Merits Pilot Service & Installation Manual
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Merits Pilot Service & Installation Manual

Merits Pilot Service & Installation Manual

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E603

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  • Page 1 Service & Installation Manual E603...

  • Page 2: Table Of Contents

    Table of Contents 1. Introduction 1.1. Intended Use ....................1-1 1.2. How to Use Installation and Service Manual ..........1-1 1.3. Safety Rules ....................1-1 1.4. Warranty ......................1-2 2. Installation 2.1. Unpack and verify the shipment ..............2-1 2.2. Determine handing ..................2-3 2.3.
  • Page 3 2.14.Assemble Rail End Covers ................2-21 2.15.Mount Charger and Remote Control Holder ..........2-21 2.16.Check Installation and Lubricate ..............2-21 i t s 3.1. Remote Control Testing .................. 3-1 3.2. Seat Testing ..................... 3-1 3.2.1. Rocker Switch Direction ................ 3-1 3.2.2.
  • Page 4 4.4.10. Key Switch Replacement ..............4-18 4.5. Top Rail Accessories Removal ..............4-19 4.6. Carriage Removal ..................4-19 4.6.1. Rollers Replacement ................4-21 4.6.2. Limit Switches Replacement ............... 4-21 4.7. Rail Removal ....................4-22 5.1. Check List ....................... 5-1 5.1.1. Rail ......................5-1 5.1.2.
  • Page 5 List of Illustrations Figure 2-1 Unpacking Carriage, Seat, and Rails ............2-1 Figure 2-2 Unpacking Seat post/Footrest and Accessories ........2-2 Figure 2-3 The rail is installed on the right side of stairs for the right-hand unit ..2-3 Figure 2-4 The top and bottom side of the rail ............2-3 Figure 2-5 Stair measurement ..................
  • Page 6 Figure 4-1 Dismantling sequence ................4-1 Figure 4-2 Rocker switch replacement ..............4-2 Figure 4-3 Armrest switch replacement ..............4-3 Figure 4-4 Emergency stop button replacement ............4-3 Figure 4-5 Seat removal ..................... 4-4 Figure 4-6 Swivel switch replacement ............... 4-4 Figure 4-7 Top cover removal ..................
  • Page 7 List of Tables Table 1-1 Specification of Stairlift ................1-3 Table 2-1 Top rail extension length ................2-5 Table 6-1 Troubleshooting ..................6-2 Table 6-2 Wiring components list ................6-5 Table 7-1 Tool Kit ...................... 7-1...

  • Page 8: Introduction

    1. Introduction The Stairlift basically consists of four parts: the carriage, the footrest, the seat, and the rail. The stairlift is powered by the rechargeable batteries inside the carriage. There are safety sensors on upper and lower covers and bottom of footrest. These sensors will stop the unit if any obstruction is detected on the rail or stairway.

  • Page 9: Warranty

    1.4.Warranty We warrant the Stairlift to be free from defective workmanship and materials for a period of 1 year from the date of purchase. The rechargeable battery is warranted for 90 days from date of purchase. Check with your dealer for more details.

  • Page 10: Table 1-1 Specification Of Stairlift

    Specifications Table 1-1 Specification of Stairlift Technical Specs: Load Capacity 158kg (350 lbs)@45° or 136kg (300 lbs)@55° 25°~55° Note: According to ASME A18.1, no lift should be Range of Stair Angle installed to operate on a greater incline than 45 deg. as measured on the mean.

  • Page 11: Installation

    2. Installation 2.1. Unpack and verify the shipment Check for any obvious damage to the carton or its contents. If possible, take a picture of any damaged part. Box 1: Carriage Box 3 & 4: Rails and Racks Carriage Box 2: Seat Rack Rails + Racks Seat...

  • Page 12: Figure 2-2 Unpacking Seat Post/Footrest And Accessories

    Box 5: Seat post/Footrest and Accessories Hand crank x 2 Red(+) x 2 Black(-) Rail charging bases Charging cable Rack x 12 Powercord Rail Brackets Seat post/Footrest Grease Cable ties Charger Central spacer plate Splice bars Rail stop cams Central side cover Spacer ring Brackets Charger holder...

