Installation Manual

Minivator 1000 series

000137.52049 issue 0200
 Minivator 1000 series Installation Manual
Contents
First check that all the required components are available: 4
Special installation tools 4
To assemble the track 5
Fit the charge strip assemblies 6
To fit the end caps 8
To assemble the track to the feet 9
To assemble the track to the staircase 10
To change the power unit hand - Electrics 11
Fit the power unit to the track 12
Fitting the seat chassis to the power unit 13
Assembling the seat 14
To fit the seat to the chassis 16
Fit upholstery to the seat 17
To remove and replace armrest upholstery 17
Program the stairlift and handset 18
To change the hand required for control 19
Connect the track loom to the transformer, and test at final installation 20
Fit the hand control holder 21
Fit the powered folding rail 22
Changing the seat position 24
Appendix 1 Electrical diagram - Right hand 30
Appendix 2 Electrical diagram - Left Hand 31
Appendix 3 Electrical diagram - options. To build a standard left hand unit 32
Appendix 4 To change the power unit hand - Electrics 32
Appendix 5 Electrical diagram - options. To build a standard right hand unit 33
Fault analysis 34
Fault analysis - Other possible problems and tests 34

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Minivator 1000 series Installation Manual

First check that all the required

components are available:
1 Lengths of track. Please note before
assembly ensure the track is the correct
length.
If it requires cutting you must use the
appropriate grade of saw.
2 Feet. You will require 1 foot per 1.5m of track
plus 1.
2A Feet assembly plates and nuts/washers 1
assembly per foot.
3 Track Joining plates. You will require 2 per
joint.
4 Power unit.
5 Seat chassis and seat.
6 Upholstery:-
Backrest.
Seat cushion (2).
Armrest Cushion (2).
7 Fitting Kit.
Special Installation Tools
1 Feeder track (Power pack to track).
2 Driving seat toggle loom.
3 300mm screwdriver extension.

Note:
The installation engineer must check with Minivator for the latest Installation
Manual issue No.

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 Minivator 1000 series Installation Manual

To assemble the track

1 Bolt in the track joining plates to one
section of track extrusion (Fig. 1).
Note: There are 2 holes in the top rebated
section of the extrusion to accept the track
joining bolts.
On the underside there are also two holes,
as shown in Fig. 1.
Torque setting 8-9Nm.

Fig. 1

2 Offer up the adjacent track section, and

bolt both together (Fig. 2).
Ensure the bolts are secure (Torque setting
8-9Nm).
3 Continue the process until the required
length is reached.

Fig. 2

4 The top and bottom final limit stops are Final limit stop
factory fitted to the rear face of the track Retaining lugs
extrusion. Slacken and rotate the upper final
limit stop, so that it does not contact the Rotate top stop
to avoid
power pack as it is loaded on to the track. contact with the
Note: Ensure the positioning lugs are not power pack as
it is loaded
damaged when the stop is rotated.
Note: Ensure the positioning lugs are
correctly located in the groove when the stop
is secured.
Re assemble as shown in (Fig. 3).
Retaining
Tighten securely. (Torque setting 8 - 9Nm). groove for
hexagon
headed
screw
7 inches (180mm)

Fig. 3

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Minivator 1000 series Installation Manual

5 The stairlift end stop brackets are factory

fitted.
The upper end stop must be removed to
load the power pack.
Final
To re fit the end stop slide the retaining
limit stop
hexagon headed screws into the track
Stairlift
extrusion, as shown in Fig. 4.
end stop
bracket Screw up the nuts loosely, to allow the
brackets to slide to their required positions.
Retaining
groove Tighten securely. (Torque setting 8-9Nm).

35mm
Fig. 4
6 Hinge track only. Fit the hinge track latch
switch on to the track extrusion, as shown
in figure 4A.
Note: This must be fitted prior to fitting
the override stops and end stops.

Fig. 4A

7 Tuck the harness into the groove as shown

in figure 4B, and hold the harness in place
with the plastic studs as shown in figure
4B, and connect to the hinge track loom.

