INSTALLATION INSTRUCTIONS SERVICE MANUAL This manual provides instructions for the proper installation of the L 06 HAWLE stair lift. It is necessary to read and understand the contents of these instructions before starting installation of the lift. Please observe and note all CONDITIONS and WARNINGS prescribed throughout this manual. The stair lift and the corresponding rail are delivered with mounting drawing stating the values of the location quotas of the rail to the room walls, the height of the rail supports, their position on the stairs of the access path, and the inclination angles of the rail elements. If the lift s delivery is accompanied by drawings from the manufacturer, the dimensions and information contained in these drawings replace the corresponding information in this manual. We recommend that you check each time, at the reception of the delivery, the correlation between the content of packages and the accompanying document. CONTENTS 1. Preliminary checks... pag. 2 2. Content of packages... pag. 2 3. Required tools... pag. 2 4. Installation procedures... pag. 3 5. Adjustments when installing... pag. 15 6. Final checks... pag. 16 1 / 18
1. Preliminary checks Before you attempt the installation, please check the contents of the entire delivery since each order is customized, visually inspect the physical condition of the lift and the rail elements. Do not start installing the lift if there are missing parts or damaged parts! Inform your dealer or carrier if parts are missing or are damaged. 2. Content of packages - Actual lift - Rail elements - Mounting supports on stairs - Batteries 2 pcs. - Power supply from 110V mains - Electric conductors (red and black) - Bag of screws - Mechanical stoppers for the rail ends 2 pcs. - Plastic covers for the rail poles - Metal covers for the rail ends 3. Required tools - Ratchet (torque) wrench - Hammer drill - Cordless screwdriver - Drill bits for metal, wood and masonry (Ø 3.2... Ø 8) - M4, M5, M6, M8 taps - Extension cord for the power supply - Wood spacers - Mounting support pipes - Tape measure - Adhesive tape - Sandpaper - Cleaning cloths - Technical alcohol for cleaning - Vaseline - Brush or sponge for vaseline 2 / 18
4. Installation procedures The lift shall be installed in the following sequence: - identify each mounting support for the rail by reading the number in the bottom of each support and place the supports on the corresponding stairs, according to the installation drawing and the table with the heights of the supports. 3 / 18
- identify the elements of the rail in the upward installation order according to the number engraved on the tag attached to each element. - unpack the first upward rail element being careful when cutting the attachment clamps to avoid scratching the element - temporarly install this element on the supports already positioned on the steps 4 / 18
- insert the 2 electrical wires through the upper pipe of this rail, the lower end of the wires being pulled through the hole in the tube near the first pole, leaving a free end sufficiently long to allow its connection to the loading rail, securing the free end with adhesive tape to avoid pulling it back into the pipe - unpack the second rail element of the rail and bring to the installation area - wipe with a clean cloth both the connection fittings on the top of the first element and the inside of the pipes of the second rail element at the bottom end - place a thin layer of grease on the previously cleaned areas - insert the electrical conductors through the upper pipe of the second element - secure the second rail element temporarily to the rail on the supports installed on the steps and connect it to the first rail element through the guide fittings 5 / 18
- secure the two rigidly together with the fastening screws M6X25 which are installed in the installation eyelets arranged at the rear of each pipe of the rail, making sure that the two ends of both the upper pipe and the lower pipe are connected perfectly - if the rail is supplied with an intermediary loading station (DIAS), remove an electrical conductor loop through the hole existing near the central intermediary loading element, a loop long enough to allow the conductors to be connected to the loading element, and secure the loop with adhesive tape to avoid pulling it back into the pipe - do the same with the other elements until the installation assembly of the rail is complete. 6 / 18
- for the last element installed, pull the upper end of the conductors from the pipe through the hole near the last pole, leaving a free end sufficiently long to allow connecting them to the loading element, securing the free end with adhesive tape in order to avoid dragging it back into the pipe - place the entire rail at the angles for each section in accordance with the installation drawing, using the wood spacers which are placed under some of the fastening supports - place the rail on the stairs and walls observing the dimensions from the installation drawing - identify the rail end at which the lift installation can be carried out if the rail has at the bottom a horizontal start and the distance between the rail end and the first obstacle is sufficiently large, then the installation of the lift on the rail shall 7 / 18
be made at this end; otherwise the installation of the lift is made at the top of the rail - install the supporting pipes on the ends of the two pipes of the rail in the lift installation area - remove charging station from that end of the rail - bring the lift into the installation area and unpack - press the E-STOP switch on the main cover, loosen the main cover of the lift and install two batteries into their housing in the correct position. Fixing screw E-Stop Switch 8 / 18