  • Page 13: Determine Handing

    2.2. Determine handing Stand at the bottom of the stairway looking upward. A right-hand unit will be installed on the right side of stairs (shown below) Figure 2-3 The rail is installed on the right side of stairs for the right-hand unit 2.3.

  • Page 14: Stairs Measurement

    2.3.1. Stairs Measurement i. Measure the length from the nose of top landing to the floor at the bottom landing. ii. Measure the angle of stairs. Top rail extension Nose to floor Angle Rail length = Nose to floor + Top rail extension Figure 2-5 Stair measurement 2.3.2.

  • Page 15: Connect Rail Sections Together (If Required)

    Table 2-1 Top rail extension length 145mm(5-5/8") 260mm(10-1/4") 170mm(6-5/8") 270mm(10-5/8") 190mm(7-1/2") 280mm(11") 205mm(8-1/8") 285mm(11-1/4") 225mm(8-7/8") 295mm(11-3/4") 240mm(9-1/2") 305mm(12-1/8") 255mm(10") 315mm(12-1/2") 2.4. Connect rail sections together (if required) Place the rail sections end to end on the floor. Connect the rail sections using the splice bars in the accessory box.

  • Page 16: Install Bottom Rail Accessories

    Note Insert T-bolts in the middle rail section before inserting thesplice bars if you are connecting more than two rail sections. 2.5. Install Bottom Rail Accessories Assemble the charging bases of the bottom rail section. The negative ports are always installed on the rack side. Tighten the set screws. Install the limit switch cam on the bottom rail.

  • Page 17: Install Racks On Rail Assembly

    9mm(3/8”) Figure 2-8 Rail bottom distance to the floor Figure 2-9 Install mounting brackets 2.7. Install Racks on Rail Assembly Loose the screws of the rack on the upper rail section and slide down to the lower rail section. Mesh the rack sections together tightly and tighten the screws to secure the rack.

  • Page 18: Install Carriage On Rail

    Figure 2-10 Mesh the rack sections Note Do not remove any of the screws on the racks once the rack is installed. The nuts in the slot will fall down and cannot be tighten again. You will have to remove the complete rack to reinstall the rack screw again if the screw has been removed.

  • Page 19: Figure 2-11 Carriage Gripping Area

    Grip area Grip area Figure 2-11 Carriage gripping area Figure 2-12 Carriage installing direction...

  • Page 20: Engage Carriage Gear With Rack On Rail

    2.8.2. Engage Carriage Gear with Rack on Rail Release the motor brake if required. Use the hand crank to drive the carriage down about 1”. Down Figure 2-13 Drive carriage down by hand crank 2.8.3. Move Carriage Down by Remote Controller Plug the short links of seat and footrest into the seat connector and the footrest cable.

  • Page 21: Install Accessories On Top Rail Section

    2.8.4. Install Accessories on Top Rail Section Assemble the charging bases on the top rail section. The negative ports are always installed on the rack side. Tighten the set screws. Install the limit switch cam on the top rail. Negative(-) Black Positive(+) Figure 2-15 Install accessories on top rail section...

  • Page 22: Install Footrest Assembly

    2.9. Install Footrest Assembly 2.9.1. Check Handing of Footrest Left Handing Right Handing Figure 2-17 Footrest Handing 2.9.2. Switch Handing of Footrest (if required) Remove covers on the footrest. Loosen two nuts and then move the bottom part to the correct side. Tighten the nuts. Figure 2-18 Switch footrest handing 2-12...

  • Page 23: Assemble Footrest

    2.9.3. Assemble Footrest Install the central spacer plate with the welding side toward the carriage.Assemble the footrest and spacer ring. Make sure the C-ring is not caught between the spacer ring and carriage side plate. Adjust the level and tighten with bolts and washers. Figure 2-19 Central spacer plate Figure 2-20 Footrest installation 2-13...

  • Page 24: Plug In Connector To Carriage Footrest Cable

    2.9.4. Plug in Connector to Carriage Footrest Cable Turn off the power and key switch. Remove jumper plug from the carriage footrest cable. Plug in either L or R connector to the carriage footrest cable. Figure 2-21 Footrest connector 2.10. Install Seat Assembly 2.10.1.

