Wabtec RICON KlearVue K Series User manual

KlearVue™
K-Series®Folding Platform
DOT – Public Use Lift
12/12/18 32DSSK06.D 2018 RICON CORPORATION
All Rights Reserved
U.S. and foreign patents pending
Printed in the United States of America
SERVICE MANUAL

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TABLE OF CONTENTS
DECEMBER 2018
32DSSK06.D
K-SERIES PUBLIC USE SERVICE MANUAL
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
32DSSK06.
D
Cvr Update to K-Series cover
1-1 Update address, website, logo.
1-4 Update to Figure 1-1 to add item 25 for Armored Cable and Cover.
1-5 Added Armored Cable and Cover description.
2-16 Added Safety Checklist for Front Rollstop.
3-12 Update to Figure 3-10 Wiring Diagram Sheet 2.
4-10 Update to Figure 4-4 Public Use Electrical System to add Rollstop
Pressure Detection PCA.
4-11 Added item 32 to Spare Parts List for Rollstop Pressure Detection PCA.
4-15 Update to Spare Parts List, items 10, 10A, 10B.
4-16 Update to Spare Parts List, items 10B.

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TABLE OF CONTENTS
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Chapter Page
I. INTRODUCTION .......................................................................................................................1-1
A. WARRANTY INFORMATION.............................................................................................................1-2
B. SHIPMENT INFORMATION ...............................................................................................................1-3
C. GENERAL SAFETY PRECAUTIONS ................................................................................................1-3
D. MAJOR COMPONENTS ....................................................................................................................1-4
II. INSTALLATION ........................................................................................................................2-1
A. GENERAL MECHANICAL INSTALLATION......................................................................................2-1
1. LIFT LOCATION............................................................................................................................................ 2-1
2. LIFT INSTALLATION GUIDELINES ............................................................................................................. 2-1
3. LIFT INSTALLATION INTO VANS................................................................................................................ 2-2
4. LIFT INSTALLATION INTO BUSSES........................................................................................................... 2-5
B. ELECTRICAL INSTALLATION..........................................................................................................2-6
1. INSTALL MAIN CIRCUIT BREAKER............................................................................................................ 2-7
2. ROUTE AND CONNECT MAIN POWER CABLE......................................................................................... 2-7
3. CONNECT CONTROL PENDANT................................................................................................................ 2-8
4. GROUND (COMMON) CONNECTIONS ...................................................................................................... 2-9
5. INTERLOCK DEVICE INSTALLATION ................................................................................................................ 2-10
C. FINAL ADJUSTMENTS ...................................................................................................................2-10
1. LIMIT SWITCH ADJUSTMENT................................................................................................................... 2-10
2. PLATFORM TILT ADJUSTMENT ............................................................................................................... 2-12
3. PLATFORM FOLDING LINKAGE ADJUSTMENT...................................................................................... 2-14
4. PLATFORM PRESSURE SWITCH CHECK AND ADJUSTMENT................................................................... 2-14
D. VERIFY INSTALLATION..................................................................................................................2-15
E. SAFETY CHECKLIST FOR VEHICLE MANUFACTURER .............................................................2-15
F. CUSTOMER ORIENTATION............................................................................................................2-15
III. MAINTENANCE AND REPAIR .................................................................................................3-1
A. LUBRICATION ...................................................................................................................................3-1
B. CLEANING .........................................................................................................................................3-2
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. LIMIT SWITCH STATES............................................................................................................................... 3-6
E. HYDRAULIC CIRCUIT DIAGRAM .....................................................................................................3-7
F. ELECTRICAL WIRING DIAGRAM.....................................................................................................3-8
1. DIAGRAM LEGENDS ................................................................................................................................... 3-8
2. WIRING DIAGRAM.................................................................................................................................................. 3-11
IV. SPARE PARTS .........................................................................................................................4-1
APPENDIX 1: K-SERIES LIFT SPECIFICATIONS ....................................................................................4-29

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I. K-SERIES PUBLIC INTRODUCTION
he RICON K-Series®Public Use wheelchair lift provides wheelchair access to vans and buses. The patented
movement provides smooth, safe entry and exit, and can lift up to 800 pounds (364 kilograms). The platform is
raised with an electro-hydraulic pump. The pump has a built-in manual backup pump, allowing it to be raised or
lowered manually.
By using the lift control switches, the platform is unfolded from the vehicle (deployed). The passenger boards the large
non-skid platform and the operator uses the control switches to gently lower the platform to the ground. After the pas-
senger departs, the platform is raised and folded into the vehicle (stowed). The lift platform splits and folds horizontally
when stowed.
This manual contains operation and maintenance instructions and a troubleshooting guide for the lift. It is important to
user safety that the lift operators be completely familiar with the Operating Instructions chapter of the operator manual
(32DSSK05). Once the lift is installed, it is very important that the lift be properly maintained by following the Ricon rec-
ommended cleaning, lubrication, and inspection instructions.
If there are questions about this manual, or additional copies are needed, please contact Ricon Product Support at one
of the following locations:
Ricon Corporation
1135 Aviation Place
San Fernando, CA 91340 ......................................................................................... [phone]
Outside (818) Area Code.......................................................................................... [phone]
World Wide Website ........................................................................................................ www.riconcorp.com
Vapor Ricon Europe Ltd.
Meadow Lane
Loughborough, Liecestershire LE11 1HS
United Kingdom................................................................................................[phone] 920
Fax .....................................................................................................................[phone] 939
T

