2054 MANUAL

Mar 2009

A.M.S.S .Ltd.
Eagle House
Village Farm Industrial Estate, Pyle
Bridgend, Mid Glamorgan CF33 6NU
United Kingdom
Tel: 01656 743700
Fax. No.01656 744265
Email office@amssgse.co.uk

Mar 2009 Page (i/ii)

 2054 MANUAL
Mar 2009

NOTES TO READERS

This manual contains general and technical information and should be used in conjunction with any
associated Publications referred to in the text and with strict regard to any CONDITIONS OF
RELEASE printed on the Title page.

This manual will as far as is practicable, be kept to the latest standard by issue of Amendment
Instruction Sheets with amended pages. It is important that these are incorporated immediately upon
receipt, and their incorporation is recorded in the Amendment Record.

Each page bears either the date of the Initial issue or the date and amendment number at the bottom. The
addition or deletion of technical matter introduced by amendment action will be indicated by the
markers >.........< to show where the material has been changed. These markers will be removed when a
subsequent amendment to the leaf is issued and additional markers inserted against the new or amended
material. When a chapter is issued in a completely revised form, the note 'Completely revised' will
appear beneath the chapter title; in this case there will be no markers to show changes.

Urgent amendments affecting safety, operating limitations, operating conditions etc. that would be
unacceptably delayed if promulgated by normal amendment action, will first be published as an
Advance Information leaflet (AIL) on blue paper. An AIL will be inserted in the manual to face the
material to which it relates. AIL's are intended to have a short life and will be replaced as soon as
possible by normal amendment action. If, after receipt of an AIL an amendment with prior date and
conflicting information is received, the AIL is to take precedence.

When an amendment is incorporated, the date and signature of the person incorporating the amendment
is to be entered against the appropriate amendment number on the amendment record.

Comments or corrections to the technical content of this manual should be addressed to:

Aircraft Maintenance Support Services Ltd

Eagle House, Village Farm Industrial Estate
Pyle, Bridgend, Mid. Glamorgan
CF33 6NU United Kingdom

Mar 2009 Page (iii/iv)

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Mar 2009

AMENDMENT RECORD

The amendments listed below have been incorporated into this publication.

Amdt Incorporated by Date Amdt Incorporated by Date

1 35
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6 40
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12 46
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Mar 2009 Page (v/vi)

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CONTENTS

Preliminary Material........................................................................................................... Page

Title Page ............................................................................................................................... i/ii

Notes to Readers .................................................................................................................... iii/iv
Amendment Record ............................................................................................................... v/vi
Contents, (this page) .............................................................................................................. vii/viii
Modification State ................................................................................................................. ix/x

General and Technical Information ................................................................................. Page

Chapter 1 - Description ......................................................................................................... 1

Chapter 2 - Operating Instructions ........................................................................................ 15
Chapter 3 - Preventative Maintenance................................................................................... 21
Chapter 4 - Illustrated Parts List and Related Information .................................................... 29
Chapter 5 - Transmission; Graziano PST2 ............................................................................ 51

Mar 2009 Page (vii/viii)

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Mar 2009

MODIFICATION STATE

This publication is technically up to date in respect of the modifications listed below.

NIL

Mar 2009 Page (ix/x)

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Mar 2009

CHAPTER 1

DESCRIPTION

CONTENTS

Paragraph Page

Leading Particulars...................................................................................................... 2

1 Introduction ............................................................................................................... 4

2 Description ................................................................................................................. 4
General ........................................................................................................................ 4
Stair Section 2000-215 Series ..................................................................................... 6
Steering and Axles ...................................................................................................... 6
Transmission ............................................................................................................... 6

3 Hydraulic system ....................................................................................................... 7

Hydraulic Oil Tank and Filters.................................................................................... 7
Pumps .......................................................................................................................... 7
Control Valves ............................................................................................................ 10
Lift and Stabiliser Cylinders ....................................................................................... 10
Hydraulic Throttle Balk .............................................................................................. 10

4 Electrical Systems...................................................................................................... 11

ILLUSTRATIONS

Figure Page

Figure 1.1 – Self Propelled 200-215 Series Passenger Stair ................................................. 5

Figure 1.2 – Hydraulic Schematic ......................................................................................... 8
Figure 1.3 – Hydraulic Parts List .......................................................................................... 9
Figure 1.4 – Electrical Schematic .......................................................................................... 13

Mar 2009
Chap 1 Page 1
2054 MANUAL
Mar 2009

LEADING PARTICULARS
2000-215 SERIES

PART NUMBER ...................................................................................................................... TLPH 215

OVERALL DIMENSIONS
Length ......................................................................................................................................... 7700 mm
O/A Width (Including Beacon) ................................................................................................... 2585 mm
Height Min. ................................................................................................................................. 3685 mm
Platform Width (INSIDE) ........................................................................................................... 2200 mm

WEIGHT
Overall........................................................................................................................................... 6015 kg
Front axle ...................................................................................................................................... 2537 kg
Rear axle ....................................................................................................................................... 3478 kg

WHEELS
Tyre Size Rear...................................................................................................................... 215/75/R17.5
Tyre Size Front .................................................................................................................... 215/75/R17.5

PERFORMANCE
Minimum Platform Height .......................................................................................................... 2200 mm
Maximum Platform Height ......................................................................................................... 5800 mm
Max. Load Per Step........................................................................................................................ 160 Kg
Max. Load Mid Landing ................................................................................................................ 240 Kg
Max. Load Top Platform................................................................................................................ 640 Kg

HYDRAULIC SYSTEM
Pump Auxiliary .....................................................................................Direct Engine Driven Gear Pump
Max. Pressure .............................................................................................................................. 1300 PSI
Oil Capacity Tank ........................................................................................................................ 89 Litres
Oil Type ................................................................................................. Standard Hydraulic Oil Grd.T46
Filtration............................................................................................... Suction Strainer - Washable Type
Main Return Line Filter .................................................................................. Replaceable Canister Type
ControlValves ................................................................................................................Cetop 3 Manifold
Hydraulic A-Frame Cylinder Type .................................................................................... Double Acting
Hydraulic Stabilizer Cylinder Type ................................................................................... Double Acting
Hydraulic Main Cylinder Type .......................................................................................... Double Acting
Main Cylinder Protection ...................................... Fitted With Burst Protection And Pilot Check Valves

ELECTRICAL SYSTEM
Voltage ................................................................................................................. 12v DC Negative Earth
Alternator ........................................................................................................................ 61A Heavy Duty
Batteries ...................................................................................................................................Main – 644
.......................................................................................................................................... Auxiliary - 644

ENGINE
Type .............................................................................................. DEUTZ 4 Cylinder Air Cooled Diesel
TRANSMISSION
Type .............................................................................................................. Automatic – Graziano PST2

Chap 1 Mar 2009

Page 2
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Mar 2009

BRAKES
Service Brakes .............................................................................. Dual Circuit Servo Assisted Hydraulic
Handbrake ............................................................................................................ Integral In Rear Drums
Front Axle......................................................................................................... Servo Assisted Disc Type
Rear Axle ................................................................................................ Drum With Integral Hand Brake

SERVICING INFORMATION
Tyre Pressures ....................................................................................................................... Front 95 PSI
.............................................................................................................................................. Rear 100 PSI
Wheel Nut Torque Settings ................................................................................................. Front 350 Nm
.............................................................................................................................................. Rear 350 Nm
Engine Oil........................................................................... Premium Diesel Engine Oil - Grade 15W/40
Rear Axle Oil............................................................................................................................HD 85/140
Hydraulic Oil ..........................................................................................Standard Hydraulic Oil Grd.T46
Brake Fluid ..................................................................................................................................... DOT 4

Mar 2009
Chap 1 Page 3
2054 MANUAL
Mar 2009

1 Introduction

1.1 The 2000-215 Series Self Propelled Passenger Stairs cover the full range of commercial
aircraft from narrow to wide bodied. The stairs are illustrated in Fig 1.1. The 215 Series is
telescopic and designed for all aircraft from the B737 to the A340 and the B777. The stairs
are mounted on a purpose-designed chassis, powered by diesel engine acting through a
conventional automotive automatic transmission.

1.2 The stairs are specifically designed for one man operation in confined apron areas and will
provide efficient passenger boarding for all aircraft within their defined platform height
range.

1.3 The stair is supplied with a totally enclosed weatherproof cab. All controls are
ergonomically placed within the cab area to provide user-friendly control whilst driving
and when positioning the stair to an aircraft.

1.4 The chassis incorporates hydraulically powered stabilisers operated from the cab, which are
deployed to provide additional stability when the stair is elevated.

1.5 The stair height is adjusted hydraulically utilising controls in the cab and optional repeater
controls on the top platform. Fail-safe electric/mechanical locks are automatically applied
once height adjustment is completed.

2 Description

General

2.1 The 2000-215 stairs comprises a two axle, four wheel, heavy duty, welded steel chassis
with forward driver platform and steel non slip wings.

