Braun Under-Vehicle Lift NUVL603C Service Manual

Service Manual for:

CJKA+%(8

CJKA+%(8

Under-Vehicle Lift

®

Private Use Wheelchair Lifts

www.braunlift.com

Series 02

DOT — Private Use Lift

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).

02

W

A

R N I N G

Man

ual

"Providing Access to the World"

International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA

1-800-THE LIFT

35033

November

2008

®

[phone] FAX: [phone]

®
®

Patent #5,305,486

Patent #5,305,486

Read manual
before installing
or servicing lift.
Failure to do so
may result in
serious bodily
injury and/or
property damage.

Braun UVL SeriesTM

Braun UVL SeriesTM

OWNER'S WARRANTY REGISTRATION

PURCHASED FROM

DATE INSTALLED

NAME

ADDRESS

CITY

TELEPHONE

TO VALIDATE WARRANTY

REGISTRATION CARDS MUST BE RETURNED TO THE BRAUN CORPORATION.

OWNER

STATE ZIP

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.
Braun UVL Series™ lifts are built for dependability and will provide years of plea­sure and independence as long as the lift is installed and serviced as specified by a
Braun certified technician, and the lift is operated by an instructed person.

Sincerely,
THE BRAUN CORPORATION

Ralph W. Braun
Chief Executive Officer

Warranty and Registration Instructions

Immediately upon receiving the lift, examine the
unit for any damage. Notify the carrier at once

Series No.

Serial No.Model No.

with any claims.

NUVL603C 02-00025

Two warranty/registration cards (shown right) are
protected in a clear envelope and attached to the
lift protective shipping wrap. The sales representa­tive must process one of the cards. The consumer
must fill out the other card and mail it to The Braun
Corporation. A detailed warranty section is provided
in this manual. The warranty cards must be

Sample Warranty/Registration Card

processed to activate the warranty.

Two Braun Serial No./Series No. identification tags (shown below) are posted on the lift. One
I.D. tag is posted on the left platform side plate (outboard end). A second I.D. tag is located
inside of the pump module. Both I.D. tags provide the product identification information
provided on the warranty/registration card. Record the information in the space provided (or
document on a copy). This information must be provided when filing a warranty
claim or ordering parts.

The Braun Corporation

1-800-THE-LIFT

BRAUNMOBILITY.COM

DOT Private Use Lift MODEL#

NUVL603C

Max. Lifting Capacity - 750Lbs.

SERIAL NUMBER

02-00025

®

®

Model No.

Series No.

Serial No.

MFG DATE

11/12/2007

e5*72/245*95/54*0102*00

Sample Serial No./Series No. Identification Tag

PATENT

5,305,486

Pump Code

Cylinder Code

Date of Manufacture

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 ....................................................11

Maintenance and Lubrication Schedule ............... 12-14

Troubleshooting Diagnosis Chart ......................... 15-18

Notes ............................................................................ 19

Lift Wiring Schematic - Main ..................................... 20

Lift Wiring Schematic - Accessories ........................ 21

Hydraulics

Hydraulics Parts List .................................................. 22

Hydraulics Diagram .................................................... 23

Repair Parts

Pump Module

Pump Module Parts List ....................................... 24

Pump Module Diagram ......................................... 25

Lift Exploded Views

Complete Lift .......................................................... 26

Repair Parts List ................................................... 27

Housing Detail ........................................................ 28

Carriage Detail........................................................ 29

Platform Detail ........................................................ 30

Warranty

®

Braun

Limited Warranty .......................................31-33

Notes ............................................................................ 34

Page 1

Hand-Held Attendant's

Control Box

Lift Terminology

Lift Mounting

Brackets (4)

Chain Drive

Motor

Hydraulic

Cylinder

Inboard

Locator

Torque

Tube

STOW

R
DOO

P
U

N
DOW

Module

Pump

Inboard

Lift Housing

Platform Cable-activated

Manual Release System

Right

Lifting

Arms

Outer Barrier

Actuator

Carriage

W

A
R

N
I

N
G

P
u
sh
ma

T

­h

n

a
ual

n

and ou

dl
l
y m

e in

lock b

ove
t t

f
u

o

lly

Fa

platform in

e
ef

n

a

ilure to lock platfo

nd

o

gage pla

re dr

re
s
u

i

vi
l
t

deploy

n

t

i

f

n

g

o

vehi

u

r
m

nint

platform d

m

cl

e

e

e.