  • Page 25: Change Handing Of Armrest (If Required)

    Right-Hand Left-Hand Figure 2-23 Rocker switch wiring for different handing 2.10.2. Change Handing of Armrest (if required) The armrest safety switch must be installed on the downstairs side. Change the armrest safety switch if required. Unscrew the four screws under the armrests. Open the armrest bottom covers.

  • Page 26: Adjust Armrest Width (If Required)

    Figure 2-25Armrest safety switch and plugs 2.10.3. Adjust Armrest Width (if required) Loosen the screws under the seat on the back side. Slide the arm in or out as required and then tighten the screws. Figure 2-26Armrest width adjustment 2-16...

  • Page 27: Adjust Seat Height (If Required)

    2.10.4. Adjust Seat Height (if required) Remove the bolt from the seat post. Move the seat up or down as required and then reinstall the bolt. Figure 2-27 Seat height adjustment 2.10.5. Plug in Seat Control Cable Turn off the power and key switch. Remove jumper plug from the carriage seat connector.

  • Page 28: Secure Seat On Seat Post

    2.10.6. Secure Seat on Seat Post Install the pin and the nylon washer under the seat to secure seat on seat post. Bend one end of pin to lock it. Figure 2-29 Install pin and nylon washer 2.11. Install Covers 2.11.1.

  • Page 29: Install Carriage Side Covers

    2.11.2. Install Carriage Side Covers Install the side covers on the opposite side of footrest. Figure 2-31 Install ca rriage side covers 2.11.3. Install Carriage Rubber Plugs Install the side covers on the opposite side of footrest. Figure 2-32 Carriage rubber plugs 2-19...

  • Page 30: Install Charger

    2.12. Install Charger Determine the charger location (upstairs or downstairs). Insert the wires from the top of the rail. The yellow connector need to be at the same location as the charger. Plug the charging wires into the charging bases. Figure 2-33 Charger and connectors 2.13.

  • Page 31: Assemble Rail End Covers

    2.14. Assemble Rail End Covers Insert the wires into the cavity of rail carefully. Assemble the end covers on top and bottom of rail. Figure 2-35 Assemble rail end cover 2.15. Mount Charger and Remote Control Holder Mount the charger on the wall at upstairs or downstairs. Mount remote control holder on the wall at both upstairs and downstairs.

  • Page 32: Remote Control Testing

    3. Testing The stairlift must be tested to ensure that it is operating correctly after installation or service. 3.1. Remote Control Testing Verify the moving direction of stairlift by pressing the up or down button on the remote control. Check the wiring of motor if the direction is reversed. 3.2.

  • Page 33: Armrest Safety Switch

    3.2.3. Armrest Safety Switch Press the rocker switch on the armrest. Lift the armrest at the downstairs side. The stairlift should stop if the armrest was lifted. The status display indicates . Check the switch inside the armrest if there is any problem.Refer to Figure 2-25 for correct wiring.

  • Page 34: Footrest Testing

    3.3. Footrest Testing 3.3.1. bstacle Detection at Unfolding Move the stairlift in up direction and then push the footrest safety cover in three directions as shown in Figure 3-4. The stairlift stops while pushing in direction “1”. The status display indicates .

  • Page 35: Carriage Testing

    3.4. Carriage Testing 3.4.1. Obstacle Detection Move the stairlift in up direction and then push the obstacle covers as shown in Figure 3-6. The stairlift stops while pushing in direction “1”. The status display indicates . Move the stairlift in down direction and test again. It stops while pushing in direction “2”.

  • Page 36: Dismantling Components

    4. Dismantling Components The stairlift must only be serviced and maintained by trained personnel. Before working on the stairlift ensure that power is switched off and unplug the charger from the household wall outlet. Follow the dismantling procedure in Figure 4-1 to replace the components.

  • Page 37: Armrest Components Replacement

    4.1. Armrest Components Replacement 4.1.1. Rocker Switch Replacement i. Loosen the two screws from the bottom of the armrest and take the cover apart from the armrest. ii. Disconnect the connector of rocker switch. iii. Press the snap features on both side of rocker switch and then push the rocker switch out.

