Inoxair. Repair Manual. Content. Edition: 12/2010. Subject to technical changes for reasons of the continous development.

Transcription

1 Inoxair Repair Manual Edition: 12/2010 Content 1) Serial number 2) Technical data 3) Functional principle 4) Problem analysis 5) Removal 6) Repairs 7) Circuit diagram and cable-connection-plan 8) Pneumatic scheme 9) Spare parts Images don t necessarily illustrate the delivered contents and are not true to scale. Damages caused by operating errors or incorrect assembly or repair are excluded of liability. Subject to technical changes for reasons of the continous development.

2 1) Serial Number The serial number is on a sticker at the loading ramp and contains the production date: For example: SN 1593 means: 15. calendar-week of the year 2009, 3rd system. Please always advise the serial number for exchange or spare part orders! Serial number 2) Technical data * Suitable for various stretchers and transport-stretchers according to DIN and DIN * System height: 160 mm (lowered) 210 mm operating height * The total height varies depending on vehicle specifications * Total length including closed loading ramp 2035 mm * Total weight estimated 70 kg * Maximum load bearing capacity ca. 200 kg (incl. stretcher) * Ignition AND main switch ON: Device ready Ignition OR main switch OFF: Device lowered (eg. for reanimation) * Electric connection: = ground (pin 31) orange = positive (ignition) (pin 15) * Power max. 6 A at 12 Volt DC.

3 2) Technical Data 1... Air-suspended hover systems with automatic weight setting for kg and hydraulic shock absorber. Swing lift 95 mm Loading ramp with cylindric roller 3... Micro switch for automatic descent and with automatic unlocking (optional) 4... Switch box, contains: a) compressor 12V, with thermic switch, release valve and unidirectional valve b) magnetic valves 12 V c) clamp block d) noise reduction e) fan 12 V=, 1W 5... Air supply tank (4 litres) with pressure switch 6... Stretcher mounting plate 7... Base frame 8... Gas spring 9... Main switch 10.. Automatic unlock (optional)

4 4) Functional principle * After successfull assembly and electric connection, start ignition of vehicle and turn on the main switch (9). The compressor will fill the air supply tank (5) with approx. 7,5 bar and the Hoverboard is ready for operation. * The Hoverboard works automatically --> when the pressure supply has lowered to approx. 6,5 bar the compressor switches itself on for approx. 2 minutes again. This allows constant operating pressure. * By opening the loading ramp (2) and/or turning off the ignition, the Hoverboard is automatically lowered to allow an easy and energy-efficient loading and unloading. * The correct loading and unloading is to be applied according to the instructions of the (transport-) stretcher. Pay attention to the correct locking of the (transport-) stretcher on the Hoverboard. * For reanimation, the main switch (9) is to be turned off, the Hoverboard will lower immediately. ATTENTION! As a precaution, the stretcher should always be held when opening the loading ramp!!

5 4) Problem analysis * Turn on ignition of the vehicle * Turn on main switch (decompressed above) * Close loading ramp * Is the compressor running? No: Possible Causes: * Problem with the power supply > continue with 5), then 6A) * Problem with the compressor > continue with 5), then 6G) * Problem at the pressure switch > continue with 5), then 6F) * Problem at the heat-protection-switch > continue with 5), then 6C) * Problem at the main switch > continue with 5), then 6B) Yes: There is insufficient pressure! Wait for approximately 5 minutes, then continue with the following test: * Does the system rise when loaded with at least 80 kg? No: Possible causes: * System is leaking > continue with 5), then 6H) * Problem at the pressure switch > continue with 5), then 6F) * Problem with the compressor > continue with 5), then 6G) * Problem at the micro-switch > continue with 5), then 6D) * Problem with the magnetic valve > continue with 5), then 6E) Yes: * System is leaking slightly > connect external compressed air-care and 12 Volts= and localize the leak with leak-search-spray. Then seal. 5) Removal For extensive analysis and repairs, it is necessary to remove the Hoverboard. Proceed as follows: * Remove the (driving-) stretcher off the hoverboard. * Remove the 4 (or 6) screws at the base-frame (Abb.1,Pos. 7), with wich the hoverboard is fastened to the vehicle! Never remove the stretcher-mounting-plate! * Turn around the hoverboard completely. * Remove the 4 screws on the cover of the noise-protection-box (Abb.1,Pos.4), then open the cover > Caution! The magnetic-valves are connected to the cover! * Now all components are accessable for all eventual repairs.