Fig. 4B

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 Minivator 1000 series Installation Manual

Charge strip assemblies

1 The charge strips are factory fitted. They
are pre assembled and snap into the
retaining groove in the track extrusion as
shown in Fig. 5 and 5A.
2 When the track sections are assembled the
gap between the top and bottom charge
strip assemblies must be filled with the
supplied filler strip. ‘Snap’ fit the
charge strips
Measure the gap between the charge into this
strips, cut the filler strip to length and snap groove
Fig. 5
fit it into the groove. (It is an identical section
to the charge strips).

‘Snap’ fit the

charge strips
into this groove
Fig. 5A

2 Feed the two core grey cable through the

track as shown in figure 5B
3 Using the two way connecting blocks wire
up the charging point cables to the two way
feed cable (Fig. 5C).
One of the wires on the grey two way cable
is has a black line moulded in for continuity
identification purposes.
5 Choose the most appropriate position for Fig. 5B
the power supply.
Note: If this is at the top of the staircase
the bottom nut plate and end cap can
be fitted to the track.
Where the power supply is located at
the bottom, fit only the nut plate, to
enable the charging circuitry to be
connected to the tpower supply at the
final stage of fitting. Fig. 5C

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Minivator 1000 series Installation Manual

Charge polarity Figure 5D and 5E are schematics of the charging

Fig. 5D wiring within the track
Schematic of
track wiring
Right Hand Rail

Fig. 5E Schematic
of track wiring - Left
Hand Rail
Charge polarity

Two way
connecting
blocks

Charge
contacts with
flying leads
Twin cable

Tuck the To fit the end caps

harness
and 1 Carefully tuck the connector and harness
connector into the track extrusion (Fig. 6)..
into the
extrusion

Fig. 6

2 Slide in the nut plate pressing (Fig. 6 - this

Fit the is retained by barbed sprung sections
bottom nut which lock against the inside of the track
plate
pressings
extrusion).
Note:
Take care not to damage the charging
wiring as the pressing is being fitted

Grooves in
Fig. 7 extrusion

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 Minivator 1000 series Installation Manual

3 Fit the end cap (Fig. 8), taking care that

the end cap moulding retaining screw is
not over tightened, and that it avoids the
wiring.
Hint: Pre-assemble the end cap, nut plate
pressing and retaining screw,
This assembly can then be feed into the
extrusion and secured as shown.

End cap

Do not over tighten the

screw
Fig. 8

To assemble the track to the feet

Ensure the track is the correct length before you
commence assembly.
1 Slide the foot assemblies into the track.
The foot retaining plate locates into the
extrusion, as shown in Fig. 9. Fig 10 & 11
show the individual components of the foot
assembly
Slot in track
accepts retaining
Note: The pressings can be assembled plates
from the top or bottom of the track. Foot retaining
plate
Fig. 9

2 Only finger tighten the nuts at this stage, Retaining plates slide in track
to allow the foot to be adjusted in position
on the stair tread.
Note: The foot must be fitted with the
straight edge (three hole side) against the
wall.

Fig. 10 Mounting foot- top only shown

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Minivator 1000 series Installation Manual

Mounting foot-
top bracket Mounting foot-
base

Mounting foot-assembly bolt.

Use the hole closest to the
Fig. 11 nose of the stair tread.

Three fixing screws on each foot To assemble the track to the staircase
3 Stand the feet on to the stairs, with one
foot on the top tread, and one foot on the
first tread, with the spacing even in
between.
If possible fit one foot over the splice, or
as close as possible to it.
4 Offer the track assembly to the stairs, and
fix the feet to the stair treads, see Fig. 14
for fitting dimension.
With the screws supplied locate the feet
Note the bottom foot component is shown in using three rear screws per foot.
isolation for clarity
5 Vertically align the track along its whole
Fig. 12
length, using a spanner on the single front
adjuster on each foot (Fig. 13).
When all the feet are
correctly adjusted Do not tighten the screws until the track
tighten all the fixing angle is correct for vertical alignment along
screws. its whole length.
Failure to align the track and feet
Screw the adjuster up or correctly prior to tightening the
down to achieve the
correct level - using a screws will twist the feet and lead
10mm A/F wrench, to permanent damage.
(under the foot) or a
6mm Allen key (before
fittting the fixing screw)
6 Tighten all feet to the track, and the feet
Finally ‘snap’ fit the pivot bolts.
plastic covers over the
adjusting screws 7 ‘Snap’ fit the protective plastic covers over
Fig. 13
the adjuster assemblies.

