Installation & Service

Transcription

1 Installation & Service STAIR LIFT WARNING! STRICT ADHERENCE TO THESE INSTALLATION INSTUCTIONS is required and will promote safety of those installing this product, as well as those who will ultimately use lift for its intended purpose. Any deviation from se instructions will void LIMITED WARRANTY that accompanies product. Additionally, any party installing product who deviates from INSTALLATION INSTRUCTIONS shall be taken to agree to INDEMNIFY, SAVE AND HOLD HARMLESS manufacturer from any and all loss, liability or damage including attorney fees, that might arise out of or in connection with such deviation.

2 INTRODUCTION This stair lift installation manual has been written to provide clear and precise instructions for proper installation procedures for Rave stair lifts. Please refer to Owner s Manual for Limited Warranty information and operating instructions. The Owner s Manual must be given to owner of lift before it is put into service. Any alterations to equipment without written authorization by manufacturer may void warranty. AmeriGlide lifts are designed to install with as little assembly by installer as possible. If you have questions, concerns or comments, please contact AmeriGlide s Technical Service Department at Important! It is imperative that this manual be read and understood prior to attempting installation of stair lift. Please observe all cautions and warnings in this manual, as well as on labels on equipment. 2 // 28

3 TABLE OF CONTENT I. PRELIMINARY CHECKS 4 A. Tools required 4 B. Included parts 4 II. INSTALLATION PROCEDURES 5 A. Determine rail length 5 B. Rail installation 6 C. Chassis installation 8 D. Final rail installation 9 E. Footrest and seat installation 10 III. REMOTE CALL/SEND CONTROL OPERATION 12 A. Remote control operation 12 B. Remote control reprogramming 12 IV. COMPLETION PROCEDURES 13 A. Test armrest control switch 13 B. Tighten brackets 13 C. Set upper and lower travel limits 14 D. Test safety stop switches 14 E. Additional System Checks 15 V. FOLDING RAIL INSTALLATION 19 VI. FOLDING RAIL CONVERSION 20 INDICATIONS OF USE STATEMENT The Rave stairway chairlift assists with transfer of patients or mobility impaired persons, up and down between levels of a residential or private facility. 3 // 28

4 PRELIMINARY CHECKS TOOLS REQUIRED The following is a suggested list of basic tools to have on hand during installation. Cordless drill Allen wrench ( 5 / 64 ", 5 / 32", 3 / 16", 5 / 16") Phillips screwdriver (#3) Nut driver ( 3 / 8" and 5 / 16") 6-10" driver extension T30 Torx bit (included) Level Hack saw or chop saw Voltmeter INCLUDED PARTS Before beginning installation, please inspect and check box contents. Report any damage to your dealer. Chassis Box: Chassis Call/send parts 2 Call/send hand controls Velcro fasteners Battery charger Manual hand crank Installation manual Owner s manual Rail Brackets (2, 3, 4 or 6 per set) Wood screws #14 x 2"(4 per rail bracket) Rail Box: Bottom rail pre-installed with: Bottom end plate Charge strip wire harness Bottom limit cam Joint pins and joint brackets (two-piece rail only) Plastic gear rack Top rail pre-installed with: Charge strip wire harness Rail accessories (plastic bag): Top end plate Compression bolts (2 sizes) Chair and Footrest Box: Self-cutting screws ( 1 / 4 "-20 x 1") Chair and seat belt Torx T30 driver bit Footrest complete with: Rail Parts (plastic bag) Adjustable seat height frame Extra plastic racks (2 or 3) Plastic vertical cover Top limit cam Nylon plugs Seat swivel post with fasteners 4 // 28

