Wessex LR Series Installation And Service Manual

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LR Range

Installation and Service Manual

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Richard kokoszka

March 3, 2025

Hi I have a Wessex lr800 lifting platform Just want to know how to connect the batteries together is it positive to neutral Or positive to positive and neutral to neutral. Thanks

1 comments:

Mr. Anderson

March 3, 2025

Connect the batteries to the override box using the six-way Molex connector. Ensure the black lead is connected to the negative terminal and the red lead to the positive terminal. Incorrect connections can damage the PCB. The batteries are constantly trickle charged, and an alarm will sound in case of a power failure.

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Summary of Contents for Wessex LR Series

Page 1 LR Range Installation and Service Manual...
Page 3: Table Of Contents
LR Installation and Service Manual Contents Section 1 Introduction Section 2 Safety Advice Section 3 Method Statement Section 4 Tooling Section 5 Installation Procedure Section 6 Twin Platform Gate Install Procedure Section 7 Electrical Drawings Section 8 Lubrication schedule Section 9 Service Procedure Section 10 Replacement Parts...
Page 4: Introduction
LR Installation and Service Manual Introduction Section 1 LR01 5020_A.doc Page 1 of 2...
Page 5 Engineers correctly trained to work on that particular item of equipment. The Wessex LR Lifting Platform should be checked and serviced at 6 monthly intervals, this is in accordance with both our own, and British Standards recommendations.
Page 6: Safety Advice
LR Installation and Service Manual Safety Advice Section 2 LR01 5030_A.doc Page 1 of 4...
Page 7 LR Installation and Service Manual Safety Advice SAFETY WHEN WORKING ON THE LIFT Safety must be of paramount importance when working on any lift. Normal workshop practices must be followed when carrying out the installation, repair or service. Read the guidelines below before commencing any work to the lift. General Safety Considerations Before carrying out work on a lift, the following precautions must be adhered to: ...
Page 8 HYDRAULIC SYSTEM Wessex hydraulic lifts operate with high hydraulic pressures that are potentially dangerous. Before removing any components from the hydraulic circuit ensure that there is no hydraulic pressure in the system. This is achieved by lowering the lift onto the ground or a suitable support and continuing to operate the manual lowering valve for a short period after the lift has stopped.
Page 9: Additional Information
LR Installation and Service Manual Safety Advice Hydraulic Fluid Continued... First Aid Measures  Inhalation Remove the effected person to fresh air. If recovery is not rapid, seek medical attention.  Ingestion Do not induce vomiting. No emergency measures are needed but if adverse health effects follow, seek medical attention.
Page 10: Method Statement
LR Installation and Service Manual Method Statement Section 3 LR01 5900_B Page 1 of 4...
Page 11 LR Installation and Service Manual Method Statement Company: Wessex Lift Company Limited Site Address: Activity: Installation of Lifting Platform Product: LR Lifting Platform Product No: LR800/LR900 & LR1100 Arrival date: Arrival time: Approx. 9.00am Installation duration: 1 day Approx. Personnel: Equipment: •...
Page 12 Refer to the documents below for further Health and Safety advice. These documents should be in your possession. Ensure you read, understand and act upon their advice. • Wessex Health and Safety Policy Statement Technical Reference Documents • Installation and Service Manual •...
Page 13 LR Installation and Service Manual Method Statement Method 1. Ensure your arrival and departure on site is made known to the Site Representative. 2. Familiarise yourself with the site generally and in particular site safety rules and access / exit routes. 3.
Page 14 LR Installation and Service Manual Installation Tooling Section 4 LR01 5040_A.doc Page 1 of 4...
Page 15 LR Installation and Service Manual Installation Tooling Item Tool Quantity Tool No 2.5mm hexagon key 4mm hexagon key 5mm hexagon key 6mm hexagon key Junior hacksaw Senior hacksaw Woodsaw 20mm hole saw and arbour IT030/031 32mm hole saw M3 tap M4 tap M5 tap M6 tap...
Page 16 LR Installation and Service Manual Installation Tooling Item Tool Quantity Tool No drive 100mm extension bar drive socket drive socket 10mm drive socket 13mm drive socket 17mm drive socket 19mm drive socket No1 crosspoint screwdriver No1 crosspoint screwdriver stubby No2 crosspoint screwdriver No3 crosspoint screwdriver 3mm flat blade screwdriver 5mm flat blade screwdriver...