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RICON FIVE-YEAR LIMITED WARRANTY
RICON K-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 authorized 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 operation
of a Ricon product that has been modified from the original Ricon design. No person or com-
pany is authorized to change the design of this Ricon product without written authorization 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 consequential
damages. Some states do not allow the exclusion or limitation of incidental or consequential
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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A. SHIPMENT INFORMATION
Because of the specialized nature of this product, Ricon does not sell directly to the user. Instead, the product is
distributed through a woldwide network of authorized Ricon dealers, who perform the actual installation.
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 the Ricon Product Support department. The warranty and owner registration cards must be com-
pleted and returned to Ricon within 20 days to validate the warranty.
NOTE: Sales or Service Personnel must review the Warranty and the 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.
B. GENERAL SAFETY PRECAUTIONS
The following general safety precautions must be followed during installation, operation, service, 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, must be attended to. Administer first aid or seek medical attention immediately.
Protective eyeshields and appropriate clothing should be worn at all times.
To avoid injury, exercise caution when operating lift and be certain that hands, feet, legs, and clothing are not in the
path of platform movement.
Batteries contain acid that can burn. If acid comes in contact with skin, immediately flush affected area with water
and wash with soap.
Always work in a properly ventilated area. Do not smoke or use an open flame near battery.
Do not lay anything metallic on top of 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 operating lift.
Inspect the lift before each use. If an unsafe condition, unusual noises or movements exist, do not use lift until the
problem is corrected.
Never load or stand on the platform until the installation is complete. Upon completion of installation, test load the
lift mounting integrity at 100% of its rated load capacity.
Stand clear of doors and platform and keep others clear during operation.
The product requires regular maintenance. A thorough inspection is recommended at least every six months. The
lift must always be maintained at the highest level of performance.

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C. MAJOR LIFT COMPONENTS
The terms used throughout this manual are illustrated in Figure 1-1 and defined in Table 1-1. Refer to the parts dia-
grams and lists in Chapter IV for more details.
RSM00805
0
FIGURE 1-1: K-SERIES MAJOR COMPONENTS

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TABLE 1-1: K-SERIES MAJOR COMPONENT TERM DEFINITIONS
TERM DESCRIPTION
Left, right, front, rear Position references when installed lift is viewed from outside of vehicle.
Baseplate Bolts to vehicle floor; provides secure foundation for lift structure.
Bridgeplate
(inboard rollstop)
Plate that bridges gap between platform and baseplate when platform is at floor level. Also
acts as a rear rollstop when platform is in motion.
Bridgeplate load
sensor
Senses if weight is present on the lowered bridgeplate.
Control pendant Hand-held device used to control platform motions.
Cycle counter Visible at top rear of housing. It records number of times platform has moved from floor level
to ground and back to floor level.
Front platform
section
Front portion of platform that unfolds during deploy and folds during stow. See “Platform fold-
ing linkage”.
Front rollstop Front barrier prevents wheelchair from inadvertently rolling off of platform during platform
movement.
Handrail (left and right) Provides handhold for standing passenger.
Hydraulic cylinder (left and right) Telescoping single-acting cylinders convert hydraulic pressure into platform
lifting and folding force.
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.
Manual backup pump
handle
Used to operate manual back up-pump (located on hydraulic power unit cover).
Platform folding
linkage
(left and right) Links that cause front platform section to unfold as it deploys or fold as it
stows.
Platform hinges Three hinges provide a flexible connection between front and rear platform sections.
Platform light (left and right) Provide illumination of platform surface when lift is in use.
Rear platform section Rear portion of platform that is folded by linkage located within the vertical arms.
Serial number This is the location of lift serial number decal.
Stow-lock catch Engages latch located on bottom of bridgeplate when platform is fully stowed.
Threshold beam (upper and lower) Light-beams detect presence of objects in threshold area.
Top and bottom arms (left and right) Upper and lower links that connect vertical arms to baseplate.
Vertical arm (left and right) Connects platform to top and bottom arms.
Visual and audible
alarms
Announce when something has passed over threshold. Activated by threshold beams.
Armored Cable and
Cover
Front Barrier sensor with cable.
END OF TABLE