2.2 The stair section comprises of steel stringers sections fitted with 5 bar aluminium tread
plate steps and steel risers. The side panels are constructed using a steel frame with sheet
metal cladding for lightweight durability. Handrails clad in 'Marley' plastic hand railing are
fitted to the top of each panel.

2.3 The top platform, which forms an integral part of the stair assembly, is of a welded steel
construction with an aluminium five bar tread plate floor. The forward edge is fitted with a
spring loaded swivel nose incorporating a heavy-duty rubber bumper.

2.4 Hydraulically actuated stabilisers are fitted to the chassis. These are controlled from the cab
via a solenoid valve and protected, in the event of hydraulic failure, by pilot check valves.

Chap 1 Mar 2009

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Mar 2009

Figure 1. 1 - Self Propelled 2000-215 Series Passenger Stair

Mar 2009
Chap 1 Page 5
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Mar 2009

Stair Section 2000-215 Series

2.5 The 215 Series Stairs utilise telescopic stair sections. The lower section is fixed to the
chassis and incorporates steel running tracks supporting the flanged wheels of the upper
adjustable section that includes the top platform. The two stair sections are supported on a
hydraulically adjustable A-frame that extends up from the chassis to provide the basic stair
support. The height adjustment is achieved by extending the upper stair section out from
the lower section. This extension is powered by a double acting hydraulic ram controlled,
via solenoid valves, from the stair height adjustment control. The cylinder is fitted with an
integral anti-burst valve, which together with the mechanical latching pawls, provide fail-
safe multi-level support in the event of a hydraulic failure. Fine height/tilt adjustment is
provided by means of the A-frame.

Steering and Axles

2.6 The front axle of the 215 series stairs is a conventional heavy-duty steering axle
incorporating a hydraulic, steering actuator and twin piston servo-assisted disc brakes.

2.7 The rear drive axle incorporates a conventional differential and drum brakes with integral
hand brake.

Transmission

2.8 The 215 range utilises a conventional automotive automatic transmission, the Graziano
PST2, to transmit motive power from the engine via a prop shaft to the rear drive axle.

2.9 Electrically operated push buttons mounted on the dashboard are used to give forward,
neutral and reverse drive.

2.10 The transmission is interlocked to ensure the engine can only be started with the
transmission in neutral. Also the engine will stop if the FWD or REV button is pressed
with the stabilisers deployed.

Chap 1 Mar 2009

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Mar 2009

3 Hydraulic system

3.1 The stair hydraulic system is shown in schematic format Fig.1.2.

3.2 The basic system is designed to be as simple as possible and comprises the following:

Hydraulic oil tank

Direct coupled engine driven pump plus emergency hand pump
Solenoid operating valves
Stair lift and stabiliser cylinders
Safety valves

Hydraulic Oil Tank and Filters

3.3 The hydraulic oil tank is made of stainless steel and installed towards the rear of the chassis
for ease of access and protection. A filler, incorporating a breather and strainer is fitted to
the top of the tank whilst the sight gauge is fitted to the front for ease of viewing. The
connections for the suction strainer and return line filter are made through threaded bosses
in the base, a tank drain is also provided.

3.4 Oil is drawn from the tank to the pump via a washable suction strainer fitted with isolating
valves.

3.5 Oil returning to the tank from the valve block and steering system passes through a full
flow replaceable element filter before entering the hydraulic oil reservoir. Isolating valves
are fitted either side of the filter allowing the element to be changed without draining the
tank.

Pumps

3.6 The auxiliary pump is a direct drive engine mounted gear pump fitted to the engine
crankcase and coupled to the crankshaft. Oil from the pump passes to the steering priority
valve and from there to the steering unit and the solenoid valve block.

3.7 An emergency hand pump is fitted in series with the main gear pump, isolated by a non-
return valve. This provides hydraulic power for vehicle recovery actions in the event of an
engine or main pump failure.

Mar 2009
Chap 1 Page 7
Page 8
Chap 1
CONNECTIONS
Mar 2009

P, T1 & T2 - 1/2" BSPP FEMALE

ALL A`S & B`S - 3/8" BSPP FEMALE
PAWL
2054 MANUAL

A FRAME CYLINDERS

16
MAIN LIFT CYLINDER
THROTTLE

14
20

25
15
19

17
18

13
FRONT LH STABILISER FRONT RH STABILISER
A4 B4 A3 B3 A2 B2 A1 B1

1300 PSI
1300 PSI 600 PSI 500 PSI

P P P

21
T T T

T T
22

P P

PRESSURE
SWITCH

10
5

9
7
3

6
T
EF P

12
2

R L

Figure 1. 2 - Hydraulic Schematic for 2000 – 215 Series Stair

23

1
24

9
8
4
STEERING CYLINDER

REAR LH STABILISERS REAR RH STABILISERS

11

Mar 2009
 2054 MANUAL
Mar 2009

ITEM No. PART NUMBER DESCRIPTION QTY

1 2054/042 HYDRAULIC TANK 1
2 D2054/008/1/1 LEVEL INDICATOR 1
3 D2054/008/1/2 RETURN FILTER 1
4 D2054/008/1/3 SUCTION FILTER 1
5 D2054/008/1/4 FILLER BREATHER 1
6 D2054/008/1/5 GATE VALVE 1" 1
7 D2054/008/1/6 PUMP 11cc 1
8 D2054/008/1/7 HAND PUMP 1
9 D2054/008/1/8 CHECK VALVE 3/8" IN LINE 2
10 D2054/008/1/9 STEERING UNIT 1
11 1286/082 STEERING CYLINDER 1
12 D2054/009/1 TEST POINT 1
CETOP 3 MANIFOLD BLOCK 5
D2054/008/1/6
13 STATION 1
14 08-01-03 CYLINER - THROTTLE 1
15 D2054/015 CYLINDER - A FRAME 1
16 D2054/015 CYLINDER - A FRAME 1
17 B065-A0013 ALUMINIUM BODY - 210 BAR RATED 1
18 08-05-65 PO CHECK VALVE CARTRIDGE 1
19 08-08-36 VALVE COUNTERBALANCE 1
20 D2019/018 CYLINDER - MAIN LIFT 1
21 D2054/017 CYLINDER - LH FRONT STABILISER 1
22 D2054/017 CYLINDER - RH FRONT STABILISER 1
23 D2054/017 CYLINDER - LH REAR STABILISER 1
24 D2054/017 CYLINDER - RH REAR STABILISER 1
25 ELECTRICAL CYLINER PAWL 1

Figure 1. 3 - Hydraulic Parts List for 2000 – 215 Series Stair

Mar 2009 Chap 1

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Mar 2009

Control Valves

3.8 The main valve block incorporates the system pressure relief valve, together with double
acting solenoid valves for the stabilisers, stair height adjustment, tilt adjustment and
throttle baulk. Pre-set flow regulating valves are inbuilt to limit the speed of operation as
necessary. Each valve section is fitted with push buttons on the valves so that it can be
used in conjunction with the hand pump to raise the stabilisers or lower the stair in the
event of a power failure.

Lift and Stabiliser Cylinders

3.9 The lift cylinders are fitted with heavy-duty chrome piston rods and long life seals for
maximum life between maintenance. In operation they are pressurised on the full bore
side to lift the stair. The twin A-frame cylinders are cross-connected and fitted with
counterbalance valves to ensure smooth, balanced movement. The main ram 'lift' ports are
fitted with anti-burst valves in case of hose failure to stop the stair retracting. The
stabilisers are fitted with pilot check valves to ensure the stability of the stair in the event
of a hose failure. A counter balance valve controls the left hand front stabiliser to ensure
that it is the last to rise.

Hydraulic Throttle Baulk

3.10 The hydraulic system also incorporates a throttle balk speed-limiter that is activated if the
stairs are raised from their rest position. On activation of the limit switch an independent
solenoid valve allows oil to a spring return single-acting ram that extends to limit throttle
pedal movement.

Chap 1 Mar 2009

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Mar 2009

4 Electrical Systems

4.1 The stair electrical systems are 12 Volt DC with negative grounded earth. Power is
provided by an engine-mounted alternator, and stored by both main and auxiliary
batteries.

4.2 The main battery is primarily for engine and control systems whilst the auxiliary is used
for the stair lighting. This ensures the stair lights cannot drain the main battery and
prevent engine restart.

4.3 As a further measure to protect battery life the stair lights are controlled through a timer
that prevents them being inadvertently left switched on when the stair is not in use.

4.4 In addition to the electric fan type cab heater, which utilises engine waste heat, the front
windscreen and rear cab window of the enclosed cab variants are electrically heated. A
timer relay is utilised to limit the time the windscreen heater is on.

4.5 Standard automotive lighting is fitted and controlled by dashboard mounted switches.

4.6 The orange hazard beacon is illuminated automatically whenever the ignition is turned on.

4.7 The engine starter circuit is interlocked to prevent the engine being started when the
transmission is not in neutral.

4.8 A stabiliser interlock is also fitted, activated by one pressure switches for stabiliser down
and one mechanical switch for stabiliser raise. The limit switch is fitted to the front left
hand stabiliser, activated when the stabiliser is full raised; a flow control in the hydraulics
ensures that this is the last to rise. A timer operated by the raised limit switch delays the
stabiliser up indicator lamp to prove the stabilisers are fully raised.

