Wabtec Ricon S Series User manual

02/25/14 2014 RICON CORPORATION
A
ll Rights Reserved
Printed in the
United States of America
32DSST04.D.4
U.S. Patent Nos: 4,534,450; 5,308,215; 5,445,488; 5,605,431; 5,944,473;
Australia Patent Nos: 661127;687066;
Canadian Patent Nos: 1,245,603; 2,168,761
Other U.S. and foreign patents pending
S-Series®
DOT - Public Use Lift
®
SERVICE MANUAL
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TABLE OF CONTENT
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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 man-
ual provides essential instructions and reference information, which sup-
ports qualified technicians in the correct installation and maintenance of
Ricon products.
Qualified service technicians have the training and knowledge to perform
maintenance work properly and safely. For the location of a service tech-
nician in your area, call Ricon Product Support at 1-800-322-2884.
“DOT – Public Use Lift” verifies that this platform lift meets the public use
lift requirements of FMVSS no. 403. This lift may be installed on all vehi-
cles appropriate for the size and weight of the lift, but must be installed on
buses, school buses, and multi-purpose passenger vehicles other than
motor homes with a gross vehicle weight rating (GVWR) that exceeds
10,000 lbs (4,536 kgs).
Customer Name:
Installing Dealer:
Date Installed:
Serial Number:

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REVISION RECORD
REV PAGES DESCRIPTION OF CHANGE ECO
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Cvr Update to date.
6663
4-5 Update to item 5A
4-7 Update to item 27
4-15 Update to item 2
4-15 Update to item 2A
4-15 Added item 2C
4-15 Added item 4A
4-15 Added item 5A
4-16 Added item 33B
4-16 Added item 33C
4-19 Added item 1A/1B
4-19 Update to item 13
4-21 Added item 69B
4-21 Update to items 70 and 70A
4-21 Added item 70B
4-23 Added item 3C and 4C

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CHAPTER PAGE
I. INTRODUCTION ....................................................................................................................1-1
A. RICON PRODUCT SUPPORT........................................................................................................1-1
B. RICON FIVE-YEAR LIMITED WARRANTY....................................................................................1-2
C. SHIPMENT INFORMATION............................................................................................................1-3
D. GENERAL SAFETY PRECAUTIONS.............................................................................................1-3
E. MAJOR LIFT COMPONENTS.........................................................................................................1-4
II. INSTALLATION .....................................................................................................................2-1
A. MECHANICAL INSTALLATION .....................................................................................................2-1
1. LIFT LOCATION.........................................................................................................................................2-1
2. VEHICLE STRUCTURAL REQUIREMENTS ............................................................................................2-1
3. LIFT INSTALLATION GUIDELINES ..........................................................................................................2-2
4. LIFT INSTALLATION INTO VANS.............................................................................................................2-3
5. LIFT INSTALLATION INTO BUSES ..........................................................................................................2-6
B. ELECTRICAL INSTALLATION.......................................................................................................2-7
1. INSTALL MAIN CIRCUIT BREAKER.........................................................................................................2-8
2. ROUTE AND CONNECT MAIN POWER CABLE......................................................................................2-8
3. CONNECT CONTROL PENDANT.............................................................................................................2-9
4. GROUND CONNECTIONS......................................................................................................................2-10
5. INSTALLATION OF INTERLOCK DEVICE .............................................................................................2-11
C. FINAL ADJUSTMENTS ................................................................................................................2-11
1. LIMIT SWITCH ADJUSTMENT................................................................................................................2-11
2. PLATFORM TILT ADJUSTMENT............................................................................................................2-13
3. PLATFORM PRESSURE SWITCH CHECK AND ADJUSTMENT..........................................................2-14
D. VERIFY INSTALLATION...............................................................................................................2-16
E. SAFETY CHECKLIST FOR VEHICLE MANUFACTURER ..........................................................2-16
F. CUSTOMER ORIENTATION.........................................................................................................2-16
III. MAINTENANCE AND REPAIR..............................................................................................3-1
A. LUBRICATION................................................................................................................................3-1
B. CLEANING......................................................................................................................................3-1
C. MAINTENANCE SCHEDULE..........................................................................................................3-2
D. TROUBLESHOOTING ....................................................................................................................3-3
1. LIFT TROUBLESHOOTING.......................................................................................................................3-3
2. PUMP SOLENOID LED STATUS INDICATOR.........................................................................................3-4
3. BRIDGEPLATE CABLE ASSEMBLY REPLACEMENT.............................................................................3-4
4. S-SERIES LIMIT SWITCH STATES..........................................................................................................3-5
E. HYDRAULIC CIRCUIT DIAGRAM..................................................................................................3-6
F. ELECTRICAL WIRING DIAGRAM..................................................................................................3-7
1. DIAGRAM LEGENDS................................................................................................................................3-7
2. WIRING DIAGRAM....................................................................................................................................3-8
IV. PARTS DIAGRAMS AND LISTS ...........................................................................................4-1
Appendix: Lift Specifications..........................................................................................................4-25