5 INSTALLATION PROCEDURES II. INSTALLATION PROCEDURES A. DETERMINE OVERALL RAIL LENGTH (Only if track did not come pre-cut to length) Step 1: Determine any obstructions that will affect position and length of rail. These may include walls, doors, hallway orientation, etc. Step 2: First, measure overall length of stairs from nose at top landing of stairs to floor at bottom (nose to floor measurement, e.g., 128", see image below). Step 3: For a normal stairway where re is adequate space for a landing, add 7" to nose to floor measurement. This will provide enough rail length to allow stair lift to be adjusted so that floor-to-seat height will be same at both top and bottom (e.g., 135"). Step 4: If top landing has restrictions (i.e., a wall or doorway), use chart below to determine length of extension needed. Step 5: To cut rail, use a standard 12" chop saw, with a blade designed to cut aluminum. Do not cut rail inside house (aluminum chips are very hard to remove from carpets). Tip! DO NOT cut end of rail that contains joint holes. Remove charger strips and wire harness before cutting. Extension 7" 9" 11" 13" 3.9" 5" 6.1" 7.2" Horizontal intrusion on top landing 5 // 28

6 INSTALLATION PROCEDURES B. RAIL INSTALLATION Step 1: Open rail box and remove contents. Step 2: Position bottom rail ( rail with end plate attached) directly on stairs with end plate towards bottom of stairs and plastic rack facing up. Place an object that measures between 3 / 4 " and 1" between end plate and floor. Tip! Step 2 Use chair box or anor heavy object, like a toolbox, at bottom to prevent rail from sliding down stairs. Step 3: Position two ends of track close toger. Locate and connect plug on ends of two charger harnesses inside two track pieces. Step 4: With plastic rack facing up, slide top rail into bottom rail and guide m toger using pre-installed pins. Gently tap top rail if necessary to get m close toger. Be cautious not to pinch charger harness. Step 5: Install two (2) joint fasteners and firmly tighten with 3 / 16" Allen wrench. Then slide rack pieces down to cover joint. Step 6: Turn over joined rails and install remaining two (2) joint fasteners and firmly tighten with 3 / 16" Allen wrench. Then slide rack pieces down to cover joint. Step 7: Install rail brackets by loosening screws and snapping each bracket edge into slot, or slide brackets on from top of rail. When in final position, nuts will be on wall side. Step 4 Step 5 Wall Side Step 6 Step 7 6 // 28

7 INSTALLATION PROCEDURES Step 8: _A. For double rails, tighten first rail bracket in place so that, _when A. For turned double over, rails, tighten back of first bracket rail bracket touches in place rear so of that, _first when step turned from over, bottom back landing. of Place bracket and touches tighten rear second of _and third first step brackets from on bottom steps landing. on each Place side of and tighten rail joint, again second and third brackets on steps on each side of rail _so joint, back again of so bracket back of touches bracket rear touches of step. rear Then of _place step. fourth Then place and final bracket fourth and on final last bracket step before on last top step _landing, before again top tightening landing, again it so it tightening touches it so front it touches of rear of front last of step. rear of last step. _B. B. For For single single rails, rails, tighten tighten first first rail rail bracket bracket in in place place so so that, that, _when when turned turned over, over, back back of of bracket bracket touches touches rear rear of of _first step first step from from bottom bottom landing. landing. Place Place or or rail bracket rail on _ bracket last step on before last step top before landing, top again landing, tightening again it tightening so it touches it so it touches rear of rear last of step. last step. Step Step 9: 9: Turn Turn rail rail right right side side up up (plastic (plastic side side facing facing up). up). Step Step 10: 10: Measure Measure any any obstruction obstruction from from wall wall (this (this may may include include handrails,molding, handrails,molding, light light switches, switches, etc.) etc.) and and adjust adjust edge edge of of brackets brackets an an equal equal distance distance from from wall. wall. Step 11: The underside of rail must be at least 2" above stair Step 9 Step 11 tread nose to provide clearance for footrest. To achieve this 2" clearance Step 11: The move underside railand of bracket rail must forward. be at Once least 2" above clearance stair is 2" tighten tread nose all bracket to provide nuts clearance to hold for brackets footrest. in position. To achieve To maintain this 2" clearance 2" clearance, move and rail to hold and bracket rail in forward. place,secure Once bottom clearance is bracket 2" tighten to all bracket first step nuts from to hold floor brackets with 2-2" in wood position. screws, To maintain using a 3/8" 2" nut clearance, driver on and a 6-10 to hold extension rail of in a place,secure cordless drill. bottom bracket to first step from floor with 2-2" wood screws, using a 3 / 8" nut driver on a 6-10" extension of a cordless drill. 7 // 28