Page 17 PCB trimming tool IT028 7mm nut spinner 8mm nut spinner Clamps IT039 Hexagon bit set IT040 Suction lifters Engineers hammer Ram bleed tool IT045 Note: This tool list covers the whole Wessex product range. LR01 5040_A.doc Page 4 of 4...
Page 18: Installation Procedure
LR Installation and Service Manual Installation Procedure Section 5 LR01 5050_B Page 1 of 27...
Page 19 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Perform the following checks prior to unloading your vehicle.  Identify yourself to the customer and briefly explain what you intend to do.  Carry out a site risk assessment before starting work.
Page 20 LR Installation and Service Manual Installation Procedure Procedure Fixings Index The gate handing is determined by 2 x M8x20 looking into the lift at the upper level. hex head FF30 1209S The side the gate hinges determines the 2 x M8 plain handing.
Page 21 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Fit the gate washer. 1 x Washer FF61 0052 Lightly grease the hinge pin and washer. 2 x M6x20 skt button hd screw 2 x M6 Form ‘B’ Washers FF60 1110A4 Grommet dia 20 EC10 6006...
Page 22 LR Installation and Service Manual Installation Procedure Procedure Fixings Index LR11 1223 Lock Assembly Note: The CISA contact can be adjusted if necessary, by adding or removing the spare packers provided. Ensure the CISA contacts are pressed in by at least 2mm when the gate is closed. CISA Contact 10.0 Note: RH lock post assembly shown.
Page 23 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Lift isolator Lift PSU Locate the lift plug socket or isolator and fix the PSU ) adjacent to it. (power supply unit ‘P’ Clip 12mm For external & public access environments, use armoured cable or conduit and diameter EC10 5087 appropriate glands, to wire from the isolator to the PSU box.
Page 24 LR Installation and Service Manual Installation Procedure Procedure Fixings Index The gate threshold panel will need cutting if the threshold height is below 1 metre. Before cutting, ensure the pre-drilled holes are at the top. Panel height = Threshold height – 4mm A cut-out will be required at the bottom of 13.0 the panel for the lower call station and...
Page 25 LR Installation and Service Manual Installation Procedure Procedure Fixings Index A tool to help fit and bleed the rams is available. Fit the spring into the counterbores at the bottom of the rams. (Note: Sprung plungers will be fitted directly to the rams in the future.
Page 26 LR Installation and Service Manual Installation Procedure Procedure Fixings Index IMPORTANT! Keep the platform surface protected until the installation is complete. Fit the platform assembly being careful not to damage the safety edge studs. Platform They must align with the slots in the fixing 2 x M8x16 platform and safety edge bracket.
Page 27 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Slide the powerpack support bracket onto the platform LH side flange as shown. Locate the powerpack onto this bracket. Note this is a jigging bracket, if you were not supplied with one; bolt the 21.0 powerpack in place.
Page 28 LR Installation and Service Manual Installation Procedure Procedure Fixings Index WARNING! Beware of trapping and shearing hazards. Connect the override box to the powerpack and batteries. (Override box part number is LR10 8500). On current powerpacks all cable colours will match up and the batteries will plug into the override box using the six way molex connector.
Page 29 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Filler Cap Send the lift to its up limit watching the level of oil in the reservoir, stop if it gets Minimum 26.0 below 20mm. If the oil level is below 20mm when at up limit 20mm send the lift fully down, and add...
Page 30 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Fit the left hand bellows guide assembly 2 x M6 full nyloc nut over the studs on the base frame. FF70 2100S Fit two cable tie bases on top of the 2 x M6 plain 29.0 bellows guide as shown.
Page 31 LR Installation and Service Manual Installation Procedure Procedure Fixings Index 4 x M8x20 skt cap head FF32 1209S 4 x M6x20 hex head FF30 1009S 4 x M6 plain washer (thick) FF60 0100S 4 x M6 spring 32.0 washer FF60 4100S 4 x M6 locking nut FF70 1100S...