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I. S-SERIES®PUBLIC INTRODUCTION
he RICON S-Series®Public Use wheelchair lift provides wheelchair access to vans and buses. The patented
movement provides smooth, safe entry and exit and lifts up to 800 pounds. It is to be operated by a trained at-
tendant. The lift contains a powerful electro-hydraulic pump that includes a built-in manual backup pump. If the
lift loses electrical power, it can be raised or lowered manually.
By using the lift control switches, the lift is unfolded out from the vehicle (deployed). The user boards the large non-skid
platform and the operator uses the control switches to gently lower the platform to the ground. After the user departs,
the platform is raised and folded into the vehicle (stowed). The lift is also available with a platform that splits and folds
when stowed, providing easy vehicle access through the lift.
This manual contains installation instructions; maintenance and repair instructions; troubleshooting guide; parts and di-
agram lists. It is important to user safety that the lift operator be completely familiar with the operating instructions.
Once the lift is installed, it is very important that the lift be properly maintained by following the Ricon recommended
cleaning, lubrication, and inspection instructions.
A. RICON PRODUCT SUPPORT
If you have 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 91402........................................................................................ [phone]
Outside (818) Area Code.......................................................................................... [phone]
Website.............................................................................................................................www.riconcorp.com
Vapor Ricon Europe Ltd.
Meadow Lane
Loughborough, Leicestershire LE11 1HS.................................................................0044 (9) 1509 635 920
United Kingdom
Website.................................................................................................................................www.riconuk.com
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B. RICON FIVE-YEAR LIMITED WARRANTY
RICON S-SERIES®PUBLIC
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 part that fails due to defective material or workmanship as follows:
• Repair or replace parts for a period of one year from the date of purchase.
• Labor costs for specified parts replaced under this warranty for a period of one year from the date of pur-
chase. A Ricon rate schedule determines the parts covered and labor allowed.
• Repair or replace lift power train parts for a period of five years from the date of purchase. A list of parts
covered can be obtained from Ricon Product Support.
If you need to return a product: Return this product to Ricon. Please give as much advance notice as possi-
ble, and allow a reasonable amount of time for repairs.
This warranty does not cover: Malfunction or damage to product parts caused by accident, misuse, lack of
proper maintenance, neglect, improper adjustment, modification, alteration, the mechanical condition of the ve-
hicle, road hazards, overloading, failure to follow operating instructions, or acts of nature (i.e., weather, light-
ning, flood).
Note: Ricon recommends that this product be inspected by a Ricon dealer or qualified service technician at
least once every six months, or sooner if necessary. Required maintenance should be performed at that time.
WARNING
THIS PRODUCT HAS BEEN DESIGNED AND MANUFACTURED TO EXACT SPECIFICATIONS.
MODIFICATION OF THIS PRODUCT IN ANY RESPECT CAN BE DANGEROUS.
This warranty is void if:
• 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 authoriza-
tion by Ricon.
Ricon disclaims liability for any personal injury or property damage that results from opera-
tion 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 authoriza-
tion 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 conse-
quential damages. Some states do not allow the exclusion or limitation of incidental or con-
sequential damages, so the above limitation or exclusion may not apply.
Important: The warranty registration card must be completed and returned to Ricon within 20
days after installation of this Ricon product for the warranty to be valid. The warranty is not
transferable.
The warranty gives specific legal rights. There may be other rights that vary from state to state.