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 Minivator 1000 series Installation Manual

Fully tighten the foot to stairtread screws. (Fig. 14). To any obstacle that may 100mm
Recheck the vertical alignment of the track, fit interfere with the back of
locking nut and tighten the front screw. the seat
Note:
This can be done when the power unit has been
loaded on to the track.
Note: A long shaft Pozidrive screwdriver will be
required for this operation. Stair Rail
Fig. 14 shows typical view ‘on site’.
The rear finishing extrusion groove should be
approximately 100mm from the wall.
(Dependant on the wall condition, and so that
any obstacle will clear the back of the seat).
(NOT THE STAIRCASE STRINGER).
Note this should ensure a seat clearance from Top finishing Use a long shaft screwdriver
the wall of 25mm. extrusion to tighten the 3 screws
Fig. 14
Figure 15 showing an end view of the track with
the top finishing extrusion in place and a foot
assembled to the track.

Foot
mounting
bracket

Fig. 15

To change the power unit hand-Electrics Dip Numbered

switches collars
Note: Should the power unit require for setting
changing hand, this must be done prior direction
and speed
to fitting to the track.
Then follow the sequence given in the
Appendix 3 and/or 4 to change the
electrics.
1 Lay the power unit with its front face down.
2 Take off the top and rear covers from the
power unit to reveal the main PCB and
wiring connectors (Fig. 16). Main Programming
motor button (Red)
3 Follow the sequence stated in the connections
schematic electrical diagrams, Appendix 1
Note: All wires have numbered collars
Fig. 16 Some wiring omitted for clarity
for identification purposes.

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Minivator 1000 series Installation Manual

Fit the power unit to the track

Cut out Cut out
1 Take off the top cover from the power unit
on fitting on fitting
rail rail 2 Lay the power unit with its rear face down.
3 Slide the power unit fitting rail into the power
unit, and lock the power unit into place,
using the plastic locking studs (Fig. 17).
5 Carefully locate the power unit/fitting rail
on to the track (Fig. 18).
Fig. 17
Note: Ensure the charging loom is not
Power unit locking stud
damaged.
When the fitting rail is securely attached,
Power tuck the charging loom into the cut out in
unit the fitting rail and check that it does not
fitting rail protrude.
This ensures the power unit override will
not be activated when the unit is being
Power unit driven on to the track.
locking Remove the power unit lock and carefully
stud
allow it to role on to the track, until it starts
to engage with the rack.
6 Connect the dummy seat toggle looms:-
Charging 6 way to 6 way (Can only be fitted one way).
loom, and cut 8 way to 8 way (Can only be fitted one way).
out on fitting 2.5mm² battery link across the flying battery
rail
leads.
Fig. 18 0.5mm² underpan link across the underpan
loom (Violet to Red).
8 Way connections as follows:
Plug Green to Orange.
8 way Plug the 0.5mm² toggle link into the
connector common (Blue) connection on the 8 way
6 way
connector, and to drive the lift connect to
Brown connector
(Brown - Up), or (White - Down).
Up
Battery Note: These will change when hand of stairlift
leads (Red) changes (White - Up), or (Brown - Down)
and link Drive the power on to the track (Fig. 19).
loom
Warning: Do not hand wind the power
White
Underpan unit on to the track, as this could trip the
Down
(Violet & Over Speed Governor (OSG).
Toggle Red) and
7 When the power unit is fully and correctly
link link loom
engaged with the rack remove the fitting
rail from the track, and the dummy seat
Fig. 19 toggle looms

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 Minivator 1000 series Installation Manual

Fitting the Seat Chassis to the power unit

1 Remove the front cover from the seat
chassis, to gain access to the mounting
slots.
Note: There are two pairs of straight slots
to give height adjustment to the footplate/
seat dimension
Note: they also allow the footplate/seat to
be adjusted towards or away from the
stairtread nose (Fig. 20).
Note: The power unit has arced slots on
the seat chassis interface, to set the angle
of the seat and footplate (see Fig. 17 - 19).