  • Page 38: Emergency Stop Button Replacement (Optional)

    Figure 4-3 Armrest switch replacement 4.1.3. Emergency Stop Button Replacement (optional) i. Loosen the two screws from the bottom of the armrest and take the cover apart from the armrest. ii. Disconnect the connector of emergency stop button. iii. Loosen the nut on the button. iv.

  • Page 39: Seat Removal

    4.2. Seat Removal Remove the pin and the nylon washer under the seat. Disconnect the seat cable from the carriage. Pull the swivel handle and wiggle the seat to pull the seat out from the seat post. Figure 4-5 Seat removal 4.2.1.

  • Page 40: Footrestremoval

    4.3. FootrestRemoval 4.3.1. Top Cover Removal i. Loosen four screws from the footrest. ii. Remove the top cover. Figure 4-7 Top cover removal 4.3.2. Footrest and Seat Post Removal i. Disconnect the footrest cable. ii. Loosen three bolts from the carriage side plate. Figure 4-8 Footrest and seat post removal...

  • Page 41: Footrest Safety Cover Removal

    4.3.3. Footrest Safety Cover Removal i. Loosen two screws from the footrest. ii. Push the cover to the left and then lift the left edge. Figure 4-9 Footrest cover removal 4.3.4. Footrest Obstacle Detecting Switch Removal Switch #1 is the bottom obstacle detecting switch. For right-handing unit, Switch #2 is the up obstacle detecting switch and Switch #3 is the down obstacle detecting switch.

  • Page 42: Footrest Parts Removal

    4.3.5. Footrest Parts Removal i. Remove C-ring on the shaft. ii. Cut off the cable tie. iii. Push the shaft out to separate the parts. Figure 4-11 Footrest parts removal iv. Rotate the spring to remove it from the assembly.. Figure 4-12 Torsion spring removal...

  • Page 43: Footrest Parts Assembly

    4.3.6. Footrest Parts Assembly i. Insert the hook of spring in the slot. Rotate the spring to fit in the footplate. Figure 4-13 Torsion spring assembly ii. Push the shaft through the footplate and the spring. Use a cable tie to fix the footrest cable.

  • Page 44: Figure 4-15 Footrest Parts Removal

    iii. Put the footrest safety cover on the footplate. Push the footrest safety cover to the left against the footplate. iv. Push the footrest safety cover down to lock it. Figure 4-15 Footrest parts removal v. Push the footrest safety cover to the right to align with the nuts. vi.

  • Page 45: Covers Removal

    4.4. Covers R emoval i. Loosen the three screws on the top obstacle sensor cover. ii. Disconnect the IR PCB cable and removethe top obstacle sensor cover. Figure 4-17 Top obstacle sensor cover removal iii. Loosen the three screws on the bottom obstacle sensor cover and remove it. Figure 4-18 Bottom obstacle sensor cover removal 4-10...

  • Page 46: Figure 4-19 Loose Screws On The Side Cover

    iv. Loosen eight screws on left and right side covers. Figure 4-19 Loose screws on the side cover v. Push the left side cover down to release the hook and remove the left side cover. Figure 4-20 Release the hook of side covers 4-11...

  • Page 47: Batteries Replacement

    vi. Disconnect the cables from the control PCB. Remove the right side cover. Figure 4-21 Disconnect cables 4.4.1. Batteries Replacement i. Disconnect the terminals of battery cable. Figure 4-22 Disconnect battery cable 4-12...

  • Page 48: Figure 4-24 Slide The Batteries Out

    ii. Loosen the battery strap. Figure 4-23 Loosen the battery strap iii. Slide the batteries out. Figure 4-24 Slide the batteries out 4-13...

  • Page 49: Control Pcb Replacement

    iv. Replace the batteries and reconnect the cables. Follow the labels on the batteries and cables to plug the terminals. Attach the foam blocks on the new battery. v. Install new batteries and plug the terminals on the control PCB. Figure 4-25 Battery cables WARNING DO NOT short the battery terminals.

  • Page 50: Dc Motor Brushes Replacement

    4.4.3. DC Motor Brushes Replacement i. Remove batteries and control PCB. ii. Open the cap and replace the brush. Another brush is on the battery side. Figure 4-27 DC Motor brushes replacement 4.4.4. Fuse Replacement i. Open the fuse holder and take out the fuse. ii.