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C. SHIPMENT INFORMATION
• When the product is received, unpack the product and check for freight damage. Claims for any damage should be
made to the carrier immediately.
• Verify that the installation kit contains all items listed on the enclosed packing list. Please report any missing items
immediately to Ricon Product Support. The warranty and owner registration cards must be completed and returned
to Ricon within 20 days for the warranty to be valid.
NOTE: The Sales or Service personnel must review the Warranty and this Operator Manual with the user to be certain
that they understand how to safely operate the product. Instruct the user to follow the operating instructions
without exception.
D. GENERAL SAFETY PRECAUTIONS
The following general safety precautions must be followed during installation, operation, and maintenance:
• Under no circumstances should installation, maintenance, repair, and adjustments be attempted without the imme-
diate presence of a person capable of rendering aid.
• An injury, no matter how slight, should always be attended. Always administer first aid or seek medical attention
immediately.
• Protective eyeshields and appropriate clothing should be worn at all times.
• To avoid injury, always exercise caution when operating and be certain that hands, feet, legs, and clothing are not
in the path of product movement.
• Batteries contain acid that can burn. If acid comes in contact with skin, flush affected area with water and wash with
soap immediately.
• Always work in a properly ventilated area. Do not smoke or use an open flame near a battery.
• Do not lay anything metallic on top of a battery.
• Check under vehicle before drilling to avoid drilling into frame, subframe members, wiring, hydraulic lines, fuel lines,
fuel tank, etc.
• Read and thoroughly understand the operating instructions before attempting to operate.
• Inspect the product before each use. If an unsafe condition is noted, such as unusual noises or movements, do not
use lift until the problem is corrected.
• Never load or stand on the platform until installation is complete. Upon completion of installation, test load the lift to
100% of its rated load capacity.
• Stand clear of doors and platform and keep others clear during operation.
• The product requires regular periodic maintenance. Inspections are recommended at the intervals prescribed in
chapter three. The product must be maintained at the highest level of performance.

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E. MAJOR LIFT COMPONENTS
The references used throughout this manual are illustrated in Figure 1-1 and defined in the Table 1-1. Refer to Chap-
ter IV “Parts Diagrams and Lists” for more details.
FIGURE 1-1: PUBLIC USE WHEELCHAIR LIFT
42
1
3
21
22
6
9
10
7
11
14
12
15 16
19
17
18
23
20
24
85
13