6 6) Repairs For checks as well as repairs on the electric components the following is required: * Screw-drivers, small-tools * Volt-meter and ohm-meter or passageway-examiner ( Multimeter ) For checks as well as repairs on the pneumatic system the following is required: * Screw-driver, small-tools * External compressed air-care with at least 7 bar * pressure gauges up to at least 8 bar * Matching compressed-air-fittings and 6-mm-tube for connection * External power-source of 12 volts=, min 6 A (for example vehicle battery) A) Power supply Test with the multi-meter at the clamp-block in the noise-reduction-box (Abb.1, pos.4), wheter there is a voltage of app volts between the inlets (see Abb. 3 as well as Abb. 5 > orange, ) No: * Ignition of the vehicle switched on? * Fuses in the vehicle blown? * Cables in the vehicle worn? * Fuses in the hoverboard blown? B) Main switch Voltage between ground wire and violet wire? No: * Main switch turned off or faulty. C) Thermal switch Remove the wires of the compressor from the clamp-block and take compressor from the noise-reduction-box. Test the thermal-switch (at the compressor) on continuity. No continuity: Only with temperatures higher than 72 C. Otherwise > thermal-switch is faulty.

7 Repairs (continued) D) Micro-switch Test continuity between the two yellow wires (Abb.3 bzw. Abb.5): Pin pressed: Pin not pressed: No continuity continuity Otherwise change connections or reconnect at the micro-switch. Alternatively micro-switch faulty. E) Magnetic valves Electric: Remove both wires (, blue) of the magnetic valve from the clamp-block (Fig. 3 resp. Fig. 5) and connect directly with 12 volts=. When doing so, you should hear the valve switch. If not > magnetic valve faulty. Pneumatic: Connect compressed air supply and pressure gauge with the connection 1 or P of the magnetic valves. Due to connecting of the inlets with 12 volts= the magnetic valve must switch and pass air on to the connection 2 or A. Afterwards disconnect the power supply again and stop the compressed-airsupply by means of closing the valve (or bending the tube). The pressure in the tube is not to decrease remarkable. Otherwise the magnetic valve is faulty. Finally connect the compressed-air-supply at the connection 2 or A and connect 1 or P by means of a closed (or bended) tube. Air must escape at the connection 3, until 12 volts= is reconnected at the inlets. Then, no more air should escape. Otherwise the magnetic valve is faulty.

8 Repairs (continued) F) Pressure switch The grey wires should be connected well to the pins 1 and 2 of the pressure switch. Then connect external compressed air supply and pressure gauge instead of the pressure hose at the distribution block. Check continuity between the grey wires and rise the air pressure continously, but slowly. Below 7 bar: continuity above 7 bar: no continuity Otherwise the pressure switch is to be readjusted: Remove dust-cover and turn the setscrew right to the end and then about a quarter-turn back. Then follow up with fine-tuning: At 7 bar the switch should turn off. If it is not possible to meet this exact adjustment, the switch is faulty. G) Compressor Remove wires from the distribution block and the pressure hose and take out the compressor. Connect the compressor directly to the pressure gauge and start it for about 15 seconds. Then there should be a pressure of at least 8 bar. Otherwise the compressor is faulty. After turning off, pressure must not decrease remarkable. Otherwise the check valve at the compressor is faulty. H) Leaks If there s a leak in the system, the compressor will run until it gets so hot, that the thermal switch will turn it off. So if the compressor runs for more than 7 minutes and finally stops, there s probably a leak anywhere in the system. Connect to external air supply, use leak detection spray to find the leak and seal.

9 Inoxair (basic) Circuit diagram 1 main switch 8A 3 postive (ignition) + P pressure switch micro switch (loading ramp) 12V= _ 4 ground Thermal overload protector release valve 5 magnetic valves fan M compressor unit 2 Circuit layout target colour target colour micro switch release valve fan micro switch magnetic valve jumper jumper release valve yellow blue red yellow magnetic valve 2 magnetic valve 1 thermal switch pressure switch pressure switch main switch magnetic valve 2 fan compressor ground blue blue green grey grey pink brown positive (ignition) red main switch orange

10 Inoxair Pneumatic connection tube colours E D 3 Red Blue Black = supply circuit = inter-valve-circuit = working circuit 3 3 F F A P G C B Parts A... compressor B... air supply tank C... pressure switch D... level control valve E... air cushion F... magnetic valve G... release and unidirectional valve E D 3 P... pressure supply 1... magnetic valve > supply 2... magnetic valve > working press air release seen from below

11 Inoxair spare parts magnetic valve complete, pre-finished exhaust retardation pressure switch complete, pre-finished microswitch bellows cable conduit air suspension complete, pre-finished gas spring 200 N gas spring 300 N roller release- and unidirectional valve

12 Inoxair spare parts wire protection tube terminal set fully fitted compressor-set noise insulation box tube red tube blue tube fuseholder main switch air fittings level control valve

13 Inoxair spare parts shock absorber air spring bushing plug 30 x plug 60 x button 6 mm button 8 mm connector 2 wires tailgate holder right tailgate holder left rubber buffer fan