8 INSTALLATION PROCEDURES C. CHASSIS INSTALLATION Step 1: Remove plastic bag from chassis box. Lift chassis with manual override hole (on bottom) facing downhill side of stairs and gently slide chassis onto rail until it makes contact with plastic rack. Do not let chassis free fall down rail. CAUTION! Be careful not to trap fingers between rail and chassis. Step 1 Step 2: Remove safety tie and turn red ON/OFF switch to ON position (I). Step 2 Step 3: Use installation switch ( black switch on top of chassis) to move chassis at least two (2) feet down rail, pushing gently on chassis to ensure chassis does not pull any rack to top. Step 4: Loosen, but do not remove, four (4) seat-leveling bolts - two (2) on each side of chassis and n align m vertically using a level. Firmly tighten two (2) bolts on side of chassis facing wall. Step 3 CAUTION! Do not ride on chassis or lift until install is complete. 8 // 28

9 INSTALLATION PROCEDURES D. FINAL RAIL INSTALLATION Step 1: Install remaining plastic rack pieces in upper rail. Step 2: Use a hacksaw or chop saw to cut last plastic rack piece flush with rail end. Place something on floor to catch debris or mark and cut rack outside. Step 1 The exposed, cut end of plastic rack should be facing top end of rail ( factory-cut side should butt against lower rack). Step 3: Slide top limit cam into one of cam slots (it doesn t matter which side), and tighten pre-inserted Allen screw with a 5 / 64" Allen wrench. This will be used to set final upper limits for stair lift. Step 4: Remove charging strip from rail box. Connect charging strip connector to charger wire that runs through center of rail from lower charging strips. Insert two (2) charger strips into keyed slots at top of rail (while standing on top landing looking down). The charging strip with red wire should be inserted into left slot with metal strip facing out. The charging strip with black wire should be inserted into right slot with metal strip pointing out. Step 2 Step 9 Bend red and black wire tabs in toward center of rack. Insert excess cable into rail, leaving pigtail with Molex connector. Step 5: Install end plate to top of rack with four (4) selfcutting Torx screws using supplied T30 Torx bit. Tip! Too much torque applied to se screws may result in damage. Take your time and apply grease to threads. Step 5 Step 6 Step 6: Install one of rack pre-compression screws in threaded hole in top plate of rail, and tighten it as firmly as possible by hand with a 5 / 32" Allen wrench. There are three (3) kinds of pre-compression screws: 1. 3 / 4" for tracks up to 12' 2. 1" for tracks over 12' Step 7: Plug in battery charger at eir end of rail, depending on closest or most convenient location of a wall power supply. Minimize wire length and intrusion. Step 6 Step 7 9 // 28

10 INSTALLATION PROCEDURES E. FOOTREST & SEAT INSTALLATION Step 1: Remove footrest from box and use installation switch to drive chassis downward to a position about 6" clear of floor. This will provide a safe area to install and adjust footrest. Do not drive unit into bottom stop. Step 2: Turn red ON/OFF switch located on top of chassis to OFF position (0). Step 3: Position footrest onto two (2) seat-leveling bolts on outside of chassis by aligning large opening at slot ends of footrest. Step 4: Ensure footrest is fully engaged. Step 5: Check that height of seat base is correctly set for intended user. A seat height guide is provided behind plastic footrest shroud. Consult with client and use an existing chair or walker with armrests as a guide. If height of seat needs to be adjusted, loosen and remove four (4) bolts on sides of seat base using a 5 / 32" Allen wrench. Adjust seat base up or down relative to footrest structure until holes align, n replace and securely tighten four (4) bolts. Step 6: Connect footrest cable to 6-pin connector on chassis. Step 7: Position keyed seat swivel post in hole in seat base hole closest to top of stairs. Securely tighten two (2) bolts on sides of hold using a 5 / 32" Allen wrench. Step 8: Use supplied white plastic plugs to secure vertical footrest shroud to main footrest cover plate. Step 9: Position seat directly aligned over carriage and place onto seat swivel post. Depress swivel lever until seat is fully engaged with swivel post. Check swivel lever to test locking mechanism. The system will not function if proper engagement is not achieved. Step 10: Connect seat cable to 8-pin connector on chassis. Tip When 6-pin footrest and 8-pin chair cables are both connected to chassis, black installation switch on chassis is disabled and will not function. Step 1 Step 5 Step 5 Step 6 Step 7 Step // 28