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TABLE 1-1: S-SERIES PUBLIC USE LIFT COMPONENT TERMS
REF NAME DESCRIPTION
1, 2,
3, 4 Left, right, front, rear Position references when lift is viewed from outside of vehicle.
5 Bridgeplate load
sensor Senses if weight is present on the lowered bridgeplate.
6 Hydraulic cylinder (left and right) Telescoping single-acting cylinders convert
hydraulic pressure into platform lifting and folding force.
7 Hydraulic power unit Contains hydraulic pump driven by electric motor that produces pressure
to raise and fold platform, and a pressure release valve to unfold and lower
it.
8 Audible alarm (inside housing for hydraulic unit) Announces when something has
passed over threshold. Activated by threshold beam.
9 Cycle counter Visible at rear of housing, it records number of times platform has moved
from floor to ground and back to floor.
10 Visual alarm Flashing light makes it known when something has passed over threshold.
Activated by threshold beams.
11 Manual backup pump
handle Used to operate manual back up-pump (located on hydraulic power unit cover).
12 Stow-Lock catch Engages latch located on bottom of bridgeplate when platform is fully
stowed.
13 Baseplate
assembly Bolts to vehicle floor; provides secure foundation for lift.
14 Threshold beams Light-beams detect presence of objects in threshold area.
15 Serial number Location of serial number decal.
16 Top and bottom arms (left and right) Upper and lower links connecting vertical arm to base as-
sembly.
17 Vertical arm (left and right) Connects platform to top and bottom arms.
18 Bridgeplate
(inboard rollstop) Plate bridges gap between platform and baseplate when platform is at floor level. Acts as barrier to prevent wheelchair from rolling off of the plat-
form during "Up" and "Down" platform motions.
19 Handrail (left and right) Provides a handhold for standing passenger.
20 Occupant restraint
belt Electrically interlocked safety belt that is intended to prevent acceleration of wheelchair from platform. Lift will not operate unless belt is properly
connected.
21 Front rollstop Front barrier prevents the wheelchair from inadvertently rolling off of the
platform during lift operation.
22 Platform Component of lift where the wheelchair and occupant are situated during
"Up" and "Down" lift motions.
23 Platform light (left and right) Directs light onto platform surface.
24 Control pendant Hand-held device controls platform motions.
END OF TABLE

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II. INSTALLATION
his chapter contains instructions for installing the RICON S-Series®Public Use wheelchair lift into most vans and
busses, although custom installations are also possible in other types of vehicles. Due to the wide range of ap-
plications for 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 concerning installations not cov-
ered. To install lift, refer to following sections and perform procedures carefully and in the order that they are presented.
Be certain that installation instructions are followed exactly and do not eliminate any steps or modify product.
NOTE: Please review carefully the installation instructions (32ii352e) that are supplied with this lift before beginning the
following procedures. Where these procedures conflict, the installation instructions take precedence.
A. GENERAL MECHANICAL INSTALLATION
1. LIFT LOCATION
The installation surface must be flat and level. It is recommended that lift be installed on a ½", minimum, high-
grade plywood sub-floor. However, this additional installation height may not be acceptable in cases where over-
head clearance is limited.
Refer to Figure 2-1.
NOTE: Check for proper travel clearance through 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. Allow a distance of 3/4", if possible, between door and the part of lift closest to it. Adjust lift 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. VEHICLE STRUCTURAL REQUIREMENTS
The following figures and text provide installation guidelines for the RICON S-Series Public Use wheelchair lift into
most vans and busses. Adherence to these requirements will verify that the lift installation conforms to the require-
ments of FMVSS 403 and 404.
a. VEHICLE DOOR OPENING DIMENSIONAL REQUIREMENTS in inches and [millimeters].
MODEL A(Width) B(Height) C(Floor-To-Ground)
S2003 * 38.5 [978] 55.0 [1397] 42.0 [1067]
S2005 41.0 [1041] 55.0 [1397] 42.0 [1067]
S2006 48.5 [1232] 55.0 [1397] 42.0 [1067]
S2010 43.0 [1092] 58.0 [1473] 42.0 [1067]
S5005 41.0 [1041] 58.0 [1473] 48.0 [1219]
S5503 * 38.5 [978] 58.0 [1473] 51.0 [1295]
S5505 41.5 [1054] 58.5 [1486] 51.0 [1295]
S5510 43.5 [1105] 58.5 [1486] 51.0 [1295]
* Non-standard production item.
RSM0044100
VEHICLE DOOR
OPENING
A
B
C
VEHICLE FLOOR
GROUND LEVEL
FIGURE 2-1: DOOR OPENING REQUIREMENTS
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b. VEHICLE FLOOR STRENGTH REQUIREMENTS
Rated Load: 800 lbs Standard Load: 600 lbs Standard Load Test: 1800 lbs
MODEL L1 L2 A * B ** C
S2000 w/51” platform 11” 36.25 -5930 7730 1800
S2000 w/54” platform 11” 37.75 -6180 7980 1800
S5000 w/51” platform 11” 41.50” -6790 8590 1800
S5000 w/54” platform 11” 43.00” -7040 8840 1800
* Negative numbers in column A indicate a tensile load pulling floor upward at the rear base plate mount-
ing holes.
** Positive numbers in column B indicate a compressive load pushing floor downward at the front base
plate mounting holes.
RSM0044200
L1 L2
C
BA
FIGURE 2-2: FLOOR STRENGTH REQUIREMENTS
3. LIFT INSTALLATION GUIDELINES
The lift mounting is a very important step. Improper mounting or fastening of baseplate can adversely affect lift per-
formance. Although fastening details may vary from one vehicle to the next, these general principles apply:
Be certain that all mounting bolts are properly installed and tightened. Bolts used to fasten baseplate assembly
to vehicle floor must have a minimum strength rating of SAE Grade 5 and be torqued to 28 ft lbs, dry. Recog-
nize that the most important bolts are those along the rear of lift, since these bolts retain the majority of the
load.
Refer to Figures 2-3 and 2-7. Improper torquing sequence of baseplate bolts may result in a warped or bowed
baseplate, which can cause platform to move erratically.
RSM0004800
CORRECT BOWED UP
TIGHTEN HERE
LOOSE N HERE TIGHTEN HERE
LOOSEN HERE
BOWED DOWN
FIGURE 2-3: EXAMPLES OF BASEPLATE WARPAGE

