Service Manual for: CJKA+%(8 CJKA+%(8 Under-Vehicle Lift® Private Use Wheelchair Lifts Series 02 DOT — Private Use Lift “DOT — Private Use Lift” verifies that this platform lift meets only the “private use lift” requirements of FMVSS No. 403. This lift may be installed on all vehicles appropriate for the size and weight of the lift, except for buses, school buses, and multi-purpose passenger vehicles other than motor homes with a gross vehicle weight rating (GVWR) that exceeds 4,536 kg (10,000 lb).
Congratulations We at The Braun Corporation wish to express our fullest appreciation on your new purchase. With you in mind, our skilled craftsmen have designed and assembled the finest lift available. This manual provides service-related material. Refer to the FMVSS No. 403 Quick Reference Installation Sheet for installation instructions, operating instructions and maintenance procedures.
Contents Troubleshooting and Maintenance Lift Terminology ............................................................ 2 Switch and Sensor Locations ..................................... 3 Certification Checklist .................................................. 4 Adjustments and Calibration ....................................... 5 LCD Diagnostic Codes ................................................. 6 Floor Level and Inboard Locator Adjustments ..... 7-10 Lubrication Diagram ............................
Lift Terminology Lift Mounting Brackets (4) Chain Drive Motor Hydraulic Cylinder Inboard Locator Hand-Held Attendant's Control Box Torque Tube Lift Housing Lifting Arms STOW R DOO UP N DOW C ar ria ge Outer Barrier Actuator WA RN ING Push manu T-han and ally dle lock out movein fully to Failurbefor engagplatfo and resulte to e drivine rm deplo in lock gplatfo in unint platfovehicrm platfoymen resultrm t. ended rm le.
Switch and Sensor Locations Lift Out Limit Switch 73950A Lift Out Cam 73774 Full Out Cam 73775 Full Out Limit Switch 73950A Below Stow Limit Switch 73950A Floor Level Limit Switch 73950A Floor Level Cam 73712 Below Stow Cam 73712 Outer Barrier Limit Switch 73950A STOW DOOR UP N DOW WARN ING Push manuaT-hand and lly le lock out movein fully to Failurbefore engagplatfo and resulte to drivine rm deployin lock gplatfo in uninteplatfovehiclrm platfo ment. nded rm e.
Certification Checklist The following operations and conditions must be functionally verified in order for the lift to be FMVSS 403/404 compliant. If an operation does not function as described or a condition is not met, follow the referenced procedures to correct the problem or contact a Braun Corporation Product Support representative. • Vehicle movement is prevented unless the lift door is closed, ensuring the lift is stowed. 1.
Adjustments and Calibration Adjustment Procedures Lift Out Switch: The Lift Out Switch stops inward travel of the carriage/platform during Stow function (activated by the housing-mounted Lift Out Cam). Move cam in to increase inward travel. Move cam out to decrease inward travel. Full Out Switch: The Full Out Switch stops outward travel of the carriage/platform during Deploy (Up/Down) functions (activated by the housingmounted Full Out Cam). Move cam in to decrease outward travel.
LCD Diagnostic Codes D6 D3 102 D2 102 D4 U16 103 103 243R D C D6 8.00M D5 D3 8.00M 102 103 U5 103 103 SOMC1601 V104 103 103 106 E 330 V104 103 D21 C11 C8 V104 U21 C10 U19 V104 VR3 FS11 MAT 5Q6 220 35A C16 D20 D12 Door Operator RL10 IN NUVL CONTROLLER REV-3.
Floor Level and Inboard Locator Adjustments Achieving proper floor level positioning of the platform and inboard locator requires a combination of Floor Level switch adjustment and inboard locator adjustment. Both are factory set but must be inspected during installation procedures (will vary per vehicle application). Ensure the lift is positioned and secured as specified on Quick Reference Installation Sheet (supplied with lift) panels 1 and 2. Adjust the Floor Level switch first (detailed below).