Fig. 20

2 Offer the seat chassis to the power unit Top pressing

(Fig. 20), and using the nuts, bolts and cut away for
washers supplied secure the seat chassis clarity
to the power unit, ensuring that the chassis
is in the correct vertical alignment. 2 pairs
Fit the flanged bolt in the radial slot and of slots
assemble the eccentric washer by rotating
to locate it within the large slot and secure
with the M8 flange nut.
Note: Do not fully tighten the assembly at
this stage, as you will need to adjust the Assembly
footrest for vertical alignment. nuts and
Note: Do not pinch any harnesses whilst bolts
assembling the chassis.
Tighten the retaining bolts to torque setting
33Nm. (Fig. 21).

The eccentric washer must be

M8 Flange Eccentric
fitted to ensure the correct nut & bolt washer
location of the seat assembly Fig. 21

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Minivator 1000 series Installation Manual

Retaining bolt, collar and washer Assembling the seat

1 Lay the seat rear face down on a suitable
non scratch surface.
2 Remove the seat stem retaining bolt ,collar
and washer (Fig. 22).
3 Fit the nylon spacer washer with its
bevelled inner diameter against the weld
(Fig 22).

Nylon spacing
washer
Fig. 22

Retaining
spigot 4 Slide the seat stem assembly over the
retaining spigot on the seat (Fig. 23), taking
care not to damage the micro switch.

Micro switch

Seat stem assy.

Fig. 23

5 Ensure the seat stem assembly can rotate

into its lockable positions and that the micro
switch is undamaged.
Replace the retaining collar, washer and
bolt and tighten (Fig. 24).
Note:
It may be advisable to remove the micro
switch to avoid damage and to replace
it after the seat stem assembly is fully
fitted.

Fig. 24

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 Minivator 1000 series Installation Manual

6 Push out the required seat stem hole in

the base moulding. (These are held with
three moulded stems for ease of removing).
Slide the moulding over the seat stem (Fig.
25) and fit using the plastic slotted head
female screws provided (Fig. 26).

Push out the required

seat stem hole

Fig. 25

Plastic slotted head

female screws
Fig. 26

7 Slide the ‘V’ shaped loom down the seat

stem, with the single 8 way connector at
the bottom (Fig. 27).

Fig. 27

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Minivator 1000 series Installation Manual

To fit the seat to the chassis

1 Place the seat chassis top moulding on
the chassis, and feed the harness and seat
stem (and seat assembly) through the
holes in the moulding and chassis (Fig.
28).

Fig. 28

2 Feed the two seat retaining bolts through

the required holes in the seat stem and
footrest chassis. Fit the strengthening
plate, and the two retaining nuts and
tighten to 25Nm. torque (Fig. 29).
NOTE: TAKE CARE WHEN FEEDING
THE RETAINING BOLTS NOT TO
DAMAGE THE SEAT WIRING
HARNESS.
3 When fitted check for correct action of the
latching mechanism on the seat swivel
assembly. Check for any chafing on the
wiring harness. Connect the seat chassis
harness to the power unit.
Fig. 29

4 When all the checks are satisfactory fit the

seat chassis front cover, plug in the wiring
harness to the cover mounted switch and
neon (Fig. 30).

Fig. 30

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 Minivator 1000 series Installation Manual

5 Connect the 2 top plugs into their

respective sockets on the seat PCB and
infra red unit (Fig. 31).

To Infra-Red
unit

Fig. 31

Fit upholstery to the seat

The seat backrest and cushions are held in place
with Velcro pads (Fig. 32).