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Refer to Figure 2-4. On Ford van installations, clamping bars are used to help evenly distribute floor loading
and should only be cut if needed to clear a subframe member. A subframe member must be used to support
clamping bar.
RSM0004000
SUBFRAME MEMBER
CLAMPING BAR
MINIMUM UNSUPPORTED
CLAMPING BAR LENGTH
12”
CLAMPING BAR SUPPORTED BY
SUBFRAME WHERE POSSIBLE
VEHICLE FLOOR
FIGURE 2-4: FORD VAN CLAMPING BAR ARRANGEMENT
4. LIFT INSTALLATION INTO VANS
This is a general procedure for installing Ricon lifts into Ford, Dodge, and Chevrolet full size vans.
a. Refer to Figure 2-5. Use four 1" x 3/8" bolts, 3/8" washers, 3/8" lock washers, and 3/8" hex nuts to assem-
ble two bracket assembly kits.
NOTE: The top bracket must overlap bottom bracket, and both slots must face outward.
RSM0004100
BOTTOM BRACKET
TWO PER BRACKETASSEMBLY
TOP BRACKET
(LEVEL WITH VEHICLE FLOOR)
VEHICLE FLOOR LEVEL
VEHICLE STEPWELL
FIGURE 2-5: STEPWELL BRACKET
b. Position brackets on stepwell and adjust height of both bracket assemblies so that top bracket is level with
vehicle floor. Tighten bracket assembly bolts.
c. Verify that lift is fully folded (stowed) with handrails folded tight against vertical arms. If necessary, use
manual pump.
WARNING
LIFT WEIGHT IS APPROXIMATELY 340 - 370 LBS. USE EXTREME CARE WHEN POSITIONING BECAUSE
STEPWELL BRACKETS MAY TIP. THIS PROCEDURE MUST NOT BE ATTEMPTED BY ONE PERSON.