Page 32 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Fix the trailing cable to the powerpack mounting bracket. 2 x Spacer Nylon FF64 0008 It is spaced off the bracket by two plastic spacers. M6x30mm 34.0 Ensure the trailing cable is fitted against pozi pan screw the return flange of the platform and is...
Page 33 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Ramp pin Ramp pin grub screws 2 x ramp pin LR10 1019 37.0 M4x5mm Grub Screw FF46 0703S Grease the ramp pins before assembling. Align the ramp to the hinges and fit the ramp pins flush at both ends of the hinge. IMPORTANT! Note: The ramp must rotate freely otherwise this will affect the actuating sensor bracket assembly.
Page 34 LR Installation and Service Manual Installation Procedure Procedure Fixings Index 2 x Nylon Scotch washers FF61 0033 Raise the lift to a height of 900mm. 6 x M6 plain washer FF60 0110S WARNING! 39.0 Disconnect the powerpack including the lowering solenoid to prevent any unexpected 6 x M6 lowering of the platform.
Page 35 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Position the unit up to the threshold. Connect the cables to the interface board. Refer to the section below for connection details. 40.0 Ensure all the cables are secured neatly to the cable tie bases.
Page 36 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Rear packer Fixing point Front packer 4 x Fischer plug FF62 0006 Fixing point 4 x Coach screw M8X60 FF63 0024S 4 x Washer M8 Form ‘C’ Ensure the gap between the platform and the threshold is 10mm or less throughout FF60 2120S the lift travel.
Page 37 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Grease all the welded corners of all the braces 44.0 Grease the vertical face of the return flange for the full length of the chassis Grease the slider pad area Ensure all the areas to be greased are clean and free from dust etc…...
Page 38 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Lower the lift down, ensuring the safety edge studs are aligned with all four slots in the platform and brackets. Fit the nylon washers and nuts, ensure the spacer is through the slot and not clamped underneath the platform.
Page 39 LR Installation and Service Manual Installation Procedure Procedure Fixings Index The up limit switch is pre-set with the lever fully extended and set to 30 degrees. The up limit switch is a different type to the down limit and final limit. It has a dual purpose;...
Page 40 LR Installation and Service Manual Installation Procedure Procedure Fixings Index Ramp up Ramp down sensor sensor switch switch Ramp Ramp up limit actuator Ramp down limit Spring adjusting nut Ramp sensor Actuator springs The ramp sensor switches are pre-set in production. Their operation must be checked on final installation.
Page 41 LR Installation and Service Manual Installation Procedure Procedure Fixings Index If there is no threshold gate required, and all of the cables are required on the same side, a cable cover can be used to allow both conduits to terminate at the same position.
Page 42 LR Installation and Service Manual Installation Procedure Procedure Fixings Index The main control PCB has several links which can be changed to provide different operations. The board is supplied pre-set with the following functions. Only change the links when the option is required by the correct paperwork. Keyswitch Configuration 2-way Upper level...
Page 43 LR Installation and Service Manual Installation Procedure Procedure Fixings Index RV 3 Light timer PL8 & PL9 LK13 30Vac from PSU CONN 6 LK12 Side Panel Lights FS1 EC15 1038 AC Power 10a A/S FS2 EC15 1040 AC Power RV 2 5a A/S Gate Release No link...
Page 44 Note: All fixings used on the LR are FF50 1013S 55.0 stainless steel. 8 x M6 It is vital that only the correct fixings washer thin supplied by Wessex are used to validate FF50 1011S the warranty given on this product. Side panel cover Grommet Manual...
Page 45 LR Installation and Service Manual Twin Platform Gate Option Section 6 LR01 5180_A.doc Page 1 of 5...
Page 46 LR Installation and Service Manual Twin Platform Gate Option Procedure Fixings Index The top plunger locks the gate in position. This springs up when the bottom plunger is pushed up. Before fitting the LH and RH bottom hinge assemblies, check both LH bottom plungers are free moving.
Page 47 LR Installation and Service Manual Twin Platform Gate Option Procedure Fixings Index Fit the LH gate assembly to the LH bottom hinge boss. Note: The gate assemblies are supplied with special dampening LR800 grease in the bushes. version LH gate assembly CAUTION! LR10 1401...