Floor Level and Inboard Locator Adjustments Inboard Locator Adjustment Do not adjust inboard locator linkage rod Do not adjust inat this time! board locator linkLinkage rod age rod. Linkage adjustment is not rod adjustment may required unless result in lift damage. extra usable platform length is needed. If the angle of the inboard locator (when in the vertical position) restricts the usable platform length for the wheelchair passenger, adjustment of the linkage rod will change the angle.
Floor Level and Inboard Locator Adjustments Inboard Locator Adjustment 3. Remove the 1/4" lock nut securing the lifting arm cam bolt. See Photos D and E. Do not remove the bolt. D Raise the platform fully (floor level) using the manual operation system. Remove the cam securement bolt (lift inboard locator to relieve pressure on bolt). Cam Bolt Allow the inboard locator to rest on the floor. Rotate the cam so the cam follower bearing engages the cam notch (saddle). See Photos F and G.
Floor Level and Inboard Locator Adjustments Inboard Locator Linkage Rod Adjustment Do not adjust the CAUTION inboard locator linkage rod unImproper inboard less extra usable locator linkage rod platform length adjustment may is needed. See result in lift damage. Photo H. If the angle of the inboard locator (when in the vertical position) restricts the usable platform length for the wheelchair passenger, adjustment of the linkage rod will change the angle.
Lubrication Diagram Drive Chain and Rollers LO Torque Tube Pivot Points LO W STO R DOO UP N DOW Drive Chain Release Latch Hydraulic Cylinder SG Eccentric Pivot Shaft Points Rollers Torque LO (bearings) Tube LO Pivot Points LO Lifting Arm Carriage Pivot Points Rollers (bearings) LO LO Rolling Horizontal Carriage Arm Slot Area DE Outer Barrier Detent Pin LO WA RN ING Push manu T-han and ally dle lock out movein fully to Failubefor enga platfo and resulre to e drivin ge rm deplot in lock gplatfo in unin
Maintenance and Lubrication Schedule Proper maintenance is necessary to ensure safe, troublefree operation. Inspecting the lift for any wear, damage or other abnormal conditions should be a part of a regular service program. Simple inspections can detect potential problems. The maintenance and lubrication procedures specified in the following schedule must be performed by a Braun authorized service representative at the scheduled intervals according to the number of cycles.
Maintenance and Lubrication Schedule 750 Cycles 1500 Cycles Inspect lift for rattles Correct as needed. Check drive chain tension. Pull out and lock manual release cable. Adjust chain tension as needed. See Drive Chain Adjustment. Inspect inboard locator and linkage for: • Proper operation. Roll stop should rest solidly on floor providing smooth transition. • Positive securement • Wear or damage Resecure, replace or correct as needed. See Inboard Locator Adjustment Instructions.
Maintenance and Lubrication Schedule 1500 Cycles 4500 Cycles Inspect limit switches for securement and proper adjustment Resecure, replace or adjust as needed. See Switch Adjustment. Inspect carriage, lifting arm and eccentric shaft rollers (bearings) for wear or damage, positive securement and proper operation Correct, replace damaged parts and/or relubricate.
Troubleshooting Diagnosis Chart WARNING Troubleshooting and repair procedures must be performed as specified by authorized service personnel only. Failure to do so may result in serious bodily injury and/or property damage. FUNCTION 1.00 NO OPERATION 2.00 PUMP RUNS BUT WILL NOT LIFT PLATFORM 3.00 PUMP DOES NOT RUN WITH MANUAL OVERRIDE OR HAND-HELD PENDANT If a problem occurs with your lift, discontinue operation immediately! Do not attempt repairs yourself.