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d. Refer to Figure 2-6. With doors fully open, position lift in vehicle doorway so that back of lift is supported
by vehicle floor, and front of lift is supported by both bracket assemblies.
RSM0004200
BRACKETASSEMBLY
LIFT FRONT
VEHICLE FLOOR
LIFT REAR
FIGURE 2-6: BRACKET ASSEMBLY
e. Fasten Baseplate to Floor:
NOTE: If Ricon power door operators are used, install them first. They may influence location of lift.
Be certain baseplate is flush against vehicle floor. The baseplate may be slightly offset in door opening to
provide proper clearance for passenger seats.
Before drilling, verify that lift position does not interfere with closing of vehicle doors or operation of passen-
ger seats.
If this lift is being installed in a Dodge van with sliding doors, omit the bolts in baseplate holes 7 and 8.
f. Mark and Drill Holes:
CAUTION
Before drilling holes, verify that underlying wires and tubing will not be damaged.
1) Refer to Figure 2-7. Mark and drill five 25/64" baseplate mounting holes (1, 2, 3, 4, and 5) through ve-
hicle floor. (On Dodge and GM vans, you must drill through vehicle floor and subframe).
RSM0004300
FIGURE 2-7: VAN BASEPLATE HOLES
2) Place five 8" x 3/8" carriage bolts (use 4" x 3/8" bolts on Ford vans) into holes to secure position.
3) Refer to Figure 2-8 on the following page. Match and align top holes of stepwell brackets 6, 7, 8, and
9, with baseplate holes 6, 7, 8, and 9. Mark lower stepwell bracket holes 10, 11, 12, and 13 onto vehi-
cle step.
4) Remove five carriage bolts installed in step 2). Carefully push lift into vehicle interior.
5) Drill 1/4" dia holes through marked locations 10, 11, 12, and 13.

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RSM0004400
VEHICLE FRONT
VEHICLE REAR
FIGURE 2-8: STEPWELL BRACKET HOLE LOCATIONS
g. Fasten Bracket Assemblies and Lift:
1) Use 1-1/2" x 5/16" sheet metal screws with 5/16" lock washers to secure lower brackets to vehicle step
holes 10 through 13.
NOTE: If the screw in position 13 interferes with proper door operation, do not install.
2) Reposition lift and verify that surface beneath lift is free of obstacles.
3) Insert five 8" x 3/8" carriage bolts through mounting holes at rear of baseplate assembly, and insert four
1-1/2" x 3/8" carriage bolts through baseplate and bracket assemblies. Place 3/8" washers, lock wash-
ers, and nuts under bracket assemblies, and finger tighten nuts.
NOTE: On Dodge and GM vans, place five 4" x 4" plates, 3/8" washers, lock washers and hex nuts on 8" x 3/8"
carriage bolts under van and finger tighten. On Ford models, reinforce vehicle floor with clamping bars.
They are installed in positions 1, 2, 3, 4, and 5 and run across width of baseplate towards center of van.
4) Before tightening carriage bolts, verify that lift is level with vehicle floor. Adjust bracket assembly bolts if
necessary.
5) Tilting lift towards inside of van may hinder its initial unfolding. Install lift with its baseplate assembly as
level as possible. Tightening carriage bolts requires special care to keep baseplate assembly from
warping when secured to vehicle floor. If baseplate assembly warps, the vertical arms will not be paral-
lel. Make corrections by shimming at appropriate locations. To help prevent warping, tighten the ten
carriage bolts (six on Dodge van with sliding door) to 28 ft. lbs. in the appropriate sequence:
DODGE WITH SWING DOORS, ALL FORD AND GM VANS.......... 3, 1, 2, 4, 5, 6, 7, 8, 9
DODGE WITH SLIDING DOORS...............................................................3, 1, 2, 4, 5, 6, 9
NOTE: Vertical arms must be parallel for proper operation. Adjust bolts as required. Best results are obtained
when lift is mounted on plywood. Shims, although best avoided, may be used if required.
6) Make certain that holes 14 and 15 on the front of each bracket assembly are drilled through, and 5/16"
bolts are inserted to lock position of bracket assemblies.