4.9 An engine speed limit, throttle balk is fitted and controlled via a limit switches on the stair
A-frame and Stair Sections. This ensures the vehicle can only be operated at low speed
when the stair sections or A-frame is elevated.

4.10 The electrical schematics are shown in Fig.1.4.

Mar 2009 Chap 1

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Mar 2009

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Chap 1 Mar 2009

Page 12
 2054 MANUAL
Mar 2008

STABS UP
11 N/O 97 97
REV LIGHT
N/C 44
BRAKE PRESS.
96
SEE SHEET 1 RL2 SEE SHEET 2 SW BRAKE LIGHTS
4 45 45

15A
A+ 811 SLR LOW FUEL SW LOW FUEL
11 11 99 99 WORK LAMP
15A WORK LAMP SW
A+ 810 SLL 11 11 11 5 5 51 51
HRS 98
VOLT FUEL INT. LIGHT PAWL LIGHT
RUN 15A
81 8+ 5 51 51
SLR
FOR
5A
81 81 E/STOP CAB E/STOP PLAT FUEL SOL 6 61
SR1
62 62
R2 64 64
A+ A1 A2 RL4 RL8 6
11 91 92 93 93A F1
82
TIMER 15A
6
NEUT
65
F1
62 64
NR3
B1 92
CAB NEUT
R1
6 66 67 64
ISOL. PLAT 11 94 11 94 REV
+VE -VE E/STOP 6 161
SR2
67 67
F2 69
A+ 69
TO GRAZIANO 94
R1
A+ AUX BATT. CONTROL FLASHER 69
HAZARD
START 3 3 31 +
CR3 MOTOR L STALK LEFT 69
15A
RL 1 33 32 33
1 32 RIGHT
1 01 +VE -VE 69
SS 34 32 34 RL7
ISOL. BATT. F3
6 162 162 FOR. SOL.
EMS 34 DASH REPEAT
100A ALT.
R3
1 M+ C 6 163 163 REV. SOL.
+VE
STRIP 6mm RED WL 33
LINK NR1 RL3
2.5mm RED
6mm RED

12 13 14 TO 11
OFF
RL1 RL5 3
HORN P/BUTTON
36
HORN
25A
1+ 11 11 11
F4 164
R4 165
ON 164 165
START 12
RL3 MOTION RELAY NR
47
CAB ENABLE TO 46 +VE DUMP
11
RL4
NR4 REV. HORN 165
RESISTOR
2 21 22 22
SPEED PROXY
10A DOWN 6 166 166
OIL PRESS 22 29 LATCH SOL SR
1+
CR4
11 15 15 UP
22 23 23 STAIR UP
HAZ
SW LATCH CR3
WATER TEMP
EMS 22 24 24 STAIR DOWN
FRONT DEMIST
11 16 16 7A 7C
22 25 25 STABS UP 6mm RED
30A N.O
9+ 903
NEUTRAL
EMS 22 26 26 STABS DOWN 15 18
SRB
NR2
11 30 30 CAB 9
22 27 27 TILT UP
RL5 A1
11 13+ 13+ PLAT 901 FRONT DEMIST
CR1 B1 T5 A2
1
13+ CAB 9
LIMIT
'A' FRAME
LIMIT
STAIRS
CR3 22 28 28 TILT DOWN
CR1 11 115 75 PLAT
15A
902 REAR DEMIST
(CORE 19) RL9 B1 T4 A2
BRAKE FAIL BRAKE PRESS SW A1
+
11 10 10 CR4 9
7 7 20 20 PAWL LATCH
BEACON
11 6mm C 18 N.O 904
30A
7 76 76 THROTTLE BAULK RL12
SIDE LIGHTS 9+
EMS RL9

ENGINE CUT OUT UNIT

N.C
41 41

11
HAND BRAKE SW PARK LIGHT 4 4 16
REAR DEMIST
11 18 18 HEAD LIGHTS 9 905
15A
42 42

15
4 WIPER
WIPER

111
18 9 908
RL4 TO 46 W

16
STABS DOWN PRESS SW STABS DOWN REV. HORN WASH

RL8
WASH
11 19 19 9 907
RL7
44
MUTE
46
REV HORN W

01
STABS UP 4 44
STABS UP LIMIT HEATER
11 N/O 97 97 REV LIGHT 9 906 CAB
44 HEATER
N/C BRAKE PRESS.
96 SW BRAKE LIGHTS
RL2 4 45 45

SEE SHEET 2 LOW FUEL SW LOW FUEL

11 11 99 99 SEE SHEET 35 5
WORK LAMP SW
51 51
WORK LAMP
11 11 11
HRS 98 INT. LIGHT PAWL LIGHT
VOLT FUEL 15A
RUN 5 51 51

Figure 1. 4 - Electrical Schematic for 215 Series Stair

Mar 2009 Chap 1

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Mar 2009

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Chap 1
Mar 2008 Page 14
 2054 MANUAL
Mar 2009

CHAPTER 2

OPERATING INSTRUCTIONS

CONTENTS

Paragraph Page

5 Preparation Before Use ................................................................................................... 16

General ........................................................................................................................ 16
Removal of Packing .................................................................................................... 16
Check All Oil and Fluid Levels................................................................................... 16
Check Tyre Pressures .................................................................................................. 16
Top-Up Fuel ................................................................................................................ 16
Function Check All Controls, Interlocks, Etc ............................................................. 16

6 Series 2000-215 Operating Instructions ........................................................................ 18

To Start ........................................................................................................................ 18
To Set the Stabilisers ................................................................................................... 18
To Raise/Lower The Stair ........................................................................................... 18
Tilt Control .................................................................................................................. 19
Automatic Stair Light Timer ....................................................................................... 19
Emergency Stops ......................................................................................................... 19
To Approach Aircraft .................................................................................................. 20
To Leave Aircraft ........................................................................................................ 20

ILLUSTRATIONS

Figure Page

Figure 2.1 - Series 2000-215 Stair Control Console ............................................................. 17

Figure 2.2 - Series 2000-215 Platform Control 17

Mar 2009 Chap 2

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Mar 2009

5 Preparation Before Use

CAUTION

DO NOT ATTEMPT TO OPERATE A NEWLY DELIVERED PASSENGER STAIR

BEFORE COMPLYING WITH THE PREPARATION FOR USE INSTRUCTIONS.

THE OPERATOR MUST BE THOROUGHLY FAMILIAR WITH THE OPERATING

INSTRUCTIONS AND PROCEDURES BEFORE USING THESE STAIRS.

5.1 General

The passenger stair has been lubricated, adjusted and tested by the manufacturers prior to
delivery; however a new unit must be properly prepared for service as described below

5.2 Removal of Packing

Remove all temporary ties from the wing panels, handrails and latches etc.

5.3 Check All Oil and Fluid Levels.

5.4 Check Tyre Pressures.

5.5 Top-Up Fuel

5.6 Function Check All Controls, Interlocks, Etc.

Chap 2 Mar 2009

Page 16
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Mar 2009

Figure 2.1 - Series 2000-215 Stair Control Console

Figure 2.2 - Series 2000-215 Platform Control Console

Mar 2009 Chap 2

Page 17
2054 MANUAL
Mar 2009

6 Series 2000-215 Operating Instructions

CAUTIONS

ALWAYS ENSURE STAIR IS FULLY RETRACTED BEFORE DRIVING AROUND.

DO NOT RAISE STAIR UNTIL IN A POSITION AND READY TO MAKE AIRCRAFT
APPROACH.

DO NOT LEAVE STAIR UNATTENDED IN RAISED OR LOWERED POSITION

WITHOUT DEPLOYING STABILISERS.

6.1 To Start

Ensure both battery isolator switches are in the ON position

Check the handbrake is on.
Start the engine by turning the ignition switch to START, hold switch until the engine fires
then release the key.
If the engine does not start on the first attempt return the key to the OFF position before
re-trying.

Check the stair is fully lowered/engaged on pawl and press STABS UP switch to ensure the
STABS UP lamp is solidly illuminated and the upper and lower safety chains are engaged
before moving off.

NOTE: Unless the stabilisers are positively engaged in raised position the engine will
stop if the transmission selected is moved from neutral.

6.2 To Set the Stabilisers

Check the handbrake is on and the transmission is in neutral.

With the engine running, lower the stabilisers by pressing the ENABLE button followed by
the STABS DOWN button. Hold until the stabilisers are fully deployed and the STABS
DOWN lamp is solidly illuminated.
Raise the stabilisers by pressing the ENABLE button followed by the STABS UP
button until all of the stabilisers are fully retracted and the STABS UP lamp is solidly
illuminated.

6.3 To Raise/Lower the Stair

6.3.1 Raise the Stair

With the engine running, press and hold the STAIR ENABLE switch on the left side
of the dashboard or, when fitted, the alternative switches at the rear of the cab.
Press and hold the STAIRS UP Button until the required height pawl has been
passed.
Press the LATCH button to allow stair to slide back onto the pawl lock.