11 INSTALLATION PROCEDURES Step 11: The armrest control is factory set for right-hand operation. If user prefers to operate armrest controls with ir left hand, loosen single screw on underside of each armrest and slide each armrest upwards. Disconnect plug on armrest control, switch armrests, and reconnect plug. Replace armrests and tighten screws. Step 11 Step 12: If lift is equipped with optional key lock, ensure that key switch on armrest control is in locked position (with key in vertical position). Step 13: Turn red ON/OFF switch located on top of chassis to ON (I) position. You should hear a single beep and LED indicator light on armrest control should cycle through a test sequence, showing red, yellow and green respectively. If any of system controls or safety sensors are engaged LED indicator light will turn to yellow. Step 14: If LED indicator light is not green, check safety sensors: 1. Seat swivel sensor (seat should be in locked position) 2. Footrest lower sensor (check by pushing in on safety pan on footrest) 3. Upper foot pan safety sensor (check by pushing on safety pan on footrest). 4. Front foot pan safety sensor (check by pushing on safety pan on footrest). 5. Uphill safety sensor (ensure nothing is blocking upward passage) 6. Downhill safety sensor (ensure nothing is blocking downward passage) Step 11 Step 12 Step 13 Step 14 If LED indicator light is still not green after testing sensors, turn unit off and recheck all wire plugs. Turn unit on again and recheck LED indicator light cycle. When LED indicator light remains green lift is ready to operate. 11 // 28

12 REMOTE CALL / SEND CONTROL OPERATION III. REMOTE CALL/SEND CONTROL OPERATION A. REMOTE CONTROL OPERATION The optional key switch on arm of chair must be in ON position to use remote call/send control. Step 1: Press and hold appropriate directional button on front of hand control. The LED indicator light will turn green when a signal is being sent. The chair lift will operate with or without a rider. All safety sensors on chair lift are designed to continue to operate in ir normal mode. The LED light indicator on armrest will also display appropriate color. Step 2: If chair lift fails to respond, this may be an indication that batteries are discharged and need to be replaced. Remove back cover of control and replace with commonly available AAA batteries, ensuring that polarity is correct. B. REMOTE CONTROL RE-PROGRAMMING All call/send controls are factory programmed. Re-programming is not normally necessary during installation. In event that remote call/ send control needs to be re-programmed, it is essential to program BOTH controls in one programming cycle. Do so by completing following: 1. Start with red ON/OFF switch in OFF position (0). 2. Disconnect 6-pin footrest and 8-pin chair wire harnesses from chassis. 3. Press and hold install switch (located on top of chassis) in eir direction. 4. Turn red ON/OFF switch to ON position (I), and n release install switch. 5. The lift will begin to beep rapidly (this means first remote control is ready to program). 6. Press and release UP or DOWN button of first remote control ( first remote control is now programmed). 7. Press and release UP or DOWN button of second remote control ( second remote control is now programmed). 12 // 28

