer to the following instructions for adjusting or removing any of the hydraulic valves.
  • Page 34 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Counterbalance Valve: This valve keeps the platform raised when the motor is not running. If the platform "bounces" as it descends while fully loaded, then the adjustment screw on this valve may need to be tightened clockwise a 1/4 turn at a time until the “bouncing”...
  • Page 35 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P Interlock Relief Valve (for Locking Rods): This in-line valve is housed within a long, hexagonal casing. It is located behind the right-hand access panels for lifts with a left- handed lower platform gate and at the back, bottom left corner of the platform for lifts with a right-handed lower platform gate.

  • Page 36: Driving Cylinders

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.17 Driving Cylinders The two double-acting driving cylinders are responsible for physically raising and lowering the platform. The cylinders are in series with the first being the “master” cylinder (right side of lift) and the second being the “slave” (left side of lift). cylinders include bypass ports that allow hydraulic fluid to pass through them when fully retracted to resynchronize the two cylinders with each other such that the platform raises level each cycle.
  • Page 37 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3. Remove the lower hinge bolt that secures the skirt base to the lift base: Loosen the cap head screw in the shaft collar using a 7/64 hex key, and then turn the hinge bolt out with a 7/32 hex key while using a standard screwdriver blade to keep the shaft collar from rotating.
  • Page 38 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 11. Loosely secure the skirt base to the base frame, raising the platform further if necessary. 12. Lower the platform to the lower landing and close the front gate. Cycle the lift vertically 4-5 times so that the locking mechanism fills with oil.

  • Page 39: Windows

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.19 Windows All standard windows are made of high impact strength acrylic sheet. The windows are pinched in the channel of a glazing strip which is attached to the lift frame with screws. See the figure below.

  • Page 40: Skirt Guard

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.20 Skirt Guard The skirt guard is located on the upper landing side of the platform, below the gate. The skirt guard blocks the dock plate from deploying while the lift is fully lowered, but slides out of the way as the platform moves away from the lower landing.
  • Page 41 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 6. Push the ball bearing slide release levers as shown in the figure on the previous page and then pull downward on the skirt guard to separate it from the platform. 7. Remove the three (3) hex head screws that secure the skirt to the skirt guard using a 5/16"...
  • Page 42 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 7. 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 7th panel down from the top of the skirt. 110057 REV N...
  • Page 43 Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 8. Reinstall two (2) or three (3) T25 Torx tamper-resistant head screws on each side of the platform to secure the top of the skirt loosely to the platform. 9. Use a 5/16" combination wrench to reinstall the two (2) hex head screws that secure the skirt and skirt support brackets to the platform, one (1) at each corner.
  • Page 44 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 45: Electrical Cord

    Maintenance & Repair Manual SECTION 3 VIRTUOSO 5460P 3.21 Electrical Cord The power/electrical cord is used to connect the lift to facility power. GFCI: The electrical cord contains a GFCI on the plug. The “Test” button may be used to test the GFCI to make sure it trips and disconnects power to the lift. Press the “Reset” button to restore power to the lift.

  • Page 46: 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 electrical and logic diagrams for the lift is shown on the following pages.
  • Page 47 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P (110057 Rev N ELECTRICAL DIAGRAM.vsd) SIMPLIFIED ELECTRICAL DIAGRAM 110057 REV N...
  • Page 48 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P (110057 Relay module logic.lld) SMART RELAY MODULE LOGIC Notes: The logic diagram above does not include any of the timers or more complicated components of the logic circuit. Rather, it only shows the contacts that must be maintained for the platform to run up or down.
  • Page 49 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P FULL ELECTRICAL DIAGRAM (Contact Ascension for electronic color copy of 5460P full electrical diagram). 110057 REV N...

  • Page 50: Control Panel

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Control 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 51: Testing The Switches

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Switches When troubleshooting the electrical system, it is recommended to begin by testing at the Smart Relay Module to determine the present state of each individual safety circuit. The control system operates on 24 VDC. Before performing any checks at the relay module, verify that the module itself is receiving power (refer to Section 4.3).
  • Page 52 Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Once a given safety circuit has been identified as the problem, the switches and wire connections in that circuit may be tested. Individual switches may be tested for continuity across the switch contacts. Note that the lift should be disconnected from power when testing for continuity.

  • Page 53: Testing The Relay Module

    6. There has been a wiring harness or connector failure. See the Electrical Diagrams at the beginning of SECTION 4 to continue troubleshooting, or contact Ascension. 7. The E-Stop is pushed in and the alarm is active. Reset the E-Stop.

  • Page 54: Testing The Power Supply

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Power Supply The power supply converts the 120 VAC input power from the facility to 24 VDC which † is used to power the entire lift control system. The power supply is located behind the inner electrical panel.

  • Page 55: Testing The Power Relays

    Maintenance & Repair Manual SECTION 4 VIRTUOSO 5460P Testing the Power Relays The power relays connect/disconnect 120 VAC power to the motor to cause the lift to † run/stop. When 24 VDC is applied to the input-side of the relays, the output-side relay contacts close and supply power to the motor.

  • Page 56: 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 57: 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 platform. CAUTION! Wear safety glasses at all times while performing the following procedures.
  • Page 58 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.1 (Upper Landing Platform 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 platform when it is moving to avoid any pinching and/or crushing hazards.
  • Page 59 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.2 (Lower Landing Platform 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 60 The lift can be pushed together manually by gripping at the locations shown. 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 platform. See Figure 5.6 on page 60 for instructions on operating the strap buckle.

  • Page 61: 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 platform. CAUTION! Wear safety glasses at all times while performing the following procedures.
  • Page 62 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.3 (Lower Landing Platform 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 platform floor members with the edges of the larger platform floor members before tightening these screws.
  • Page 63 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.4 (Upper Landing Platform 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 64 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 Platform Gate View) 11.
  • Page 65 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 platform exactly three (3) full rotations clockwise.
  • Page 66 Maintenance & Repair Manual SECTION 5 VIRTUOSO 5460P Figure 5.6 Ratchet buckle instructions (when using Ascension Toolkit) 110057 REV N...

  • Page 67: 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 N...

  • Page 68: 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 69 Maintenance & Repair Manual SECTION 6 VIRTUOSO 5460P Problem Possible Cause Remedy Section Platform will not Lower platform gate locking rod Adjust the upper lock go more than 2" is not engaging rollers [50 mm] off the Locking rod switch failure Test locking rod switch ground &...
  • Page 70 Maintenance & Repair Manual SECTION 6 VIRTUOSO 5460P Notes: 110057 REV N...
  • Page 72 A DIVISION OF AGM Printed in the U.S.A. 110057 REV N...

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