6.3.2 To Lower the Stair

With the engine running, press and hold the STAIR ENABLE switch
Press and hold the STAIRS UP button to lift stair off pawl lock.
Press and hold the STAIRS DOWN button to allow stair to slide down to required
height.

Chap 2 Mar 2009

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 2054 MANUAL
Mar 2009

NOTE: Always raise stair and lock onto a pawl before leaving or moving vehicle.
The STAIR UP/DOWN buttons will not operate unless a stair enable switch is
pressed and held. When selecting stair height always approach aircraft below the
doorsill height. Then raise stair slightly, if required, using tilt (see below)

CAUTIONS

THE STAIR STABILISERS MUST BE DEPLOYED AT THE EARLIEST

OPPORTUNITY AFTER RAISING STAIR SECTION AND POSITIONING
TO THE AIRCRAFT.

STABILISERS MUST ALWAYS BE DEPLOYED BEFORE ANY

PERSONNEL ACCESS THE STAIR.

UNDER NO CIRCUMSTANCES MUST AN ELEVATED STAIR BE LEFT

UNATTENDED WITHOUT DEPLOYING STABILISERS.

DO NOT RAISE TELESCOPIC STAIR SECTION WHEN

DEPLOYED AGAINST AIRCRAFT

6.4 Tilt Control

Minor adjustments to stair platform height may be made using the tilt controls on the
top platform.

6.4.1 Height Adjustment Using Tilt

With the engine running and stabilisers deployed, press and hold the ENABLE
button and the UP button until the required height is achieved.
To lower press and hold ENABLE button and the DOWN button until the required
height is achieved.

NOTE: The stair must always be initially positioned below the doorsill and then
raised, if required, using the tilt UP. It is not possible to tilt DOWN unless the stair
has been previously been adjusted using tilt UP.

6.5 Automatic Stair Light Timer

To switch on the stair lights press and release the STAIR LAMP switch on the left side
of the dashboard. The lights will remain on for the pre-set time.
To re-set the light timer if required, press the STAIR LAMP switch again.
To re-set lights from top platform press and release the illuminated blue RESET button
situated above the tilt controls.

6.6 Emergency Stops

Two EMERGENCY STOPS buttons are fitted, one in the cab and one on the top platform,
adjacent to the tilt controls. If either of these controls are pressed, all functions will
be stopped.

To reset: Turn button and release.

Mar 2009 Chap 2

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Mar 2009

NOTE: The cab Emergency Stop incorporates a lamp assembly. If either it or the top
platform E/stop are activated this lamp will be lit.

6.7 To Approach the Aircraft.

Raise stabilisers and drive the stair to a position adjacent to aircraft door and some 15/20
metres off.
Raise stair section to correct height for aircraft type.

NOTE: The platform should always be set approximately level and below aircraft sill
height.

Approach aircraft door stopping with swivel nose in light contact.

Set stabilisers.
Clip back safety belts (if fitted)
From top platform, make minor adjustments to height if necessary using tilt controls.

NOTE: Safety belts (if fitted) at both locations have to be located before any stair
movements are made.

6.8 To Leave the Aircraft.

Set upper safety belt (if fitted)

Retract flexible cover (if fitted) using control on top platform.
Set lower safety belt (if fitted)
Raise stabilisers.
Reverse back until some 15/20 metres from the aircraft.
Fully retract stair section.
Fully lower stair tilt.
Drive to parking stand and set stabilisers and hand brake before leaving vehicle.

Chap 2 Mar 2009

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Mar 2009

CHAPTER 3

ROUTINE MAINTENANCE

CONTENTS

Paragraph Page

7 Safety Precautions ............................................................................................................. 22

8 2000/215 Series Passenger Stair Routine Maintenance..................................................... 23

1. 1st Service Schedule (50 HRS) ..................................................................................... 23
2. Safety Check Schedule (Monthly) ................................................................................. 24
3. Minor Service Schedule (Three Monthly/100hrs) ......................................................... 25
4. Major Service Schedule (Twelve Monthly/600hrs) ...................................................... 26

9 Troubleshooting.................................................................................................................. 28
1. General .......................................................................................................................... 28
2. Troubleshooting Chart - Electrical ................................................................................ 28
3. Troubleshooting Chart - Hydraulic................................................................................ 31

Mar 2009 Chap 3

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Mar 2009

7 Safety Precautions

Do not enter an unprotected area or go underneath a vehicle that is not on approved stands.

Do not smoke or use naked flames when putting fuel in the tank or when the fuel system is open.

Clean away spilt fuel and remove contaminated material to a safe place.

Do not fill the fuel tank with the engine running.

Do not clean or add lubricating oil to the engine whilst it is running.

Use extreme caution when making adjustments to a running engine.

Do not make adjustments you do not understand.

Do not run the engine in locations where fumes can build up to toxic levels unless exhaust
extraction equipment is in operation.

Keep other persons clear of the engine/vehicle whilst it is in operation.

Do not allow loose clothing or long hair near moving parts.

Keep away from moving parts. Fast rotating items, i.e. fans cannot always be clearly seen.

Always refit safety guards before running the engine. Use extreme care if the engine must be run
for adjustment with the guard removed.

Do not remove the radiator filler cap whilst the engine is hot and coolant is under pressure
(Where Applicable).

Do not use salt or contaminated water in the cooling system (Where Applicable).

Do not use oils contaminated with water, fuel or solvent.

Beware of acid when working near the vehicle batteries.

Always disconnect the battery, if possible, before working on the vehicle. The positive and
negative terminals of both batteries must be disconnected before undertaking welding work on the
vehicle.

Do not allow sparks or naked flames near to the batteries, which can give off explosive gases.

Diesel fuel and engine oil can cause damage to the skin. Always wear suitable gloves or barrier
cream.

Do not move mobile equipment with faulty brakes unless appropriate safety precautions have
been taken.

Do not use starting fluids.

Do not use an anti-freeze mix with a concentration of greater than 50% at high ambient
temperatures (Where Applicable).

Chap 3 Mar 2009

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Mar 2009

8 2000/215 Series Passenger Stair Routine Maintenance

8.1 1st Service Schedule (50 HRS)

ITEM DESCRIPTION
1 Visually inspect for missing items, loose fasteners, damaged parts, adjust/repair as
necessary.
2 Renew engine lubricating oil
3 Check transmission oil level replenish as necessary
4 Renew engine oil filter
5 Drain fuel pre-filter
6 Clean air filter
7 Check tension alternator belt, adjust if necessary
8 Check tension vac pump belt, adjust if necessary
9 Check coolant hoses for tightness/damage; tighten clamps if necessary
10 Check coolant level replenish as necessary with anti freeze mix
11 Check and correct any engine leaks
12 Replace hydraulic oil filter cartridge
13 Replace transmission pump filter cartridge
14 Check all hydraulic hoses and fitting for damage/leaks; tighten/replace as
necessary
15 Check hydraulic oil fluid level; replenish as necessary
16 Check brake fluid level; replenish as necessary
17 Check battery fluid level; replenish as necessary
18 Check rear axle oil level; replenish as necessary
19 Check tyres and tyre pressures
20 Check wheel nuts
21 Function-check all vehicle lights, horn and reverse bleep.
22 Function-check windscreen wiper and washer; adjust as necessary
23 Check condition and security of wing mirrors; adjust as necessary
24 Check condition and security of door hinge and latch, adjust as necessary
25 Check stair section roller and stabiliser pins for undue wear
26 Check security and condition of axles suspension rubbers and bump stops (If
Necessary)
27 Check security and operation of swivel nose and D rubber
28 Check security and operation of top platform folding canopy (where fitted)
29 Function test stair and stabiliser functions and interlocks
30 Function test vehicle and adjust as necessary:
Brakes - Service and Parking
Transmission and Interlocks to stabilisers and engine start
Steering
Throttle and Transmission pickup

Mar 2009 Chap 3

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Mar 2009

8.2 Safety Check Schedule (Monthly)

ITEM DESCRIPTION
1 Visually inspect for missing items, loose fasteners, damaged parts,
adjust/repair as necessary.
2 Check engine lubricating oil level, replenish as necessary
4 Check transmission oil level, replenish as necessary
5 Drain fuel filter and pre-filter
6 Clean air filter
7 Check tension alternator belt, adjust if necessary
8 Check tension vac pump belt, adjust if necessary
9 Check coolant hoses for tightness/damage, tighten clamps if necessary
10 Check coolant level replenish as necessary with anti freeze mix (If
Necessary)
11 Check and correct any engine leaks
12 Check hydraulic system for leaks and rectify as necessary
13 Check hydraulic oil fluid level, replenish as necessary
14 Check brake fluid level, replenish as necessary
15 Check battery fluid level, replenish as necessary
16 Check tyres and tyre pressures
17 Check wheel nuts
18 Function check all vehicle lights, horn and reverse bleep.
19 Function check windscreen wiper and washer, adjust as necessary
20 Check condition and security of wing mirrors, adjust as necessary
21 Check condition and security of door hinge and latch, adjust as necessary
22 Check stair section, rollers and stabiliser for security/abnormal wear
23 Check security and operation of sliding wing panels, swivel nose and D
rubber
24 Check security and condition of axles suspension rubbers and bump stops (If
Necessary)
25 Check security and operation of top platform folding canopy (where fitted)
26 Check Plexiglas canopy (where fitted) for security/damage, repair as
necessary
27 Check security of electrical connectors and cables
28 Function test stair and stabiliser functions and interlocks including stair
barrier belts.
29 Function test vehicle and adjust if necessary:
Brakes - Service and Parking
Transmission and Interlocks to stabilisers and engine start
Steering
Throttle
30 Check exhaust system for security/ damage
31 Inspect for accident damage and complete damage report