13 COMPLETION PROCEDURES 8. Upon completion, two beeps will indicate that both remote controls have been programmed. 9. Turn ON/OFF switch to OFF position (0). 10. Connect 6-pin footrest and 8-pin chair wire harnesses to chassis and n turn red ON/OFF switch to ON position (I). 11. Test each remote control in both up and down directions. IV. COMPLETION PROCEDURES A. TEST ARMREST CONTROL SWITCH The optional key switch on arm of chair must be in ON position to use remote call/send control. Step 1: Ensure that unit travels correctly by operating armrest control switch while standing in front of unit. Step 2: Depress switch in upstairs direction to move up. The lift will beep, wait three (3) seconds and begin to smoothly accelerate upwards. The lift will continue to move upwards as long as switch is depressed. Step 3: Release switch and lift will come to an immediate stop. Step 4: Depress switch in downstairs direction to move down. The lift will beep, wait three (3) seconds and begin to smoothly accelerate downwards. Step 5: Release switch and lift will come to an immediate stop. Step 6: Run chair all way up and down rail to ensure that top of seat back has at least a 1/2" clearance from wall and any obstructions. Caution! Do not ride on chassis or lift until install is complete. B. TIGHTEN BRACKETS Step 1: Install and fully tighten rail bracket mounting screws four (4) screws per bracket. For hardwood stairs, a pilot hold should be drilled first. For plywood or particle board stairs care must be taken to prevent stripping. 13 // 28

14 C. SET UPPER AND LOWER TRAVEL LIMITS Step 1: Test lower travel limit by operating lift downward, keeping switch depressed. The unit should begin to decelerate about 3" from its final resting position and stop clear of floor. Step 2: The final stopped position can be adjusted to accommodate height of user by repositioning limit cam located in a slot in rail. Step 3: Use a 5 / 64" Allen wrench to loosen set screw in limit cam. Adjust limit cam up or down and retighten set screws. Repeat above Steps until lift stops in desired position. Step 4: Repeat above Steps to set upper limits. For safety, footrest should be set at least level with upper landing. Step 5: The optimum position is met when seat height above floor is same at top and bottom of stairs. D. TEST SAFETY STOP SWITCHES Step 1: Safety stop switches are located in both upward and downward ends of chassis providing protection from obstructions on rail. Step 2: Safety stop switches are located in footrest bottom pan providing protection from obstructions and trapping hazards on stairs. Step 3: Safety stop switch is part of swivel seat mechanism and prevents lift from operating when swivel is in use. Step 4: Test all safety stop switches by driving lift down and touching downward end of chassis, lower edge of footrest, and underside of footrest in both its folded and unfolded positions. Step 5: In each of above cases unit should come to an immediate halt. The LED indicator light on armrest control should turn to orange and unit should beep intermittently. Step 6: When control switch is released, unit should NOT be able to be driven in direction that lift initially engaged obstacle. Test this condition. Step 7: Test to ensure that lift can only be driven away from obstruction. The LED indicator light will turn to green and stop beeping indicating a safe operating condition. Step 8: Repeat above tests while driving lift in opposite direction. Step 9: If any safety condition does not function properly, carefully review all installation instructions, reset ON /OFF switch and check that LED indicator light is green. Repeat above tests. Step 10: If any safety stop switch fails to immediately stop lift and/or a red LED indicator light appears, remove key to prevent furr use of lift and immediately call manufacturer for assistance in diagnosing and repairing problem. Do not use lift until repaired. 14 // 28

15 E. ADDITIONAL SYSTEM CHECKS Step 1: After successful testing of all safety switches, sit on lift and operate to top of stairs. Keeping control switch depressed continuously, lift should gently decelerate and n stop at top of track. Step 2: As a final adjustment, sit on lift and do two (2) complete up trips and stop with chair at bottom. Then tighten compression screw in top end plate, n run chair to top and again tighten compression screw. Run chair to middle and do a final tightening of compression screw. Step 3: Drive lift to bottom, keeping control switch depressed all time, and check that lift gently decelerates and stops so footrest pan is clear of floor. If necessary adjust limit cams with a 5 / 64" Allen wrench. Step 4: Move lift about three (3) feet from eir top or bottom of rail. After 30 seconds armrest LED indicator light will show orange and beep indicating that lift is not positioned on a charge point. The beep will stop after 30 seconds, but armrest LED indicator light will continue to flash orange. Step 5: Test seat swivel at top by using levers and swiveling seat towards landing and stop seat at 35 and 85. The seat swivel levers will release into a locked position at each of se angles. The lift will not operate in any of se positions if control switch is depressed, and LED indicator light will turn orange. Return seat to its normal position and LED indicator light will turn green and lift will now operate normally. Step 6: Drive to top or bottom and check battery charging light. If light is orange or red, batteries are being charged. THE LIFT IS NOW READY TO USE! 15 // 28