nt. Unintended

n

rm

r

d

e
sult

ed pla

ma

eployment

a

y

i

n

n

d/or p

t

se

f
o
rm

riou
roper

s

m

bo

a

ty da

y

dil

y
injury

Do not remove!

m

a
g
e

.

8
1
8
23

Platform

Rolling

Horizontal Arms

Outer

Barrier

Left

Outboard

Page 2

Switch and Sensor Locations

Lift Out
Cam
73774

Lift Out
Limit Switch
73950A

Full Out
Limit Switch
73950A

Full Out
Cam
73775

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

OWN
D

Inboard

Left

Right

Outboard

W

A
R
N

I
N

G

Pu
sh

T­m
a

h
n

a

uall

n

an

dle

d

y

o

m
i
n

l

ut to
o

o

f

c

ve

u

k

l
l

b

pl

y a

Fa

en

ef

a

i

nd

o

g

l

tf

u

re

a

o

r
result in

g

e to

rm

e plat
d
r

i
i
v

n
l

d

i
o
n

ep

c

f

g

o
k pl

unin

r

l

ve

o

m

plat

yment

hi
a
t

t

cle.

f

e

o

f

o

n

r

r

r

m
ded

e

m

.

sult in

Uni

m

de

a

p

an

y
p

lat
n

l

d/o

t

o

e

se

fo
yment may

n

r

r

d

r

m
i

pr

ed
o
u

o

s
p

bo
e
r
t

d
y

ily
d

amage

Do

inju

not rem

ry
.

81
8
2
3

ov

e!

Pressure
Transducer
30426

Page 3

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. Verify lift stowed signal (pin 9) in the 9 conductor plug on the side of the pump module has a +12 volt
signal.

2. Refer to the interlock installation instructions.

• Lift operation shall be inhibited unless the vehicle is stopped and vehicle movement is prevented.

1. Verify vehicle secure signal (pin 6) in the 9 conductor plug on the side of the pump module has a +12
volt signal.

2. Refer to the interlock installation instructions.

• The platform will not fold/stow when occupied.

- Refer to Platform Sense Calibration.

• The outer barrier will not raise if occupied.

- Refer to Outer Barrier Occupied Calibration procedure

• An audio warning (and visual warning for public use lifts) will activate if the threshold area is occupied

when the platform is a least 1" below floor level.

1. Make sure connectors to threshold mat are properly connected.

2. Call Product Support.

• Lift platform movement shall be interrupted unless the outer barrier is deployed (up).

- Check Barrier Down limit switch, wires and connector.

- Diagnostic LCD should display a value of “1” for OBAR SW when outer barrier is deployed (up).

Page 4

Adjustment Procedures

Adjustments and Calibration

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. Move cam out to increase outward
travel. Carriage rollers must be inside housing a
minimum 1/2". The platform will not raise or lower
until this switch is activated.

Floor Level Switch: See page 6 for procedures.

Stow Switch: The Stow Switch controls the height

of the carriage/platform before it moves inward dur­ing the Stow function (activated by the torque tube­mounted Stow Cam). Rotate the cam in to decrease
platform height. Rotate the cam out to increase plat­form height. Adjust cam so lifting arms are aligned.
View the platform position in the housing.

Barrier Down Switch: This platform-mounted
switch prohibits the platform from raising unless the
outer barrier is in the full up position. The Up func­tion is prohibited if the outer barrier detent pin is not
fully engaged also.

Remove eccentric plate mounting screw. Using
screwdriver or small rod, rotate the shaft clockwise to
increase carriage height. Rotate the shaft coun­terclockwise to decrease carriage height. Reinstall
mounting screw in nearest retainer hole. Adjust
left and right side eccentric shafts (screw positions
may vary from side to side). Adjust height such that
horizontal arms do not contact top or bottom of tracks
(align center).