Chap 3 Mar 2009

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Mar 2009

8.3 Minor Service Schedule (Three Monthly/100hrs)

ITEM DESCRIPTION.
1 Visually inspect for missing items, loose fasteners, damaged parts,
adjust/repair as necessary.
2 Renew engine lubricating oil
3 Replace engine lubricating oil filter
4 Drain fuel filter and pre-filter
5 Renew fuel canister filter
6 Clean air filter
7 Check tension alternator belt; adjust if necessary
8 Check tension vac pump belt; adjust if necessary
9 Check coolant hoses for tightness/damage; tighten clamps if necessary
10 Check coolant level; replenish as necessary with anti freeze mix
11 Check engine idle speed and adjust if necessary
12 Check and correct any engine leaks
13 Check hydraulic oil filter indicator; replace cartridge if necessary
14 Check all hydraulic hoses and fitting for damage/leaks; tighten/replace as
necessary
15 Check hydraulic oil fluid level; replenish as necessary
16 Check brake fluid level; replenish as necessary
17 Check battery fluid level; replenish as necessary
18 Check rear axle oil level; replenish as necessary
19 Check tyres and tyre pressures
20 Check wheel nuts
21 Function-check all vehicle lights, horn and reverse bleep.
22 Function-check windscreen wiper and washer; adjust as necessary
23 Check condition and security of wing mirrors; adjust as necessary
24 Check condition and security of door hinge and latch; adjust as necessary
25 Check stair section and stabiliser for security/abnormal wear
26 Lubricate stair tracks and stabiliser pivots and grease swivel nose pivot
27 Check security and operation of sliding wing panels, lubricate
28 Check security and operation of swivel nose and D rubber
29 Check operation of stair pawl latch
30 Check security of electrical connectors and cables
31 Function check CCTV (where fitted)
32 Function test stair, stabilisers, and related interlocks
33 Function test emergency hand pump
34 Lubricate brake cables and steering axle pivots
35 Check security and condition of axles suspension rubbers and bump stops,
tighten/replace as necessary
36 Function test vehicle, inspect and adjust if necessary:
Brakes - Service and Parking
Transmission and interlocks to stabilisers and engine start
Steering and steering joints
Throttle
37 Check exhaust system for security/damage
38 Inspect for accident damage and complete damage report

Mar 2009 Chap 3

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Mar 2009

8.4 Major Service Schedule (Twelve Monthly/600hrs)

ITEM DESCRIPTION
1 Visually inspect for missing, loose fastenings, damaged parts, adjust/repair
as necessary
2 Renew engine lubricating oil
3 Replace engine lubricating oil filter
4 Drain fuel filter and pre-filter
5 Renew fuel canister filter
6 Clean air filter
7 Check tension alternator belt; renew/adjust as necessary
8 Check tension vac pump belt; renew/ adjust as necessary
9 Check coolant hoses for tightness/damage; tighten clamps if necessary
10 Renew coolant checking concentration and level
11 Check engine idle speed and adjust if necessary
13 Tighten cylinder head
14 Check and adjust valve clearances
15 Check injectors for performance
16 Check and correct any engine leaks
17 Check engine mounts, replace if damaged or deformed
18 Replace hydraulic oil filter cartridge
19 Replace transmission oil filter
20 Clean hydraulic oil strainer
21 Check all hydraulic components, valves fittings and hoses for damage/leaks;
tighten/replace as necessary
22 Check hydraulic oil fluid quality and level; replace/replenish as necessary
23 Check condition and operation of oil cooler
24 Check battery fluid SG and level; replenish as necessary
25 Check rear axle oil level; replenish as necessary
26 Check tyres and tyre pressures; renew as necessary
27 Check wheel nuts
28 Check front brake pads and rear brake shoes; replace as necessary
29 Check all brake pipes and flexible hoses; renew if evidence of damage or
deterioration.
30 Check brake fluid level; replenish as necessary
31 Adjust brakes
32 Function-check all vehicle lights, horn and reverse bleep.
33 Function-check windscreen wiper and washer; adjust as necessary
34 Check condition and security of wing mirrors; adjust as necessary
35 Check condition and security of door hinge and latch; adjust as necessary
36 Test CCTV (where fitted) clean camera lens and screen
37 Check heater for function and leaks
38 Check stair section and stabiliser for security/abnormal wear
39 Lubricate stair and stabiliser pivots and lubricate stair rollers
40 Check security and operation of swivel nose and D rubber
41 Check security of electrical connectors and cables
42 Function test stair and stabiliser functions and interlocks
43 Function test emergency hand pump
44 Lubricate brake cables and pedal shaft bearings
45 Inspect front axle steering pivots, replace pins/bush if worn
46 Lubricate front axle pivots

Chap 3 Mar 2009

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Mar 2009

ITEM DESCRIPTION
47 Check security and condition of axles suspension rubbers and bump stops;
tighten/replace as necessary (If Applicable)
48 Function test vehicle, inspect and adjust if necessary:
Brakes - service and parking
Transmission and interlocks to stabilisers and engine start
Steering and steering joints
Throttle and throttle balk
50 Check exhaust system for security/damage
51 Inspect for accident damage and complete damage report

Mar 2009 Chap 3

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Mar 2009

9. TROUBLE SHOOTING

1. GENERAL

This Section gives recommended procedures for locating faults on the AMSS 300T Stair.
It is intended that trouble shooting should be carried out with reference to the relevant
electrical or hydraulic circuit diagrams.

For trouble shooting on the vehicle, refer to the vehicle manufacturer's handbook.

2. TROUBLE SHOOTING CHART – ELECTRICAL

FAULT/SYMPTOM POSSIBLE CAUSE REMEDY

Ignition switch on -No dashboard Battery isolator switch is off Turn on battery isolator switch.
lights or beacon.
No battery supply Check wiring. Check batteries are
connected & charged.

Check for cause of blow fuse.

Main fuse is blown or Fuse 1 blown Replace fuse.

Ignition switch faulty Replace

Starter motor will not turn Handbrake off Apply handbrake

Transmission not in neutral Check / return to neutral

Relays NR, RL1,RL3 OR RL4 faulty Check / replace

Starter motor or solenoid faulty Check / replace

Engine cranks but will not fire Fuel solenoid not energising Check wiring

One or both emergency stops pushed Check / reset

Relays RL2 or RL8 Faulty Check / replace

Side/Headlights, Fuse 4 blown Check for cause of blow fuse.
brake lights not working Replace fuse.

Faulty switch Check / replace

Lamps or fittings faulty Check / replace

Reverse lights/sounder not working As above

Relay RL7 not working Check / replace

Fuse 6 blown Check for cause of blow fuse.

Replace fuse.

Reverse selector button faulty Check / replace

Brake lights not working As Side/headlights above

Brake pressure switch faulty Check / replace

Chap 3 Mar 2009

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 2054 MANUAL
Mar 2009

FAULT/SYMPTOM POSSIBLE CAUSE REMEDY

Cannot select forward reverse gear Fuse 6 blown Check for cause of blow fuse.
Replace fuse.

Handbrake is on Release handbrake

Speed sensor not working Check & re-adjust/replace.

Engine cuts out when transmission Stabilisers are not fully up Check for light on dashboard,
forward/reverse is selected re-power stabs up

Forward/reverse solenoids not Check for voltage at

energising solenoid/replace

Selector switches faulty Check / replace

Pawl latch does not operate Fuse 7 blown Check for cause of blow fuse.
Replace fuse.

Relay CR4 faulty Check / replace

Enable or selector switch faulty Check / replace

Diode failed Check / replace

Throttle baulk does not operate Fuse 7 blown Check for cause of blow fuse.
Replace fuse.

Relay RL9 faulty Check / replace

Motion warning lights / sounder not Fuse 2 blown Check for cause of blow fuse.
working Replace fuse.

Enable switch faulty Check / replace

Lamps / sounder failed Check / replace

Hydraulic functions do not work Fuse 2 blown Check for cause of blow fuse.
Replace fuse.

Enable switch faulty Check / replace

Dump valve not working Check solenoid / plug.

Repair/replace.

Hazards / indicators /horn do not work Fuse 3 blown Check for cause of blow fuse.
Replace fuse.

Switch / stalk / flasher relay faulty Check / repair /replace

Direction lamps not working As above

Lamps / fittings / horn faulty Check / repair /replace

Hours run / voltmeter / fuel gauge not Faulty gauges Check / repair /replace
working
Low fuel lamp not working Float switch faulty / sticking Check / repair /replace

Mar 2009 Chap 3

Page 29
2054 MANUAL
Mar 2009

FAULT/SYMPTOM POSSIBLE CAUSE REMEDY

Stair lights do not work with ignition Fuse10, 11 & or 12 blown Check for cause of blow fuse.
off Replace fuse.