Troubleshooting Diagnosis Chart FUNCTION 4.00 LIFT WILL GO UP WITH OVERRIDE SWITCH BUT NOT WITH HAND-HELD PENDANT 5.00 LIFT WILL NOT GO DOWN WITH MANUAL OVERRIDE OR WITH HAND-HELD PENDANT OR GOES DOWN SLOWLY OR DRIFTS DOWN BY ITSELF 6.00 LIFT WILL GO DOWN WITH OVERRIDE BUT NOT WITH HAND-HELD PENDANT 7.00 LIFT WILL NOT GO OUT WITH HAND-HELD PENDANT 8.00 LIFT WILL NOT GO OUT WITH OVERRIDE OR HAND-HELD PENDANT 9.00 LIFT WILL NOT STOW WITH HAND-HELD PENDANT Page 16 POSSIBLE CAUSE 4.
Troubleshooting Diagnosis Chart FUNCTION POSSIBLE CAUSE REMEDY 10.11 Poor plug connections Check harness connectors A1 and A2, E1, N1, N2, E1, F1 and F2. 10.12 Faulty barrier actuator motor or actuator out of adjustment Check power at motor. Adjust or replace actuator if necessary. 10.13 Bad power and ground See 1.00 11.11 Faulty Outer Barrier switch Check diagnostic LCD for Outer Barrier Switch status. Adjust or replace switch as necessary. 11.12 Barrier occupied Remove weight from barrier.
Troubleshooting Diagnosis Chart CONTACT REMOVAL 1. Remove orange wedge using needle nose pliers or a hook shaped wire to pull wedge straight out. Page 18 2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver. 3.
NOTES This page intentionally left blank.
Lift Wiring Schematic - Main SW PWR IGN PWR BELOW STOW FULL OUT NOT FULL OUT LIFT OUT BAR DN GND SENS SAFETY FLOOR IN FLOOR LVL RD GN OR BU GN / BK OR / BK BU / BK BK / W BK WH RD / WH GN / WH BU / WH BK / RD NOT USED NOT USED NOT USED NOT USED WH / RD OR / RD BU / RD RD / GN RD / WH GN / WH BU / WH BK / RD NOT USED NOT USED NOT USED NOT USED WH / RD OR / RD BU / RD RD / GN 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 BK WH RD GN SW PWR IGN PWR BELOW STOW FULL OUT LIFT OUT BU LIFT OUT BA
U Li nfo Sc ft ld he Wi fo -M m rin r: ai at g n ic Lift Wiring Schematic - Lift Accessories #33496KS REMOTE, RECEIVER & HARNESS #86476 REMOTE & RECEIVER #86483 UP DOWN STOW DOOR CLOSE #86477 THE BRAUN CORPORATION 10 9 8 7 6 5 4 3 2 1 RD YL OR WH GN BU BK #33496A BK BU WH GN YL RD OR 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 86478 TAILLIGHT MAGNETIC SWITCHES-FORD #33576K RD B A E L D H F C I G B J K A CLOSE MAGNET WH HAND PENDANT 25’ EXTENSION WH BK RD GN YL BU 1 2 3 4
Hydraulic Parts List Item Qty.
Hydraulic Diagram 1 33 34 35 13 11 24 2 12 9 Arrow must face pump 25 30 7 29 26 11 27 31 28 8 3 10 6 32 16 4 14 5 15 23 22 21 20 17 19 18 Page 23
Pump Module Parts List Item Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 4 4 5 1 1 1 1 1 3 1 1 7 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 2 2 2 Description Pump Assembly, M259 Adapter, 1/4” Male NPT x 7/16-20 Male JIC 37° Hose Assembly, 1/4”- F.