  • Page 51: Charging Pins Replacement

    4.4.5. Charging Pins Replacement i. Loosen the screws on the charging pin cover. There is another pin on the opposite side of carriage. ii. Loosen the nut and replace the charging pin. Figure 4-29 Charging pin replacement 4.4.6. Obstacle Switch Replacement i.

  • Page 52: Power Switch Replacement

    4.4.7. Power Switch Replacement i. Loosen the screws on the power switch and remove cables. ii. Press the snap features on both side of power switch and then push the switch out. Figure 4-31 Power switch removal 4.4.8. IR PCB Replacement i.

  • Page 53: Status Display Pcb Replacement

    4.4.9. Status Display PCB Replacement i. Loosen the two screws on the status display PCB. ii. Remove status display PCB from the right side cover. Figure 4-33 Status display PCB removal 4.4.10. Key Switch Replacement i. Loosen the locking nut on the key switch. ii.

  • Page 54: Top Rail Accessories Removal

    4.5. Top Rail Accessories Removal i. Loosen the two screws on rail end cover. Remove the cover. ii. Loosen the nut on mechanical stop. Remove the mechanical stops on both sides. iii. Loosen the set screw on the charging base. Remove the charging bases from the rail.

  • Page 55: Figure 4-36 Carriage Jumpers And Rubber Plugs

    Figure 4-36 Carriage jumpers and rubber plugs Figure 4-37 Move carriage up by hand crank 4-20...

  • Page 56: Rollers Replacement

    4.6.1. Rollers Replacement i. Remove C-rings and rollers from the shafts. ii. Clean the shafts and apply lubricant on the shafts and inner bores of new rollers. iii. Install new rollers and shafts on the carriage. Figure 4-38 Carriage rollers 4.6.2.

  • Page 57: Rail Removal

    4.7. Rail Removal i. Loosen the rack screws on the top rail section. Do not remove the screws. ii. Slide the racks up onto the upper rail section. Tighten the screws to fix the racks. iii. Loosen the set screw on the splice bars. iv.

  • Page 58: Check List

    5. Service 5.1. Check List 5.1.1. Rail i. Check all rail brackets are correctly positioned. ii. Check all bracket-fixing screws are secure. iii. Check charging bases are secure and undamaged. iv. Check rack screws are secure and racks are not worn-out. 5.1.2.

  • Page 59: Pcb Layout

    5.2. PCB Layout Figure 5-1 PCB layout...

  • Page 60: Troubleshooting

    6. Troubleshooting 6.1. Troubleshooting Flowchart Refer to the following flowchart to troubleshoot and correct any faults when stair won’t run. Contact technical support Contact technical support Contact technical support Figure 6-1Troubleshooting chart when stairlift won’t run...

  • Page 61: Diagnostic Codes

    6.2. Diagnostic Codes Refer to the following table to help diagnose and correct any faults. Table 6-1 Troubleshooting Code Status/Fault Recommended Corrective Action Check that the key switch and ON/OFF switch are turned on. No display. Replace status display PCB if stairlift is working correctly except no display.
  • Page 62 You have reached the lower limit. Run the unit in the up direction. Lower limit switch is activated. Check the switch if the stairlift is not stopping at the lower limit. Safety sensor in down direction is Remove any obstacle that may have activated.

  • Page 63: Wiring Diagram

    6.3. Wiring Diagram Figure 6-2Wiring diagram...

  • Page 64: Table 6-2Wiring Components List

    Table 6-2Wiring components list item description item description rocker switch down footrest LS control PCB footrest wire (lower) on/off switch key switch charger charging wire - motor IR PCB up jumper IR PCB dn battery wire (include fuse 30A) on/off switch wire batteries battery series wire display module...

  • Page 65: Tool Kit

    7. Tool Kit The service tools are shown in Figure 7-1 and list below. Figure 7-1 Tool Kit of Service Table 7-1 Tool Kit Item Tool Name Metric Hex L-Key Set External Retaining-Ring Plier Needle-nose Plier Wire Cutter 17mm Combination Wrench 13mm Combination Wrench 10mm Combination Wrench Slotted-head Screwdriver...
  • Page 66 Rev. 1. 19/05/2017...

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