16 FOLDING RAIL INSTALLATION Note! The photos in this section show a left folding rail, assembled to be installed on left side of stairway. If you re assembling a right side, please complete all of se steps in mirror-image to what s shown. The rail can be disassembled and switched from a left or a right if necessary. Instructions for this procedure can be found on page 20 of this book. As always, if you encounter any difficulty, please call Ameriglide Technical Support toll free at A. RAIL INSTALLATION PREPARATION TOOLS REQUIRED The following is a suggested list of basic tools to have on hand during installation. q Wrenches q High torque drill q Allen wrenches (standard SAE set) q Carpenter s square q Pencil q Tape measure INCLUDED PARTS Before beginning folding rail installation, please inspect and check box contents. Please note that Rave Parts Box is omitted on new units since se parts are factory installed on stair lift. Report any damage to Ameriglide or freight carrier. Rail Box: Assembled Folding Rail Track Bracket Box: Two (or more) assembled short track brackets, rack pieces, two adjustable feet Rave Parts Box: Folding track side-plate Screw Modified front and rear Rave safety switch bumpers. For new units, this box is omitted and se parts are already installed on stair lift. 16 // 28

17 B. FOLDING RAIL INSTALLATION PROCEDURES STEP 1: Orient two track brackets onto folding rail as shown at right, with nuts on same side as folding mechanism (for eir left or right folding). STEP 2: Expand and snap two brackets over track, so top is in bracket-groove. STEP 3: Tighten partially two whiz nuts that position se on track, using a 1 / 2" wrench (deep socket preferred), so y won t slide when you re test-fitting position. STEP 4: Place track onto stairway with bottom bracket on second step, as shown. Note that bottom feet should approximately rest on floor with rail straight, but y will be adjusted later. If you re adding folding rail to an existing stairway, run Rave all way to top of stairs so it is out of way. Note that track brackets install with roundhead of carriage bolts facing stairs, nuts are toward wall. In this position, y are designed to lean track slightly toward wall. STEP 5: Measure to verify that underside of rail is more than 2 inches from stair noses, both at second step bracket and at upper bracket. If not, reposition brackets as needed. This clearance is required for stair lift footrest. In some installations, you may not be able to get 2 or more inches with standard stair-bracket. Contact Ameriglide to get higher brackets. STEP 6: Retrofits: FIT THE RAIL: If this is a new-install, upper rail will be pre-cut at factory to correct length. If this installation is a retrofit to an existing stair lift, use a carpenter s square to match-mark from top of folding rail to point on existing rail where it will have to be cut to splice. STEP 7: Retrofits to existing stair lifts, measure how much you ve marked to cut from upper section, but don t cut it at splice because you ll need to keep countersunk holes. Instead, remove very top cap and cut it from top of very top track piece. Loosen remaining brackets and slide tracks all up so new cut part is at top where old part was. Step 1 Step 3 Step 4 Step 6 Step 7 17 // 28