Pump Module Diagram 13 46 OW ST DO OR 7 UP DO WN 8 9 12 53 8 14 55 6 37 11 WH 51 56 52 TO CIRCUIT SENTRY 1 33 53 18 39 49 32 10 35 17 RD 38 48 TO DOWN SOLENOID 15 16 19 TO DOWN SOLENOID 56 55 18 36 35 LIFT STOWED SIGNAL (OUTPUT) 35 40 45 34 42 41 50 25 VEHICLE SECURE SIGNAL (INPUT) 21 25 28 23 22 54 2 38 24 31 BK TO PUMP GROUND 47 44 24 5 43 RD 25 26 4 24 32 54 27 29 3 30 20 24 35 35 Page 25
Pu Un m fo E x p ld p M fo V lod od r: ie e u w d le Complete Lift Exploded View 39 39 39 104 85 39 39 13 105 39 110 106 109 38 38 38 38 38 132 70 70 38 133 38 38 70 38 38 71 69 61 72 39 14 2 38 15 14 9 10 13 76 86 6 76 76 2 100 12 1 88 39 101 116 3 97 39 17 31 54 30 99 29 103 107 98 107 39 96 127 65 32 112 67 129 7 49 39 9 11 38 13 25 20 26 21 26 23 24 64 45 63 65 39 56 39 5 59 125 126 24 118 89 114 117 119 90 82 73 43 131 55 120 3
Repair Parts List Item Qty.
Lift Housing Detail Exploded View 39 39 39 104 39 39 13 105 39 110 106 109 38 38 38 38 38 39 14 2 38 15 99 14 9 10 13 6 2 100 12 1 11 39 101 3 2 60 97 39 18 16 17 99 8 2 99 4 75 103 107 98 107 39 96 127 5 5 94 92 91 95 93 Page 28 129 7 9
Lift Carriage Detail Exploded View 57 31 54 30 64 29 63 29 65 32 45 67 62 39 11 38 13 20 49 25 20 26 49 21 39 56 39 59 23 64 45 63 65 60 26 24 26 57 62 33 60 39 21 22 26 60 39 39 56 21 27 34 22 26 35 28 35 19 27 58 40 34 49 49 51 50 41 56 51 52 39 23 21 50 52 24 24 41 37 56 56 24 28 24 111 53 37 24 48 36 Page 29
Lift Platform Detail Exploded View 85 38 38 38 132 70 70 38 133 38 70 71 69 61 72 76 76 76 86 76 76 76 102 88 116 114 77 44 44 77 134 39 46 47 113 114 66 45 63 64 47 24 128 118 57 81 55 134 89 121 108 87 66 45 46 68 112 125 126 74 24 115 130 78 82 114 117 119 90 73 43 131 55 120 42 84 83 Page 30 79 80 124 122 123
Braun® Limited Warranty WARRANTY COVERAGE AND WARRANTY COVERAGE TIME PERIODS The Braun Corporation (“Braun”) warranty covers certain parts of this wheelchair lift for three (3) years or 10,000 cycles and the cost of labor to repair or replace those parts for one (1) year or 3,000 cycles. This limited warranty covers substantial defects in materials and workmanship of the lift, provided that the lift is operated and maintained properly and in conformity with the owner’s manual.
Braun® Limited Warranty This warranty does not cover, and in no event shall Braun be liable for towing charges, travel, lodging, or any other expense incurred due to the loss of use of the product or other reason. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. HOW TO GET SERVICE To obtain warranty service the owner must do all of the following: 1.
Braun® Limited Warranty EVENTS DISCHARGING BRAUN FROM OBLIGATION UNDER WARRANTY The following shall completely discharge Braun from any express or implied warranty obligation to repair or replace anything and void this warranty: misuse, neglect, collision, accidents, failure to provide routine maintenance (See Owner’s Manual), unauthorized alteration, off road use, Acts of Nature, damage from weather or the environment, theft, vandalism, tampering, fire, explosions, overloading the product and odometer tamp
NOTES This page intentionally left blank.
"Providing Access to the World" ® Over 300 Braun Dealers Worldwide ® "Providing Access to the World" International Corporate Hdqrs: P.O.
Series 02 Service Manual for: CJKA+%(8 Under-Vehicle Lift® Private Use Wheelchair Lifts "Providing Access to the World" www.braunlift.com TM TM Braun UVL Series 31937 35033 November 2008 ® ® International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA 1-800-THE LIFT ® (574) 946-6153 FAX: (574) 946-4670 All illustrations, descriptions and specifications in this manual are based on the latest product information available at the time of publication.