Calibration Procedures

Platform Sense Calibration

1. Place 20 lbs. in the center of the platform.

2. Press UP button on the hand-held pendant to raise
the platform a minimum of 3" above stow level.

3. Press and hold 50# CAL button on control board.
While pressing the 50# CAL button, press and
hold the STOW button on the hand-held pendant.
The platform will lower to stow level, raise slightly,
lower to stow level, and begin inward travel.
Release the 50# CAL button when the platform
begins moving inward. The platform sensing is
now calibrated.

4. After calibration, the LCD screen should read “PF
OCCUPIED” when 50 lbs., or more, are present
on the platform. If 50 lbs. does not activate the
“platform occupied” signal readout, recalibrate with
less weight to lower the “occupied” setting or more
weight to increase the “occupied” setting.

Drive Chain Adjustment

In event the drive chain sags 1/2" or more, adjust
tension as detailed. Tighten to eliminate visible sag
but do not overtighten.

1. Remove bottom pan.

2. Pull the manual release cable and lock.

3. Remove adjustment bolt (tensioner) access
cover.

4. Loosen inside jam nut. Secure tensioner and
tighten outside jam nut. Tighten to eliminate vis­ible chain sag but do not overtighten.

5. Lock jam nuts together making sure the ten­sioner roller is horizontal. Release and push the
manual cable in fully. Ensure platform is locked
by moving the platform in and out until chain
release assembly engages chain.

Carriage Ride Height Adjustment

The carriage horizontal arms move (roll) in and out
of the housing tracks on roller bearings. Follow­ing installation or extensive lift operation, clearance
between horizontal arms and tracks may diminish.
The eccentric shaft mounting plate allows height
adjustment.

Ground Sense Calibration

1. Press hand-held pendant DOWN switch to lower
platform fully to ground level.

2. While continuing to press the pendant DOWN
switch, press and then release the control board
O_BAR/GROUND LVL button.

3. Release the pendant DOWN switch. Ground
Level sensing is now calibrated.

4. After calibration, the outboard roll stop should
not unfold (down) until the platform is fully on the
ground.

Outer Barrier Occupied Calibration

1. Press hand-held pendant DOWN switch to lower
platform fully to ground level.

2. Once outer barrier is fully unfolded (ramp position),
release the pendant DOWN switch.

3. Press and hold the control board O_BAR/
GROUND LVL button. While holding O_BAR/
GROUND LVL button, press hand-held pendant
UP switch to raise the outer barrier. Be sure to
release O_BAR/GROUND LVL button when outer
barrier reaches approximately half full up (vertical)
position.

4. After calibration, the LCD screen should read
“OUT-BAR OCCUPIED” whenever there is weight
present on the outer barrier.

Page 5

LCD Diagnostic Codes

2

C

To change the LCD display from cycle count to diagnostic
mode, press the “diag” button on the control board (see
illustration at right). When finished, press button again to
return to cycle count mode. When all of the harnesses
are correctly connected to the control board, the values
shown in the chart below will display when the correspond­ing action is taken. “1” will appear to the right of the switch
or sensor name on the LCD module when activated as
shown. If any other value appears on the LCD screen
during the specific diagnostic procedure, verify that the
correct harness is properly connected to both the control
board and the associated lift harness. Repeat the harness
diagnostic procedure. If an incorrect value is still present
after checking the harness and connections, contact The
Braun Corporation Product Support Department.

All basic functions (UP,
DOWN, STOW and
DOOR) should show a
value of 1 when activated
via a controlled input
(Hand-held Pendant,
Magnetic, Remote Entry
or 3rd Station Controls).