Fig. 32

To remove and replace armrest upholstery Philips head

screws (2)
Remove both armrest pads by rotating the
armrests vertically and unscrewing the Philips
head screws to release the armrests (Fig. 33).

Fig. 33

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Minivator 1000 series Installation Manual

Program the stairlift and handset

1 Rotate the seat through 90O to gain access
RED
button to the main control board as shown in Fig.
34.
2 Press the red button on the main control
Main
control board (adjacent to the green connectors)
board and keep it held down (Fig. 34).
Note: Wiring has been omitted for clarity.

Fig. 34
3A If the lift is at the top of the stairs press the
Move lift up DOWN button on the remote control (Fig. 35).
3B If the lift is at the bottom of the stairs press
Move lift
down the UP button on the remote control (Fig. 35).
4 Release the red button.
The lift and remote control are now programmed
for normal operation.

Fig. 35

Location of Main Should the lift require any additional

controller
Dip board PCB programming, first determine if the program is
standard, by pressing ‘park’ on the hand set.
The lift should head upwards in ‘standard’ mode.
Then move the dip switches on the main
controller board to the required settings (Fig.
36).

Finally fit the power unit top cover.

Fig. 36
Should there be more than one lift operating in
the same vicinity the handsets will require
programming.
1 Remove the 4 screws from the rear covers
and remove the covers to gain access to
the dip switches, which can be set in 4
different positions as shown in Fig. 37.
2 Set the switches as required and replace
the rear covers.
Note: Ensure each set of handsets have
Fig. 37 the same dip switch settings.

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 Minivator 1000 series Installation Manual

To change the hand required for control

The chair is factory supplied for the user to use
their right hand for controlling the chair.
To change the control position:
1 Carefully unplug all armrest wire sockets
from the printed controller board (PCB)
located in the rear centre seat backrest Connect all
(Fig. 38), taking care to note the sockets wires to seat
PCB
correct positions on the PCB.
2 Unclip the wires from their mountings on
the seat. PCB

Power unit
and seat
chassis looms

Fig. 38
3 Remove the both armrest pivot covers, by Arm retaining screws Armrest pivot cover
turning approximately 45% and lifting clear
(Fig. 39).
4 Unfasten the retaining screws on the
controller arm and carefully withdraw the
arm and control wires through the arm
mounting (Fig. 38, 39).
5 Unfasten the opposite arm and thread the
safety shut off wires through the arm
mounting.
6 Fit the control arm on to its required
mounting, carefully threading the control
wires through the arm mounting moulding. Fig. 39 Arm retaining screws
Tighten the mounting screws securely and
refit the cover moulding. Infra Red
detector
7 Fit the opposite arm following the sequence
outlined in 7 (Fig. 40 shows completed
sequence).
8 Refit the sockets on to their respective
plugs on the control PCB (refer to Fig. 38),
and ensure the infra red detector is
correctly positioned in its transparent dome
in the rear of the backrest.
Note: If the detector is not correctly
positioned the hand control will not
operate the stairlift. Fig. 40

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Minivator 1000 series Installation Manual

Connect the track loom to the Power

Supply and test at final installation
Note: The Minivator 1000 series stairlift
is battery operated from the 33V output
power supply, and can therefore be
safely connected to the household
Power supply
mains supply via the normal ring main.
33V Output
1 Locate the power supply in an appropriate
Fig. 41 position, and connect to the mains at a
fused spur or with a fused plug on to the
normal household ring main.
Note: All mains wiring must comply
Two way
with the standards in force at the time
connecting
block of installation.
2 Connect the charging point wiring to the
transformer (Fig. 41, 41A, 41B).

Fig. 41A Schematic

3 Slide in the nut plate (this is retained by
of track wiring - Right springed sections which lock against the
Hand track iside of the track extrusion), as shown in
Charge polarity Power supply Fig. 42
(See also page 5 and 6).
4 Fit the final limit stop (Fig. 42).
5 Earth bond the track at base of the ‘L’
shaped end stop through the M5 clearance
Charge hole specifically for cable connection.
contacts with
flying leads 6 Fit the top end stop to the stringer side of
the track (Fig. 42).
Twin cable 7 The magnetic limit stops can be adjusted
Fig. 41B Schematic of track wiring - Left Hand track at this stage, to position the stairlift’s static
position relative to the end of the track.
Nut plate End stop Final
limit Note: They are held in place on a Velcro
stop
backing strip. The whole strip must be
moved to give final adjustment.