Page 48 LR Installation and Service Manual Twin Platform Gate Option Procedure Fixings Index Fit the RH gate assembly to the RH bottom hinge boss. LR800 version RH gate Note: The gate assemblies are assembly supplied with special dampening LR10 1402 grease in the bushes. LR900 RH Gate version...
Page 49 LR Installation and Service Manual Twin Platform Gate Option Procedure Fixings Index Plastic gate drive The gates shut automatically when the ramp closes and are locked into position. Check the gates when closed are parallel with each other, and the plungers are locking them in position.
Page 50: Electrical Drawings
LR Installation and Service Manual Electrical Drawings Section 7 LR01 5070_C Page 1 of 2...
Page 51 LR Installation and Service Manual Electrical Drawings LR10 8101 LR Wiring Schematic (Std buttons) Issue D LR10 8102 LR Wiring Schematic (H/Spec buttons) Issue E EC15 1038 LR Circuit Diagram Heavy Duty Issue B EC15 1040 LR Circuit Diagram Std Duty Issue B EC15 1037 LR Interface PCB...
Page 57: Lubrication Schedule
LR Installation and Service Manual Lubrication Schedule Section 8 LR01 5080_A.doc Page 1 of 2...
Page 58: Installation
LR Installation and Service Manual Lubrication Schedule  Time of Application Production Installation Service Items to be lubricated MM31 5010 Castrol MM31 5010 Castrol Scissor Pivots CL Grease CL Grease MM31 5010 Castrol MM31 5010 Castrol Slider Block Area CL Grease CL Grease MM31 5010 Castrol Check it has been...
Page 59: Service Procedure
LR Installation and Service Manual Service Procedure Section 9 LR01 5140_A.doc Page 1 of 3...
Page 60 LR Installation and Service Manual Service Procedure Procedure The service schedule is based on recommendations by BS6440:1999. A technically competent person should carry out the service and inspection within 6 months of commissioning the lift. Subsequent service intervals should not exceed 6 months. Refer to the safety advice in section 2 before commencing any work.
Page 61 LR Installation and Service Manual Service Procedure Procedure Ram Service Bleeding Procedure 1. This procedure should only be used if the lift is completely assembled, and you have no access to fit the ram bleed tool. 2. If the platform is going up and down level, and is not spongy DO NOT bleed the rams. Proceed to the next step if you need to bleed the rams.
Page 62: Replacement Parts
LR Installation and Service Manual Replacement Parts Section 10 LR01 5130_A.doc Page 1 of 3...
Page 63 LR Installation and Service Manual Replacement Parts EC08 3039 Up Limit/Anti creep LR10 0422 Pod Cover EC08 1517 Safety edge switch switch EC08 1520 Ramp Safety Switch HC00 1021 Ram LH Master EC14 3006 Battery 12v 9Ah PT04 0011 Ramp Actuator EC08 3034 Down Limit and Final (NOT VM HC00 1022 Ram RH Slave...
Page 64 LR Installation and Service Manual Replacement Parts EC10 6041 Key Switch Bezel EC08 1507 Ramp Limit switch HC00 0023 Hydraulic Powerpack EC08 2182 Button push dual arrow LR10 1045 Ramp block EC10 6000 Grommet 16mm EC10 6039 Manual Lowering LR20 1263 Lock Assembly LR10 0025 Scissor Roller Grommet EC10 6032 Gate Post End Bung...
Page 65 LR Installation and Service Manual Technical Sales Specification Section 11 LR01 5120_B_1...
Page 66: Technical Specification
LR Range Technical Sales Specification...
Page 67 LR Technical Sales Specification Contents Basic Specification Product Lifting Range Platform Dimensions Footprint Dimensions Lift Speed Drive System Safe Working Load Electrical Specification Controls Safety Features Lift Weight Finish & Colour Specification Loadings Standards Compliance Options Manufacturers Warranty LR01 5120_B_2 Page 2 of 7...
Page 68 LR Technical Sales Specification Introduction This document outlines the technical specification for the Low Rise Lifting Platform and is to be read in conjunction with drawing no. LR00 7000 & LR00 9000 Basic Specification  Vertical lifting platform to 1000mm floor to floor travel ...
Page 69 LR Technical Sales Specification Lift Speed 20mm per second Drive System Hydraulic cylinders with a 24Vdc Hydraulic Powerpack Safe Working Load 300 kg (47 stone) Electrical Specification LR800 Arrangement:  Simply plugs into 3 pin plug socket as standard. If this is not available, a socket must be installed at an agreed location prior to lift installation.
Page 70 LR Technical Sales Specification Control Switches Standard  Post mounted call stations to upper and lower levels with Up & Down rocker switch.  In car, Up & Down rocker switch, plus emergency Stop Button  ‘Hold to run’ operation ...