Timer faulty Check / repair /replace

Relay SLR faulty Check / repair /replace

Aux battery isolator off Check / switch on

Stair lights do not work with engine
running
Stabiliser up lamp not working
As above plus
Relay CR3 faulty
Stabilisers not fully up
Aux battery not charging.
Check / recharge & replace
CR3
Re-power stabilisers up

Indicator lamp blown Check / replace

Limit switch damaged or moved Check / adjust / replace

Stabiliser down lamp not working Stabilisers not fully down Re-power stabilisers down

Indicator lamp blown Check / replace

pressure switch faulty Check / adjust / replace

Stabiliser down lamp comes on but Relay RL10 faulty Check / replace
goes off when switch released
Hydraulic leak Refer to hydraulic faults
Engine running & instruments Relay CR1 Faulty Check / replace
working but no other circuits

Most electrical faults can easily be diagnosed using a digital multi-meter to check cable
continuity and voltages at the item that is being operated.

A common problem with automotive circuits is bad earthing (Negative return to battery).

Always check the earth (grounding) connections for good electrical continuity to the battery
negative terminal.

Chap 3 Mar 2009

Page 30
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Mar 2009

3. TROUBLE SHOOTING CHART – HYDRAULIC

FAULT/SYMPTOM POSSIBLE CAUSE REMEDY

No hydraulic functions Insufficient Hydralic oil Check level in tank and top up if
necessary. Check for leaks.

Dump valve not operating Remove / Check seals / repair /

replace
Refer to electrcal faults.

Defective pump Check hydraulic pressure & replace

pump if necessary.
Quick check:-
Use emergency pump to
operate function. If this is o.k. Then
hydraulic pump is faulty.

Blocked hydraulic filter Replace filter element. Check quality

Stair will not raise or lower
Stair will not lower
Tilt does not operate
Stabilisers do not operate
Stabilisers retract under pressure
Defective control valve
Stair is locked onto pawl
Defective control valve
Defective control valve
Defective counterbalance / check
valve
of oil – if heavily contaminated, drain
and refill with fresh fluid.
Check hoses for damage and replace if
neccessary
Inspect / adjust / Replace control
valve
Raise stair off pawl block and retry. If
the pawl latch does not operate then
refer to the electrical fault section.
Inspect / adjust / Replace control
valve
Inspect / adjust / Replace control
valve
Remove / Check seals / repair /
replace

Throttle baulk does not operate Defective control valve Inspect / adjust / Replace control
valve

Most hydraulic faults can easily be diagnosed using a pressure gauge fitted to the test point on the
valve block to check if pressure is present when operating individual circuits.

A common problem with hydraulic circuits is lack of oil through leaks or blockages. These can be
external and obviously seen or internal to a component because of damaged seals.

Always repair leaks immediately and take care when working on

hydraulic circuits as trapped oil is usually under pressure.

Mar 2009 Chap 3

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Mar 2009

THIS PAGE LEFT INTENTIONALLY BLANK

Chap 3 Mar 2009

Page 32
 2054 MANUAL
Mar 2009

CHAPTER 4

PARTS LISTS

CONTENTS

Paragraph Page

Illustrated Parts List ............................................................................................................... 334

ILLUSTRATIONS

Figure Page

Figure 4.1 – General Assembly ............................................................................................. 35

Figure 4.2 – Chassis Assembly ............................................................................................. 37
Figure 4.3 – Lower Stair Assembly ....................................................................................... 39
Figure 4.4 – Upper Stair Assembly ....................................................................................... 41
Figure 4.5 – ‘A’ Frame Assembly ......................................................................................... 43
Figure 4.6 – Pawl Assembly .................................................................................................. 45
Figure 4.7 – Enclosed Cab Assembly.................................................................................... 47
Figure 4.8 – Electrical Assembly .......................................................................................... 49
Figure 4.9 – Hydraulic Assembly .......................................................................................... 53

Mar 2009 Chap 3

Page 33
2054 MANUAL
Mar 2009

Illustrated Parts List

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.1 D2054 GENERAL ASSEMBLY 1

1 D2054/010 CHASSIS ASSEMBLY 1
2 D2054/103 LOWER STAIR ASSEMBLY 1
3 D2054/012 UPPER STAIR ASSEMBLY 1
4 D2054/014 A FRAME ASSEMBLY 1
5 D2054/070 NON-POWERED FLIP STEP ASSEMBLY 1
6 D2054/010 STAIR SUPPORT FRAME ASSEMBLY 1
7 D2054/050 PAWL ASSEMBLY 1
8 D2054/031 CROSSBEAM SUPPORT ASSEMBLY 1
9 D2054/020 SLIDING NOSING ASSEMBLY 1
*10 D1367/008 FUEL TANK 1
11 D1930/200 CAB ASSEMBLY 1
*12 D2054/007 ELECTRICAL SCHEMATIC 2000/215 1
*13 D2054/008 HYDRAULIC ASSEMBLY 2000/215 1
14 D1866/035 WING PANEL ASSEMBLY 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 34
 2054 MANUAL
Mar 2009

Figure 4.1 – General Assembly

Mar 2009 Chap 3

Page 35
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.2 D2054/011 CHASSIS ASSEMBLY 1

1 D2054/004 CHASSIS WELDMENT 1
2 D1930/200 CAB ASSEMBLY 1
3 07-18-023 BATTERY BOX 1
4 09-07-12 FRONT STEER AXLE 1
5 1286/082 STEERING CYLINDER 1
6 B033-A0019 REAR DRIVE AXLE 1
7 D1126/327/LH ENGINE MOUNTS L/H 1
8 D1126/327/RH ENGINE MOUNTS R/H 1
9 B900-A0019 WHEEL AND TYRE ASSEMBLY 4
10
11 B638-A0008 PROP SHAFT 1
12 B180-A0014 DEUTZ ENGINE ASSEMBLY 1
13 B253-A0003 GEARBOX ASSEMBLY 1
14 86000/EM/1 ENGINE MOUNT DEUTZ 2
15 1919/103 GEARBOX MOUNT 2
16 90250 ELECTRICAL ENCLOSURE 1
17 B2054/008/1/A 5 STATION MANIFOLD BLOCK 1
18 D2054/042 HYDRAULIC TANK 1
19 D1367/008 FUEL TANK 1
20
21 D2054/017-A L/H STABILISER CYLINDER 2
22 D2054/017-B R/H STABILISER CYLINDER 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 36
 2054 MANUAL
Mar 2009

22
11
18
13 15
7 8 12 14

20
19

10
1

6
17

3
16
9
4 5
2

Figure 4.2 – Chassis Assembly

Mar 2009 Chap 3

Page 37
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.3 D2054/103 LOWER STAIR ASSEMBLY 1

1 D2054/003 LOWER STAIR WELDMENT 1
2 D2054/103A SIDE PANEL A 4
3 D2054/103B SIDE PANEL B 4
4 D2054/103C SIDE PANEL C 4
5 D2054/040/B TREAD INTERMEDIATE STEP 1
6 B883-A0008 THRUST WASHER 16
7 B078-A0034 BUSH 4
8 DA488/026/G ROLLER STAIR SECTION 4
9 D1827/026/L RETAINING WASHER 4
10 D2054/040/A LOWER STAIR TREAD 14
11 D2019/018 CYLINDER STAIR LIFT 1
12 NON-POWERED FLIP STEP
D2054/070 1
ASSEMBLY
13 87933/1 REVERSING LAMP 1
14 07-11-20 BULB 1
15 B443-A0010 STAIR LIGHT 16
16 B443-A0001 BULB 16
17 07-31-18 REAR LAMP ASSEMBLY R/H 1
18 07-31-19 REAR LAMP ASSEMBLY L/H 1
19 07-31-04 REAR LAMP HOLDER 2
20 07-31-04RL RED LENS 2
21 07-11-12 BULB 2
22 07-01-012/1 NUMBER PLATE LAMP 1
23 B443-A0001 BULB 1
24 2203 BLACK HANDRAIL COVER 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 38
 2054 MANUAL
Mar 2009

22 23
13 14

12
19 20 21
17
24
15 16
10

18
5

4
11
3
6 7 8 9
2
1

Figure 4.3 – Lower Stair Assembly

Mar 2009 Chap 3

Page 39
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.4 2054/012 UPPER STAIR ASSEMBLY 1