DOOR

STOW

DOWN UP

cycle

diag Button

OBAR S 1

R31

R39

102

R13

R5

243R

R20

C

D

A

B

R19

R18

Lift Devices

K

L

U14

JIH

G

D/S

U/D

C7

321

321

J1

J2

6H23EM

HAND-1

R28

6H23EM

103

HAND-2

U18

Magnetic

C9

V104

INLK-1

U21

OH

RL11

4 3 2 1

321

RL10

Operator

Door

IN

MAT

VR3

FS11

C16

35A

220

5Q6

IN L H

U20

R25

102

FS1

R43

1802

R41

1002

GND

VR2

VR1

PWR-IN

FS2

12V-B

FS8

LIGHT

U16

103

103

103

103

V104

8.00M

C6

V104

U15

cycle

B LIGHT A

103

103

Remote

R1

R16

R26

103

C105

U12

C14

D23

D24

D25

C15

102

V104

D26

R33

103

R11

R37

C5

R36

106 E

330

C8

103

V104

103

U7

U17

D13

D10D11

C22

6C5

100

VHA

D12

U19

R34

C12

5Q6

220

35A

RL9

D9

FS7

LIGHT

W

102

102

OB AR S 1

R31

diag

U5

SOMC1601

CLOSECLOSE

OPEN

C10

V104

C13

RL4

ALARM

ALARM

W

102

102

CONTRAST

102

102

R29

103

U3

R27

CHA

220

6C5

C21

R32

102

V104

U2

C1

ZD3

R38

102

R42

102

R9

103

50# CAL

SW1

R10

103

U22

103

GROUND LVL

O_BAR

SW2

C11

RL2

RL3

D21

D19

D18

FS10

FS9

MP916

0.010Ω
.5% R

FS5

R40

PUMP

VALVE

B_DN

R4

R2

R1

103

R6

103

R7

D20

D7

D8

D5

D6

D3

D4

D

D7

D8

D5

D6

D3

D4

D2 D1

C20

CHA

220

6C5

U8

8.00M

L_UP

L_DN

C4

V104

R15

102

R14

B_DN

B_UP

103

R8

103

C3

V104

L_IN

L_OUT

103

103

NUVL CONTROLLER REV-3.1-1

The Braun Corporation

C2

V104

RL1

D16

D17

D15

D14

R3

U9

FS6

FS4

FS3

L_IN

L_OUT

B_UP

Hand-held Pendant

LCD Display Moving Out

STLV SW 1 1

Stowed

Of Cassette

Moving Up
From Stow

At Floor

Level

Moving Down

From Stow

NUVL Control Board

Ground

Level

Ground Level

OB Out

LOUT SW 1

FOUT SW 1 1 1 1 1

FLV SW 1

OBAR SW 1 1 1 1 1 1

MAT SW = 1 when mat is activated.

DO SW = 1 when door is full open or pin 3 and pin 4 are jumpered.

*IBAR SW = 1 when inboard locator is activated

*(NUVL855C only)

Page 6

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).

Floor Level Switch Adjustment

Adjust the Floor Level switch

first! (before adjusting the inboard
locator)!

The Floor Level switch stops up­ward travel of the platform during
the Up function (activated by the
torque tube-mounted Floor Level
cam).

Position the bottom of the lift plat-

Ensure the lift is positioned and
secured as specified on Quick
Reference Installation Sheet (sup­plied with lift) panels 1 and 2. Ad-
just the Floor Level switch first
(detailed below). Then, adjust
the inboard locator as detailed
in Inboard Locator Adjustment
Instructions (adjust only if neces-

form 1" above floor level (thresh-
old mat) using the manual op
eration system. Do not operate
the lift with the electric pump dur­ing adjustment procedures.

Loosen the clamp securing the
torque tube-mounted Floor Level
cam. Rotate the cam until the
Floor Level switch is activated
(cam depresses switch).

sary). The inboard locator must
rest properly on the vehicle floor
for wheelchair entry and exit.

Note: Check the floor level posi-
tion of the platform and the in­board locator after powering the
pump. Hydraulic pressure may af­fect platform height slightly. Fine
tuning adjustment (tweaking) of
the Floor Level switch may be
required.

Floor Level Cam

Torque Tube

Floor Level Switch

A

Cam depressing switch.