- connect the supply wires to the battery terminals according to the wiring diagram Batteries Wires - Pozition the seat inside the reaming from the metal frame of the chair lift and fix it in the correct position. 9 / 18
- plug in the electrical connectors and tight securely the fixing screw. Electrical connectors Fixing screws - re-install the main cover, release the E-STOP switch and check engine operation by operating the control joystick in both directions. - if the engine is running properly, press again the E-STOP switch. - remove the wooden support plate at the bottom of the lift; this requires the lift to be mounted on a support (the first step of the stair) so that the two fastening screws at the bottom are visible. During the disassembly of the fastening screws, the lift must be supported in that position by one of the installers. - the lift moves to the end of rail. 10 / 18
- place the lift on the supporting pipes, making sure that all plastic rollers are well aligned with the installation pipes, and, for the guide rollers on the bottom pipe, making sure that they are in the correct position: the larger diameter ones must be at the top this is also indicated by the yellow warning labels installed on the sides of the cover that covers these rollers - move the lift on the supporting pipes until the sprocket comes into contact with the first tooth of the rack. - release the E-STOP switch button - check the position of the sprocket teeth to the rack so that one sprocket tooth is positioned in the direction of the first empty space between the rack teeth. 11 / 18
If this condition is not met, reposition and rotate the sprocket by turning it away from the rack until you get a desired sprocket position - operate the control joystick moving the lift toward rack, and move the lift in that direction until all plastic rollers entered the rail and have past the area where the loading element is installed - remove the supporting pipes and reinstall the charging station from the end of the rail - make a trial run with and empty lift on the full length of the rail, observing carefully both its proper functioning and its minimum distances to the stairs and walls (railing) - this pre-installation and these trials are used to check the rails adjustment on the stair and to make a primary check of the electrical and mechanical functions of the lift, since possible malfunctions due to transport and handling may occur. If these checks are positive, proceed with the permanent installation of the rail. - park the lift in an intermediary area of the rail so that its weight does not change the position of the rail, and press the E-STOP switch. - install the rail on the steps of the stair from the first support at the bottom and ending with the last support at the upper end, firstly installing the stair support foot with the supplied screws installed in the three holes provided in the foot, after which install the rail support pole by drilling the pole besides the hole existing in the support s pipe, and install the fastening screw. 12 / 18
- before making any electrical connections, bear in mind that all the ends of the electrical conductors entering the pipe through the holes should be wrapped in that area in a rubber tube to avoid damage to conductors at the contact with the holes edges - connect the electrical conductors passing through the upper pipe of the rail, the electrical conductors from the supply and stainless steel reeds from the loading element supplied with power with the supplied connectors, according to wiring diagram and instructions on the loading element: white conductor from the charger is installed to the indicated + reed, and the black one to the reed. - connect the electrical conductors passing through the upper pipe of the rail and the stainless steel reeds on each loading element (from the other end of the rail or from the intermediary station) using the supplied connectors, according to wiring diagram and the instructions on the loading elements - connect the charger to the mains 110V. - move the lift to one of the rail s ends and check its stop when connecting the brass pins on the lift s plastic loading support and the stainless steel reeds on the loading elements at the end of the rail - install the mechanical stopper at the end of the rail so that its front side (covered with rubber) is in free contact with the plastic cover covering the guide rollers, and that the fastening screw is positioned in the middle of the groove in the hald-round support of the stopper 13 / 18
- move the lift away from the loading element by cca. 19 in. (500 mm) - switch of the power supply - move the lift towards the loading element and check its stop at the contact with the mechanical stopper - move the lift away from the loading element by cca. 19 in. (500 mm) - reconnect the charger to the 110V supply - do the same for the other end of the rail - install the plastic cover on each rail pole - install the metal covers on the ends of the rail pipes 14 / 18
5. Adjustments when installing For the final vertical positioning of the lift adjust the ball joint item 1 from Figure 1 at the end of the tie bar item 2 to the correct position of the lift, then secure the thread of the ball joint with an adhesive type LOCTITE 243 and lock the safety item 3. Carefully install the snap ring item 4 on the bolt item 8, and the snap ring item 5 on the bolt item 7. CHECK THAT THE DIMENSION A IN FIG. 1 IS BETWEEN 0 0.55in (14mm). NO VALUES GREATER THAN 0.55in (14 mm) ARE ALLOWED FOR THIS DIMENSION! Fig. 1 15 / 18