1 D2054/002 UPPER STAIR WELDMENT 1
2 D2054/029 TOP PLATFORM WELDMENT 1
3 MOD/A/488/026/H SHAFT 2
4 1866/035 WING PANEL ASSEMBLY 2
5 MOD/A/488/026/L RETAINING WASHER 2
6 D2054/041 TREAD - UPPER STAIR 12
7 DA488/026/G ROLLER STAIR SECTION 4
8 B883-A0008 THRUST WASHER 16
9 D2054/032/A TREAD A - TOP LANDING 1
10 D2054/032/B TREAD B - TOP LANDING 1
11 D2054/032/C TREAD C - TOP LANDING 1
12 B078-A0034 BUSH 4
13 D2054/020 SLIDING NOSING ASSEMBLY 1
14 B443-A0010 STAIR LIGHT 12
15 B443-A0001 BULB 12
16 07-30-25 HEAVY DUTY WORK LAMP 1
17 07-11-23/1 BULB 1
18 2203 BLACK HANDRAIL COVER 2
19 D2054/210 BEACON LIGHT STAND 1
20 88247 BEACON 1
21 D2054/012/A STAIR PANEL A 2
22 D2054/012/B STAIR PANEL B 4
23 D2054/012/C STAIR PANEL C 2
24 D2054/012/D STAIR PANEL D 2
25 D2054/012/E STAIR PANEL E 2
26 D2054/012/F STAIR PANEL F 2
27 D2054/012/G STAIR PANEL G 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 40
 2054 MANUAL
Mar 2009

Figure 4.4 – Upper Stair Assembly

Mar 2009 Chap 3

Page 41
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.5 2054/014 ‘A’ FRAME ASSEMBLY 1

1 D2054/015 CYLINDER 'A' FRAME 2
2 D2054/016 A FRAME WELDMENT 1
3 D1827/026/K A FRAME PIN - LOWER 2
4 D1827/026/D PIN - TOP OF A-FRAME RAM 2
5 D2054/50 PAWL ASSEMBLY 1
6 D2054/028 SUPPORT ARM 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 42
 2054 MANUAL
Mar 2009

Figure 4.5 – ‘A’ Frame Assembly

Mar 2009 Chap 3

Page 43
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.6 D2054/050 PAWL ASSEMBLY 1

1 D2054/049 PAWL FABRICATION 1
2 D1827/047 PIVOT ROD SOCKET 2
3 D1829/011 SOLENOID ASSEMBLY 1
4 100902 PAWL LAMP 1
5 07-11-20 BULB 1
6 D2054/031 CROSS BEAM SUPPORT WELDMENT 1
7 D1827/026C ROLLER PIN 2
8 D1827/026D TOP OF A FRAME RAM PIN 2
9 DA488/026F ‘A’ FRAME ROLLER 4
10 B078-A0032 BUSH 4
11 DA488/069 RETAINING BRACKET 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 44
 2054 MANUAL
Mar 2009

9 10

6
2

4 5
1

11
3

8
7

Figure 4.6 – Pawl Assembly

Mar 2009 Chap 3

Page 45
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.7 D1930/200 ENCLOSED CAB ASSEMBLY 1

1 D1866/200/A 120mm hinges 2
2 D1866/200/B Aluminium Slider O.S 1
3 D1930/200/C Lower Door Glass O.S. 1
4 D1930/200/D Front Quarter Glass N.S. 1
5 D1930/200/E Front Quarter Glass O.S. 1
6 D1930/200/F Escape Window N.S. 1
7 D1930/200/G Fixed Lower Glass. N.S. 1
8 D1930/200/H Roof Glass (Green) 1
9 D1866/200/I Escape Window Handle Assy 2
10 D1866/200/J Escape Window Stand-Off Hinge Assy 2
11 D1866/200/K Rubber Check Strap Assy 1
12 D1866/200/L Escape Window Rubber 1
13 D1866/200/M Door Rubber 5
14 D1866/200/N Rear Window Weather Strip 1
15 D1866/200/O Rear Window Filer bead 1
16 D1866/200/P Squeeze Type Interior lock 1
17 D1866/200/Q Stud For Squeeze Type lock 1
18 D1866/200/R Nut For Door Stud (M12 x 1mm Nut) 1
19 D1866/200/S Outer Locking Handle Gasket Large 1
20 D1866/200/T Outer Large Handle Gasket 1
21 D1866/200/U Outer Locking Handle Gasket Small 1
22 D1866/203 Front Light Mesh Guard 2
23 07-41-11 Front Headlamp Assembly L/H 1
24 07-41-12 Front Headlamp Assembly R/H 1

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 46
 2054 MANUAL
Mar 2009

Figure 4.7 – Enclosed Cab Assembly

Mar 2009 Chap 3

Page 47
 2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.8 D1866/007 ELECTRICAL ASSEMBLY 1

1 87954 12V RELAY 9
2 07-26-01 BASE RELAY 9 BLADE 10
3 87699 FUSE BLADE GREEN 30A 3
4 B759-A0008 IGNITION SWITCH 1
5 FUSE BLADE ORANGE 5A 1
6 90132 PRESSURE SWITCH 1
7 65663/1 12V TIMER 4
8 07-18-31 FUEL GAUGE 52mm C/W SENDER 1
9 07-12-15 VOLTMETER 12V 52mm 1
10 07-30-26 FLASHER 12V (LED) 1
11 87693 FUSE BLADE RED 10A 6
12 87745/1 INDICATOR STALK 1
13 07-07-15 FUSE BLADE BLUE 15A 4
14 1017 JOYSTICK CONTACT BLOCK KA2 2
15 1016 JOYSTICK CONTACT BLOCK KA1 1
16 1019 JOYSTICK 1
14 07-12-002 HOURS RUN METER 1
15 B818-A0008 FLASHER/HAZARD UNIT 12V 1
16 B883-A0013 WASHER KIT 1
17 1020 LIMIT SWITCH 1
18 1020/B SWITCH BODY 1
19 102001 SWITCH LEVER 1
20 87732 SWITCH PRESSURE (BRAKE LIGHT) 1
21 87957 12V RELAY SRB600 4
22 B293-A0004 CAB HEATER 1
23 07-30-25 WORKLAMP HEAVY DUTY 1
24 100902 PAWL LAMP 1
25 B443-A0054 INTERIOR LAMP SWITCH 1
26 07-36-01/1 REVERSE SIREN 1
27 046008/12/1 SOLENOID 12V 1
28 07-13-26/1 SWITCH HAZARD (FLASHER) 1
29 87921 HORN 12V 1
30 B759-A0071 BLUE ILLUMINATED PUSH BUTTON 1
31 B759-A0070 GREEN ILLUMINATED PUSH BUTTON 1
32 B759-A0069 RED ILLUMINATED PUSH BUTTON 1
33 07-22-47 SWITCH FLOAT 1
34 5049 RELAY 14 PIN 12V DC COIL 4
35 07-22-190 DIODE 1
36 07-22-189 RESISTOR 1
37 B065-A0008 BLUE PILOT LIGHT 1
38 B065-A0007 GREEN PILOT LIGHT 1
39 07-35-01 BATTERY 12V 2
40 B443-A0010 STAIR LIGHT (MARKER LAMP) 28
41 5078 ISOLATOR SWITCH 2

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 48
 RL2
11 97
11 99
2054 MANUAL LOW FUEL
HR V F
Mar 2009
F 01+ 1+ 11

43 42

40
7
SEE SHEET 1
F12 15x LIGHT FITTINGS 12V
15 AMP 810 SL1 10WATT (FIXED STAIR)
F13 15x LIGHT FITTINGS 12V F 01+ 1+ 11
15 AMP 811 SL2 10WATT (MOVING STAIR)
F11 PLATFORM CONTROL
5 AMP STATION 81
A1
83
SR
STAIR LIGHTS RL2
11 91 92 93 93A
TIMER 1
41 30 MIN
94 92 RL7
81 AUXILIARY
BATTERY
069
AUXILIARY -
FUEL
82 B1 A2 ISOLATOR
BATTERY RL SOLENOID
CAB 11
E/STOP

39
SPRING RETURN SW. F+ PLATFORM 94 LAMP
MAIN 069
BATTERY MAIN -
ISOLATOR BATTERY 11 115 113A
RL9

39

2
CR3
THROTTLE BAULK

17
10
17
11 113
F

41
F 01+ 10A 3 31 C
MAIN BATT START F4 FLASHER
SOLENOID 1+ 32 RELAY
F
SM 33 LEFT

45
F HAZARD
A

12
SWITCH 34 RIGHT
WL
CR1
36

35

45

29
11 WL
CR3 36 HORN
WL
RL3 01+ F3 2 RL HORN
25 STABS
41K BUTTON
RESISTOR 1FR 22 STABS UP UP

1
OIL PRESS 26 STABS
15 DOWN
STABS DOWN
3

OIL TEMP 22 23 STAIRS

16 UP
30A 22 24 STAIRS
01 DOWN
11

14 15 16
21 22 29
CR2
22

21
ENGINE MOTION
SHUT DOWN 110
RL7

28
110 TILT
1 01

1
SS STAIR
27
11
4

1
25A 22 28
12 13 14
RL1

13
NEUT RL3
47 38 31

27
NEUT
11 30 LIGHT CR2
1+ FOR MS R1 NEUT F 15A (2.5) 20 PAWL
134 134A
49 38 30

136
F 01+ 10A 4 41
LATCH

11B
NEUT F
11C 137
R F1
R 11
42
135 135A
R
34

F REV MS
11 11A 111A
RL 22
48 47 32

F 131
FOR R1 44 46A REV MOTION
34

20

REV LIGHT
CR1

26
R 132 PRESSURE
REV SWITCH
34

45

23
50

MOTION 01+ F6 5 51 WORK LAMP

21

F 01+ 1+ SENSOR 124

MS PAWL LIGHT
34

11 A1 A2 F7

24
WIPER SWITCH
15 AMP 6 WINDSCREEN WIPER
64
M
11 B1 214 START
INHIBIT
11 214A WINDSCREEN WASH SWITCH
PARK
18 HANDBRAKE
WINDSCREEN WASH MOTOR
6 61
11 M