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5. LIFT INSTALLATION INTO BUSES
Refer to Figure 2-9. Clamping bars are used on most bus installations to help distribute floor loading, and should
only be cut if needed to clear a subframe member. A subframe member should be used to support clamping bar.
RSM0004500
12”
VEHICLE FLOOR
SUBFRAME MEMBER
CLAMPING BAR
MINIMUM UNSUPPORTED
CLAMPING BAR LENGTH
CLAMPING BAR SUPPORTED BY
SUBFRAME WHERE POSSIBLE
FIGURE 2-9: BUS CLAMPING BAR ARRANGEMENT
WARNING
LIFT WEIGHT IS APPROXIMATELY 340-370 LBS. TAKE EXTREME CARE WHEN POSITIONING BECAUSE
STEPWELL BRACKETS MAY TIP. THIS PROCEDURE MUST NOT BE ATTEMPTED BY ONE PERSON.
a. Open doors fully and position lift so that it is centered in vehicle doorway. Close doors and move lift out-
ward until it clears doors by a minimum of ½”. The baseplate must be parallel to side of bus. Open manual
pump release valve (CCW) and allow folded platform to fully settle against latch on baseplate. Verify that
interference is not present between lift and doors. Reposition lift, if necessary. Close pump release valve;
do not overtighten valve.
b. Refer to Figure 2-10. Mark and drill ten 25/64" baseplate mounting holes (1 thru 10) through vehicle floor.
CAUTION
Before drilling holes, verify that underlying wires and tubing will not be damaged.
c. Fasten Lift:
1) Insert ten 4" x 3/8" carriage bolts through baseplate and vehicle floor.
2) Refer to Figure 2-9. Install five clamping bars on bolts underneath vehicle floor (across baseplate), i.e.,
from 1 to 6, 2 to 7, etc, and secure lift to vehicle floor with 3/8" washers, lock washers and hex-nuts.
3) Use care when tightening carriage screws to prevent baseplate warpage. If baseplate assembly warps,
vertical arms will not be parallel. Make corrections by shimming at appropriate locations. To help pre-
vent warping, tighten the ten carriage bolts to 28 ft. lbs. in the following sequence:
3, 8, 1, 2, 4, 5, 6, 7, 9, 10
NOTE: Vertical arms must be parallel for proper operation. Adjust bolts as required. Best results are obtained
when lift is mounted on plywood. Shims, although best avoided, may be used if required.
1245
67910
3
8
FIGURE 2-10: BUS BASEPLATE HOLES

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B. ELECTRICAL INSTALLATION CAUTION
Do not route any wire while it is connected to the battery.
Route wires clear of moving parts, brake lines, and the exhaust system. Secure to the vehicle.
When routing an electrical wire through vehicle floor or walls, use a grommet to protect wires from chafing.
Check underside of vehicle before drilling to avoid damage to fuel lines, vent lines, brake lines, or wiring.
RSM0043800
4 AWG POWER CABLE:
SHORT CABLE NOT TO EXCEED 12”,
CONNECTED BETWEEN BATTERY (OR
MAIN POWER SOURCE) AND MAIN
CIRCUIT BREAKER
90 AMP MAIN
CIRCUIT BREAKER
BUS BAR
8 AMP CIRCUIT
BREAKER
GROUND
18 AWG WIRE
(BLUE)
10 AWG WIRE
(RED)
SPOOL VALVE
(DECELERATION)
LH PUMP
TERMINAL
BRACKET
4 AWG POWER CABLE:
LONG CABLE CONNECTED
BETWEEN MAIN CIRCUIT
BREAKER AND POSITIVE
CONNECTION BLOCK
POSITIVE CONNECTION
BLOCK
(CUTAWAY SHOWN FOR
CLARITY)
12V PUMP
HARNESS
HYDRAULIC POPPET
VALVE (DOWN)
PRESSURE SWITCH
MAIN POWER HARNESS
CONNECTED TO
SOLENOID
SIDE PUMP
SOLENOID
BUS BAR
8 AMP CIRCUIT
BREAKER
TOP PUMP SOLENOID
4 AWG GROUND CABLE
FROM BATTERY TERMINAL
A
MOTOR TERMINAL BOOT
FACTORY INSTALLED ON PUMP
A
B
MOTOR TERMINAL BOOT
KIT P/N 37152 SHIPPED WITH PUMP HANDLE
ATTACH TO TERMINAL
B
FIGURE 2-11: ELECTRICAL INSTALLATION DIAGRAM
CAUTION
KIT P/N 37152 (SHIPPED WITH PUMP HANDLE) MUST BE INSTALLED ONTO RING TERMINAL
BEFORE ATTACHING POWER CABLE TO A BATTERY OR POWER SOURCE.