Page 71 LR Technical Sales Specification 13 Loadings Lift base – 5Kn Threshold –2.5Kn / Fixing 14 Standards Compliance  Built in compliance with BS 6440:1999 - specification for Lifting Platforms.  Part M Building Regulations 2004 when fitted with appropriate options 15 Options ...
Page 72 All new Wessex LR Lifting Platforms are covered by a five year anti-corrosion warranty. Wessex, or a Wessex Authorised Repairer, must carry out all repair work undertaken under the anti-corrosion warranty. The warranty covers corrosion, which occurs on any surface of the Lifting Platform.
Page 73: Builders Work Drawings
LR Installation and Service Manual Builders Work Drawings Section 12 LR01 5200_C Page 1 of 2...
Page 74 LR Installation and Service Manual Builders Work Drawings LR00 9000 LR Builders Work Drawing Concrete Issue G LR00 9002 LR Builders Work Drawing Wood Issue C LR00 7000 LR Lift Specification Issue D LR00 7001 Bridging Assy 1000mm Issue A LR00 7002 Bridging Assy 810mm Issue A...
Page 75 BASE SIZE LR800 LR900 LR1100 Wessex reserves the right to decline warranty claims arising from any accumulation of water within the base. BASE WIDTH 1304 1404 1604...
Page 76 SO51 0HA Decimal Places: X = 1 WORK DRG X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED WOOD ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 77 SO51 0HA Decimal Places: Specification No X = 1 X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT X.XX = 0.13 Gate COMPANY LIMITED, AND MAY NOT BE PUBLISHED ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 78 SO51 0HA Decimal Places: With the Gate X = 1 X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT Option X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 79 SO51 0HA Decimal Places: SPECIFICATION X = 1 X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT WIRING DETAILS X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 80 SO51 0HA Decimal Places: Specification X = 1 X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT Gate frame fixings X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 81 SO51 0HA Decimal Places: X = 1 Specifications X.X = 0.25 FINISH: THIS DRAWING IS THE PROPERTY OF WESSEX LIFT X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED Base Dimensions ANGULAR: 0.5 Weight: REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 82 Decimal Places: LR00 7001 BRIDGING ASSY X = 1 FINISH: Refer to details X.X = 0.25 THIS DRAWING IS THE PROPERTY OF WESSEX LIFT 1000 X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED Refer to details ANGULAR: 0.5 Weight...
Page 83 LR00 7002 BRIDGING ASSY X = 1 FINISH: Refer to details X.X = 0.25 THIS DRAWING IS THE PROPERTY OF WESSEX LIFT X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED Refer to details ANGULAR: 0.5 Weight REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 84 LR00 7003 BRIDGING ASSY X = 1 FINISH: Refer to details X.X = 0.25 THIS DRAWING IS THE PROPERTY OF WESSEX LIFT X.XX = 0.13 COMPANY LIMITED, AND MAY NOT BE PUBLISHED Refer to details ANGULAR: 0.5 Weight REPRODUCED OR USED FOR MANUFACTURE WITHOUT...
Page 85 LR Installation and Service Manual Archive Drawings Section 13 LR01 5190_A.doc Page 1 of 1...
Page 86: Threshold Power Gate Option
LR Installation and Service Manual Threshold Power Gate Option Section 14 LR01 5051_A Page 1 of 5...
Page 87 LR Installation and Service Manual Threshold Power Gate Option Threshold Power gate Option Actuator The slot must be fitted parrallel with the slot threshold face when fitting the gate actuator. The actuator is shown in the closed position PT04 0013 (Pin at the top of the slot) It may be supplied LR Gate Actuator...
Page 88 LR Installation and Service Manual Threshold Power Gate Option Fit the 3 way molex connector EC11 1048 to the actuator lead, pin 1 black wire & pin 3 red Power gate actuator wire. wires Connect the power gate actuator connecting EC11 1048 loom LR10 8083 from the down limit loom connector to the actuator.
Page 89 LR Installation and Service Manual Threshold Power Gate Option Interface PCB Connection: The power gate actuator loom LR10 8083 connects into the down limit loom: • 6 way down limit loom Connector Pin 1 yellow wire. • 6 way down limit loom Connector Pin 3 red wire.
Page 90 LR Installation and Service Manual Threshold Power Gate Option LR10 8079 RV14 EC15 1044 LR10 8084 Threshold Power gate Motor reverse switch LR10 8079 Loom R7 = Adjusts the delay before the gate starts closing. threshold R2 = Adjusts how far the gate opens. power gate R14 = Adjusts how long the gate closes for.

This manual is also suitable for:

Lr800 Lr900 Lr1100