11 BRAKE RES 10 BRAKE RES CAB HEATER SWITCH

CAB HEATER FAN
62
11 BEACON M

11 19 STABS DOWN

22
F 7A
11 19+ A1 A2
1

903
B1 96 9
RL2
6

9A
11 97
7

901
11 99 LOW FUEL 01+ 9B T4
902
9A T5
HR V F 904
F
F 01+ 1+ 11
33
7
8

SEE SHEET 2
7
9

Figure 4.8 – Electrical Assembly

F 01+ 1+ 11

RL2
11 91 92 93 93A
94 92 RL7
FUEL
RL SOLENOID
CAB 11
E/STOP
PLATFORM 94 LAMP
11 115 113A
RL9
THROTTLE BAULK
11 113
F 01+ 10A 3 31 C
F4 FLASHER
1+ 32 RELAY

Mar 2009 Chap 3

Page 49
 2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.8 D1866/007 ELECTRICAL ASSEMBLY 1

42 33742 11 PIN RELAY BASE 1

43 07-22-73 11 PIN RELAY 1
42 B261-A0002 FRONT HEATED WINDSCREEN 1
43 B904-A0003 REAR HEATED WINDSCREEN 1
44 B759-A0062 MICRO SWITCH 2
45 108004 SPLIT CHARGE RELAY 33RA 1
46 90107 STABILISER LIMIT SWITCH 1
47 B065-A0006 RED PILOT LIGHT 1
48 B062-A0001 ELECTRICAL CONTACT NO 2
49 B062-A0002 ELECTRICAL CONTACT NC 2
50 B759-A0072 MOTION SENSOR 1

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 50
 RL2
11 97
11 99 LOW FUEL
HR V F
2054 MANUAL
F 01+ 1+ 11 Mar 2009

43 42

40
7
SEE SHEET 1
F12 15x LIGHT FITTINGS 12V
15 AMP 810 SL1 10WATT (FIXED STAIR)
F13 15x LIGHT FITTINGS 12V F 01+ 1+ 11
15 AMP 811 SL2 10WATT (MOVING STAIR)
F11 PLATFORM CONTROL
5 AMP STATION 81
A1
83
SR
STAIR LIGHTS RL2
11 91 92 93 93A
TIMER 1
41 30 MIN
94 92 RL7
81 AUXILIARY
BATTERY
069
AUXILIARY -
FUEL
82 B1 A2 ISOLATOR
BATTERY RL SOLENOID
CAB 11
E/STOP

39
SPRING RETURN SW. F+ PLATFORM 94 LAMP
MAIN 069
BATTERY MAIN -
ISOLATOR BATTERY 11 115 113A
RL9

39

2
CR3
THROTTLE BAULK

17
10
17
11 113
F

41
F 01+ 10A 3 31 C
MAIN BATT START F4 FLASHER
SOLENOID 1+ 32 RELAY
F
SM 33 LEFT

45
F HAZARD
A

12
SWITCH 34 RIGHT
WL
CR1
36

35

45

29
11 WL
CR3 36 HORN
WL
RL3 01+ F3 2 RL HORN
25 STABS
41K BUTTON
RESISTOR 1FR 22 STABS UP UP

1
OIL PRESS 26 STABS
15 DOWN
STABS DOWN
3

OIL TEMP 22 23 STAIRS

16 UP
30A 22 24 STAIRS
01 DOWN
11

14 15 16
21 22 29
CR2
22

21
ENGINE MOTION
SHUT DOWN 110
RL7

28
110 TILT
1 01

1
SS STAIR
27
11
4

1
25A 22 28
12 13 14
RL1

13
NEUT RL3
47 38 31

27
NEUT
11 30 LIGHT CR2
1+ FOR MS R1 NEUT F 15A (2.5) 20 PAWL
134 134A
49 38 30

136
F 01+ 10A 4 41
LATCH

11B
NEUT F
11C 137
R
11
R F1 42
135 135A
R
34

F REV MS
11 11A 111A
RL 22
48 47 32

F 131
FOR R1 44 46A REV MOTION
34

20

REV LIGHT
CR1

26
R 132 PRESSURE
REV SWITCH
34

45

23
50

MOTION 01+ F6 5 51 WORK LAMP

21

F 01+ 1+ SENSOR 124

MS PAWL LIGHT
34

11 A1 A2 F7

24
WIPER SWITCH
15 AMP 6 WINDSCREEN WIPER
64
M
11 B1 214 START
INHIBIT
11 214A WINDSCREEN WASH SWITCH
PARK
18 HANDBRAKE
WINDSCREEN WASH MOTOR
6 61
11 M

11 BRAKE RES 10 BRAKE RES CAB HEATER SWITCH

CAB HEATER FAN
62
11 BEACON M

11 19 STABS DOWN

22
F 7A
11 19+ A1 A2
1

903
B1 96 9
RL2
6

9A
11 97
7

901
11 99 LOW FUEL 01+ 9B T4
902
9A T5
HR V F 904
F
F 01+ 1+ 11
33
7
8

SEE SHEET 2
7
9

Figure 4.8 – Electrical Assembly

F 01+ 1+ 11

RL2
11 91 92 93 93A
94 92 RL7
FUEL
RL SOLENOID
CAB 11
E/STOP
PLATFORM 94 LAMP
11 115 113A
RL9
THROTTLE BAULK
11 113
F 01+ 10A 3 31 C
F4 FLASHER
1+ 32 RELAY

Mar 2009 Chap 3

Page 51
2054 MANUAL
Mar 2009

FIGURE & PART NUMBER NOMENCLATURE UNITS PER

ITEM NO. ASSY

Fig 4.9 D2054/008 HYDRAULIC ASSEMBLY 1

1 2054/042 HYDRAULIC TANK 1
2 D2054/008/1/1 LEVEL INDICATOR 1
3 D2054/008/1/4 RETURN FILTER 1
4 D2054/008/1/3 SUCTION FILTER 1
5 D2054/008/1/4 FILLER BREATHER 1
6 D2054/008/1/5 VALVE 1" 1
7 ON ENGINE PUMP 11cc 1
8 D2054/008/1/6 HAND PUMP 2
9 D2054/008/1/8 3/8” CHECK VALVE 1
10 B818-1148 STEERING UNIT 1
11 1286/082 STEERING CYLINDER 1
12 D2054/009/1 TEST POINT 1
13 D2054/008/1/6 MANIFOLD BLOCK 5 STATION 1
14 08-01-03 CYLINDER - THROTTLE 1
15 D2054/015 CYLINDER - A FRAME 1
16 D2054/015 CYLINDER -A FRAME 1
17 B065-A0013 ALUMINIUM BODY – 210 BAR RATED 1
18 08-05-65 PO CHECK VALVE CARTRIDGE 1
19 08-08-36 COUNTERBALANCE VALVE 1
20 D2019/018 CYLINDER - STAIR LIFT 1
21 D2054/017/A CYLINDER - LH FRONT STABILISER 1
22 D2054/017/B CYLINDER - RH FRONT STABILISER 1
23 D2054/017/A CYLINDER - LH REAR STABILISER 1
24 D2054/017/B CYLINDER - RH REAR STABILISER 1
25 ELECTRIC CYLINDER - PAWL 1

ITEMS MARKED THUS; *, NOT SHOWN

Chap 3 Mar 2009

Page 52
 CONNECTIONS

P, T1 & T2 - 1/2" BSPP FEMALE

ALL A`S & B`S - 3/8" BSPP FEMALE
PAWL

Mar 2009
A FRAME CYLINDERS

16
MAIN LIFT CYLINDER
THROTTLE

14
20

25
15
19

17
18

13
FRONT LH STABILISER FRONT RH STABILISER
A4 B4 A3 B3 A2 B2 A1 B1

1300 PSI
1300 PSI 600 PSI 500 PSI

P P P
21
T T T

T T
22

P P

PRESSURE
SWITCH

10
5

9
7
3

Figure 4.9 – Hydraulic Assembly

T
EF P

12
2

R L
23

1
24

9
8
4

STEERING CYLINDER

REAR LH STABILISERS REAR RH STABILISERS

11

Page 53
2054 MANUAL

Chap 3
Mar 2009
2054 MANUAL
Mar 2009

THIS PAGE IS INTENTIONALLY LEFT BLANK

Chap 3 Mar 2009

Page 54
 2054 MANUAL
Mar 2009

CHAPTER 5

GRAZIANO PST 2 Transmission

Mar 2009 Chap 5

Page 55