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INSTALLATIO
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FEBRUARY 2014
32DSSST04.D.4
S-SERIES PUBLIC USE SERVICE MANUAL
1. INSTALL MAIN CIRCUIT BREAKER
a. Disconnect battery.
b. Mount main circuit breaker inside engine compartment within 12 inches of battery (to minimize length of un-
protected cable). Avoid installing near a heat source.
2. ROUTE AND CONNECT MAIN POWER CABLE
CAUTION
Check under-side of vehicle before drilling to avoid damage to fuel lines, vent lines, brake lines, or wiring.
NOTE: For applications where power cable is to pass through sheet metal, drill a 3/4" 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 Figures 2-11 and 2-12. Drill a hole through vehicle floor near positive connection block so power
cable can reach stud of positive connection block. Drill hole where the installed pump cover will cover it.
A
B
0.75” DIAMETER FOR FLOOR METAL
1.00” DIAMETER FOR OTHER
MATERIAL
30” PLATFORM WIDTH = 3.375”
32” PLATFORM WIDTH = 4.375”
A
RSM0043900
HYDRAULIC PUMP
BASEPLATE
B
1.25”
FIGURE 2-12: POWER CABLE ACCESS HOLE
b. Refer to Figure 2-11. Install supplied heavy ring terminals to each end of the short (12" long) 4 AWG pow-
er cable. Install one ring terminal, only, to one end of long power cable. Use an appropriate crimp tool
(such as Ricon hammer tool, part of kit P/N 01243).
c. Connect ring terminal end of long 4 AWG power cable to 90A main circuit breaker, then route power cable
underneath vehicle floor and up through hole in floor.
d. Refer to Figure 2-11. Detach Kit P/N 37152 (Shipped with pump handle) then install onto ring terminal
connector before installing ring terminal onto positive connection block.
e. Tie power cable to vehicle chassis, and to pump assembly harness using cable ties. Avoid pinch points,
exhaust system, moving parts, and brake lines. Verify that power cable is secure.
CAUTION
Be sure that there is no interference with any parts that
could damage power cable or other wires in any way.

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32DSST04.D.4
INSTALLATIO
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FEBRUARY 2014 S-SERIES PUBLIC USE SERVICE MANUAL
f. Refer to Figure 2-13. Cut excess wire from long cable, install heavy ring terminal, and then connect to pos-
itive connection block. Verify that red wire from main circuit breaker (if applicable) is securely connected to
positive connection block.
RSM0044000
POSITIVE CONNECTION
BLOCK TERMINAL
GROMMET 4AWG POWER CABLE
INSTALL BOOT (KIT 37152)
FIGURE 2-13: CABLE ROUTING
g. Connect 12" cable, with ring terminals, from positive battery terminal to main circuit breaker terminal.
3. CONNECT CONTROL PENDANT
a. Refer to Figure 2-14. Connect hand-held control pendant to six-pin connector at left side of baseplate and
secure cable with bracket and supplied cable clamps.
PENDANT INTERFACE
INTERLOCK INTERFACE
STRAIN RELIEF
CABLE CLAMP
BRACKET
FIGURE 2-14: STRAIN RELIEF KIT
b. Install wall portion of dovetail clip (pendant storage) in an appropriate and safe location near lift.
CAUTION
Be sure that harness does not interfere with any moving
parts, or binds against any parts, or is pinched in any way.