Page 7

Floor Level and Inboard Locator Adjustments

CAUTION

Inboard Locator Adjustment

Do not adjust
inboard loca­tor linkage rod

Do not adjust in­board locator link­age rod. Linkage
rod adjustment may
result in lift damage.

at this time!

Linkage rod
adjustment is not
required unless
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.

With the platform at ground level and the
inboard locator in the vertical position, there
should be a minimum of 1” clearance between
the inboard locator and torque tube.

Adjust the inboard locator as detailed in the
following procedures. Then, adjust the linkage
rod as detailed on page 9 (only if necessary).

1. Raise the lift platform fully (floor level) us­ing the manual operation system (Manual

Operating Instructions detailed on Quick
Reference Installation Sheet). If the inboard
locator rests properly on the floor, do not ad-
just the inboard locator. Lower the platform
to ground level. If the angle of the inboard
locator (when in the vertical position), does
not restrict the usable platform length for the
wheelchair passenger, disregard inboard
locator adjustment procedures. See Photo H
on page 9. Refer to the following procedures
if adjustment is required.

Inboard Locator

Linkage Rod

Manual Operation Systems

T-Handle

Release

Cable

W

A

R

NI

N

G

Push T-handle in fully
manually move platfo
and out to engage platfo
lock before driving
Failure to lock platform may

and

result in unintended platform

rm in

deployment. Unintended

rm

veh

platform deployment

icle.
result in serious bodily injury
and/or property dam

may

Do not remove!

ag

e.

81823

Figure A

N

E

P

O

Pump

Handle

VALV E

Stow Level

B

Hand

Pump

C

L

O

S

E

Val ve

2. Position the lift platform below
stow level using the manual op-
eration system. See Photo C.

Lowering the platform will al­low access to the cam bolt
securement nut. See Photo E.

Page 8

Platform

below

Stow

Level

C

Floor Level and Inboard Locator Adjustments

Inboard Locator Adjustment

3. Remove the 1/4" lock nut se-

curing the lifting arm cam bolt.
See Photos D and E. Do not
remove the bolt.

Raise the platform fully (floor
level) using the manual op-
eration system.

Remove the cam securement
bolt (lift inboard locator to re­lieve pressure on 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.

Reinstall the cam securement
bolt in one of the three lifting
arm holes that best lines up
with one of the nine holes in the
cam. See Photos F and G.

D

Cam Bolt

1/4" Lock Nut

Reposition the securement bolt
lock nut. Note: Lowering the
platform will allow access to
cam bolt. Tighten securely.

Cam Notch (Saddle)

e

t

C

a

t

o

R

a

m

F

Lifting Arm

(3 available holes)

Slider Block

Rocker

Cam

(9 available holes)

E

Cam Notch (Saddle)

Engaging

Cam Follower Bearing

e

t

C

a

t

o

R

a

m

G

Page 9

CAUTION

Floor Level and Inboard Locator Adjustments

Inboard Locator Linkage Rod Adjustment

Do not adjust the
inboard locator
linkage rod un-

Improper inboard
locator linkage rod
adjustment may
result in lift damage.

the vertical position) restricts the usable platform
length for the wheelchair passenger, adjustment
of the linkage rod will change the angle.

Adjust the inboard locator as detailed in the
previous procedures. Then, adjust the linkage
rod as detailed (only if necessary). If the link-
age rod is adjusted too long or too short, it will
exceed the travel of the slider block resulting in
damage to the cam follower bearing, the cam
and/or other components.

less extra usable
platform length
is needed. See
Photo H. If the an­gle of the inboard
locator (when in

Linkage rod adjustment affects angle
of inboard locator (vertical position).

H

Inboard Locator

1. Position the lift platform below stow level
using the manual operation system. Do
not operate the lift with the electric pump

during adjustment procedures.

2. Loosen the jam nuts at each end. Adjust
rod length as needed. Minimize adjust­ment. Carefully check the inboard locator
angle and operation using the manual
operation system. Ensure the rod has not
been over adjusted resulting in pressure on
components (damage will result). Tighten
the linkage rod jam nuts.

I

Linkage Rod

Page 10