18 STEP 8: Retrofit to existing track, saw track following usual procedure, described in installation manual. STEP 9: Measure from side of rail to wall. The minimum clearance that will work with a folding stair lift rail is 3". Set folding section of stair lift rails to a distance of 3" from wall or more. This will leave about 1 / 2" of clearance at ball of gas-spring. Step 9 STEP 10: Fasten down near corner of lower bracket using a drill that has extensions at least ten-inches long and a 3 / 8" socket. Step 10 STEP 11: Measure from side of rail at upper bracket of folding rail. Also set this at 3" or more. Screw down one corner of bracket. STEP 12: Install new or join to existing upper rail, following regular procedures (this procedure is detailed in Rave Installation Manual (not shown). This procedure includes plugging battery charging wire harness for folding rail into charging harness from upper track. The charger itself can be plugged into eir top rail (for top of stairs), or to charge plug from folding rail, which comes out just higher than folding mechanism for bottom of stairway. STEP 13: Fasten down or three bolts of both track brackets using power drill and long extension with 3 / 8" socket. STEP 14: Install and adjust height of two feet using a 9 /16" open end wrench. Set m so that both rest on floor with rail fully straight. The foot farr from Step 14 wall should be set a little taller than inside one to get it to seat flat on floor, since Rave track brackets intentionally lean track toward wall just a little. STEP 15: If you re installing feet onto carpet, you may want to screw-down a piece of wood or metal to make feet seat reliably. Orwise, you can set lift at bottom of rail and let it compress carpet for a day, and n re-adjust feet. Step 11 Step // 28

19 STEP 16: Carefully move fork with your hand (don t get pinched!) To make sure it operates smoothly. Watch it go to floor. Make sure both feet sit fully on floor. Make sure hinge-joint is going fully straight. STEP 17: Follow normal procedure for installing track brackets and tightening m. This procedure (not shown here) is detailed in Rave Installation Manual. STEP 18: Begin to install folding rail parts onto Rave chassis. Shown here is just a bare Rave chassis, to make pictures more clear. First, with a 5 /16" Allen wrench, remove two large black cap screws from wall-side of unit, n install folding rail side-plate, but don t tighten m yet. STEP 19: Install #8 screw, n tighten it and two Allen head bolts. If your Rave stair lift is still installed on track, you ll have to use a short wrench and maybe a right-angle screwdriver. STEP 20: Remove both front and rear bumpers from Rave chassis. Switch m for ones in parts box. They both are attached with Phillips screws. STEP 21: Test ride unit a couple of times to verify that folding rail is operating properly. STEP 22: This completes this procedure. We recommend you use a household cleaner and paper towels to clean it before turning it over to end user. Step 18 Step 19 Note! Step 20 The Ameriglide folding rail for Rave is designed so that all of parts are ambidextrous and can be switched from one side to anor in about 15 minutes by a skilled technician. Also, se pictures show changes to Rave being made to a chassis that are not installed on a rail. There s no reason that se changes cannot be made on a Rave that is already mounted on a rail, but you may have to remove more items than are shown here. If you encounter any problems or questions, call Ameriglide Technical Support toll free at // 28

20 FOLDING RAIL CONVERSION VI. FOLDING RAIL CONVERSION A. WHERE YOU SHOULD WORK Ensure that you have a sufficient amount of space. This process can be done on a workbench or on floor. Choose a work surface that isn t going to damage finish, such as carpet or a large piece of cardboard. B. TOOLS REQUIRED q Wrenches ( 1 /2" deep socket, 9 /16 " open end and 13mm wrench or socket q Allen wrenches ( 3 /16", 1 /4", and 5 /16") q Pencil q Phillips screwdriver, size #2 ( medium size) TOOLS Optional q White lithium grease q Spray cleaner q Paper Towels C. FOLDING RAIL CONVERSION PROCEDURES STEP 1: Remove gas strut from right-hand stair rail s two ball mounts. These two Step 1 To remove ball mounts, remove wire retainer clips that hold m on. Pull ball-ends straight-up to remove. Step 1 Use a 13mm wrench to remove both ball mounts from link arm and fork. Take both ball-ends out and set m aside. Leave jam-nuts on m. Step 1 20 // 28