6. Final checks Perform the final checks and adjustments to ensure a secure lift operation. Check the good electrical contact between the battery terminals and supply conductors clamps Check the correct position of all elements of the lift (chair, arms, leg support, covers) Check the travel command for the lift descent Check the travel command for the lift ascent Check the operation of the end of travel sensor situated beneath the cover of the upper guide rolls when ascending by pressing it and performing the ascent and then descent travel commands several times. At the first command, the lift should NOT start, and at the second IT SHOULD Check the operation of the end of travel sensor situated beneath the cover of the upper guide rolls when descending by pressing it and performing the descent and then ascent travel commands several times. At the first command, the lift should NOT start, and at the second IT SHOULD Check the operation of the fault limiting device when ascending by pressing its cam, which should interrupt any lift command activation Check similarly the fault limiting device when descending Check the operation of the obstacle sensors on the main cover when ascending by pressing the cover (simulating an obstacle) and performing the ascent and then descent travel commands. At the first command, the lift should NOT start, and at the second IT SHOULD Check the operation of the obstacle sensors on the main cover when descending by pressing the cover (simulating an obstacle) and performing the descent and then ascent travel commands. At the first command, the lift should NOT start, and at the second IT SHOULD. Similarly, check the operation of the obstacle sensors for the leg support and of the protection covers on the railing rollers. Check the «seat s correct position» protection by rotating the seat to left and right several times and performing the ascent and then descent travel commands. THE LIFT SHOULD NOT START FOR ANY OF THE COMMANDS. Check the sensors for limiting the rotation of the seat. Perform the rotation command and check if the seat stops at an angle 90 according to the client s requirement. 16 / 18
Perform the rotation command in reverse order and check if the seat stops in the correct position for travelling. Move the lift at the bottom of the rail and check if the travel speed reduces at a distance between 50-100 mm before activating the end of travel sensor. Proceed similarly for the top of the rail. Checking the battery charging devices: - Move the lift in the parking area and, when the end of travel sensor has stopped the lift, check if the collector reed of the supply device located on the lift is positioned at half length of the supply positioned on the rail, and that the electrical contact between them is done correctly If some of the results of the checks were not adequate, remedy deficiencies, and then recheck to make sure everything is working correctly. After these checks, perform a lift movement under load throughout the length of the rail observing the rigidity of the assembly and the clearance space between the lift and stairs, which should not be less than 20 mm. Similarly, check the clearance between the lift or any other possible obstacle (wall, rail, etc.), which should not be less than 10 mm. Check the operation of the remote control by sending the lift in the parking area and recalling it from the parking area THE RACK TEETH MUST BE LUBRICATED ALONG THEIR LENGTH WITH THICK VASELINE TYPE LGHP 2 LUBRICANT. After performing these operations, the lift is considered installed; fill in the installation check list shown in Annex M 1, which will be kept by the dealer for the entire life of the chair lift. Perform a practical demonstration of the operation of the lift in front of the client, making sure that they understand all the maneuvers necessary for the movement of the lift and all the stair lift features. Fill in the acceptance protocol of the lift in two copies according to Annex CT 1 from the TECHNICAL BOOK, a copy remaining in the technical book, and the other being retained by the company which carried out the installation for its records. Hand over the Operation manual to the final client and answer all questions related to the stair lift. 17 / 18
ANNEX M 1 SERIAL NO: STAIR LIFT CHECK LIST ON INSTALLATION DATE: VERIFIED BY: Last name: First name: Signature: 1. LEFT START: YES NO 2. RIGHT START: YES NO 3. MICRO-SPEED: YES NO 4. LOADING STOP DOWN: YES NO 5. LOADING STOP UP: YES NO 6. LEFT REMOTE CONTROL: YES NO 7. RIGHT REMOTE CONTROL: YES NO 8. LEFT MAIN COVER SENSOR: YES NO 9. RIGHT MAIN COVER SENSOR: YES NO 10. LEFT FOOT REST REED SENSOR: YES NO 11. RIGHT FOOT REST REED SENSOR: YES NO 12. FOOT REST COVER SENSOR: YES NO 13. FAULT MICRO-SWITCH: YES NO 14. LEFT ROTATION: YES NO 15.LIFT TRAVEL CHECK WITH ROTATED SEAT: YES NO 16. RIGHT ROTATION: YES NO 17. SUPPLY VOLTAGE CHECK: YES NO 18. NOISE: YES NO 19. VIBRATION: YES NO 20. SIDE INCLINATION: YES NO 21. FRONT INCLINATION: YES NO 22. RACK SPROCKET CLEARANCE: YES NO 23. LIFT VISUAL APPEARANCE: YES NO 24. RAIL VISUAL APPEARANCE: YES NO 25. ARM LIFTING: YES NO 26. SEAT LIFTING: YES NO 27. FOOT REST LIFTING: YES NO 28. POLE FASTENING: YES NO 29. MINIMUM LIFT-WALL DISTANCE >= 10 mm YES NO 30. MANUAL LIFT TRAVEL YES NO 18 / 18