21 STEP 2: Remove shoulder bolts for link arm. Use a 3 /16" Allen wrench to remove link bolt from lift arm. These two Step 2 STEP 3: Catch link and set it aside. Be careful not to damage paint. Step 3 STEP 4: Use a 1 /4" Allen wrench to remove shoulder bolt that lift-arm pivots from. STEP 5: Remove shoulder bolt that fork pivots from. Step 4 Step 5 STEP 6: To remove lift arm from slider shoulder-bolt, insert a 3 /16" Allen wrench into shoulder bolt of lower bracket. STEP 7: Remove shoulder bolt and jam-nut from lift arm. Step 6 STEP 8: Flip lift-arm over and reinstall shoulder bolt with its jam-nut. Step 8 STEP 9: Use a 1 /2" socket to loosen two nuts that hold lower slide-bracket to lower track. Don t remove m, only loosen about two turns. Step 9 21 // 28

22 STEP 10: With elbow of folding track bent, slide hole lower slide-bracket off lower track out of opening from elbow. Flip it over so black plastic is toward floor. Step 10 STEP 11: Reinstall it back on track. Slide it to about same position where it was. Don t tighten it yet. Step 11 STEP 12: Turn whole assembly over to allow you to reach or side. Step 12 STEP 13: Use a pencil to mark where upper bracket is mounted on track. Step 13 STEP 14: Use a 9 /16" wrench to loosen two bolts on upper bracket. Loosen each about 2 turns. Step 14 STEP 15: Slide upper bracket off upper track out of open elbow. Step 15 STEP 16: Flip upper bracket over. Step // 28

23 STEP 17: Slide it back onto upper track section. Step 17 STEP 18: Line it up with your pencil mark and move lift arm until pivot aligns with new position of upper bracket. Step 18 STEP 19: Install pivot shoulder-bolt. Get it tight, ref about 15'-lb of torque. Step 19 STEP 20: Position fork on or pivot. Install fork pivot shoulder bolt and tighten. Step 20 STEP 21: Position link arm as shown at right between tracks and two pivoting arms. Step 21 STEP 22: Start both shoulder bolts on ends of link arm. Don t tighten both until both are started. Step 22 STEP 23: Put two ball-studs for gas strut, with ir two jamnuts, into ir holes and tighten m. Step // 28

24 STEP 24: Make sure wire-retainers aren t in gas strut, n snap gas strut onto ball ends. You have to compress strut a little to fit both ends. STEP 25: Push ends of gas strut onto ball-studs. Step 24 STEP 26: Put wire-retainers into both ends of gas strut. Step 26 STEP 27: Unfold rail so it is straight. 1/4" Gap STEP 28: Position bottom bracket so re is about a 1 /4" gap between shoulder bolt and forward end of slot. Step 28 STEP 29: Tighten two nuts with a 1 /2" socket wrench, ref. tighten to about 10' lb. Step 29 STEP 30: Now begin changes necessary for Rave unit. The changes are shown here on bar chassis for clarity here. Use a #2 (medium size) Phillips screwdriver to remove screw toward up-side of Rave side-plate. Step 30 STEP 31: Use a 5 /16 " Allen wrench to remove two large bolts that hold side-plate onto Rave unit. Step 31 STEP 32: Remove side plate. Step // 28

25 STEP 33: Reinstall both of large Allen bolts in unit and tighten m. Step 33 STEP 34: Remove two large bolts from or side and install side-plate. Align and start Phillips screw and two large bolts before you tighten any of m. Step 34 STEP 35: Use a #2 Phillips screwdriver to remove lower safety switch bumper from Rave unit. It has four screws. Step 35 STEP 36: On back side of bumper, remove two screws that hold angled metal arm. This arm is to prevent Rave from being able to travel down if rail is already folded down. Step 36 STEP 37: Flip arm to or side and reinstall it. The necessary holes should already be in safety bumper. Step 37 STEP 38: Reinstall bumper onto Rave. STEP 39: You may now spray unit with a household cleaner and wipe it clean. Step // 28

26 NOTES: 26 // 28

27 NOTES: 27 // 28

28