Magnetic
limit stops
Fig. 42

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 Minivator 1000 series Installation Manual

6 Fit the track top plastic finishing extrusion,

sliding under the power unit, and snapping
it into place, (Fig. 43). Track top plastic finishing
extrusion

Fig. 43
7 Tuck the 2 way connecting block and wiring
into the track.
Fit the track end cap, ensuring that no
wires are trapped (Fig. 44).

8 Test the final installation.

Fig. 44

Fit the hand control holder

Fit the hand control holder to the wall in the
required position using the fixings supplied (Fig.
Move lift up
45).
When the stairlift assembly is complete and Move lift
down
tested satisfactorily demonstrate all the
features on the hand control. Park and lift
folding rail *
Note; the hand controller can be fixed into the
holder by locking it with the supplied plastic Hinge track
down *
moulding.
Hinge track up *

Fig. 45

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Minivator 1000 series Installation Manual

Fit the powered folding rail

Locate as many screws as are accessible 1 Splice the hinge rail section to the main track
as per the track assembly instructions, and
fit the required number of feet, and then
proceed as follows:-

Rail joining
2 Offer up the folding rail to the adjacent track
bolts on top section, and bolt loosely together at this
and bottom stage (Fig. 46).
of the rail
3 Fasten the foot/rail assembly to the stair
tread:-

Due to the overhang of the operating

Gear train gear train and the possible position of
cover the foot you may only be able to locate
1 or 2 fixing screws in the foot. If this is
the case use the following procedure.

Folding
rail

Fig. 46 4 a Fit the screws

b Adjust the rail angle to ensure the stairlift
is vertical using the adjuster screw as
shown in Fig. 47. (Bottom plate only shown
- for clarity).

Angle adjuster
with flats, and
hexagon for
adjusting

Fig. 47

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 Minivator 1000 series Installation Manual

c Withdraw the foot top bracket/bottom

bracket bolt (Fig. 48).
d Unscrew the rail joining bolts and
withdraw the folding rail assembly (Fig. 46).

Fig. 48

e Locate the remaining screws (Fig. 49). Locate the

remaining
screw(s)
f Reassemble the folding rail to the fixed
rail, (see Fig. 43).
Torque setting 8-9Nm.

Fig. 49

g Relocate and secure the top bracket/

bottom bracket bolt (Fig. 50).
h Finally ‘snap’ fit the protective plastic
covers over the adjuster assemblies.
6 Fit the track top finishing extrusion on all
rails.

Fig. 50

When all the feet are

correctly adjusted
tighten all the fixing
screws.

Screw the adjuster up or

down to achieve the
correct level - using a
10mm A/F spanner,
(under the foot) or a
6mm Allen key (before
fittting the fixing screw)

Finally ‘snap’ fit the

plastic covers over the
Fig. 50A adjusting screws

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Minivator 1000 series Installation Manual

Seat harness Changing the seat position

connector
The seat can be mounted at the left or right
side of the seat chassis.
Front cover
cut away for Refer to Figures 51, 52, 53
clarity Note:
The seat stem should be fitted to the upper
side of the unit.
On the left for right hand stairs.
On the right for left hand stairs.
1 Unclip the front cover, and remove the
female terminals from the switch and
neon on the front cover, and unclip the 8
way seat harness connector (Fig. 51).
2 Remove the seat cushions and backrest
upholstery to gain access to the wiring,
Fig. 51 and unclip the plugs on the seat PCB and
on the infra red unit.
3 Remove the two tube retaining bolts (Fig. 52),
nuts, and flat plate, and carefully withdraw
the seat assembly from the chassis (Fig.
53).

Fig. 52

Fig. 53

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 Minivator 1000 series Installation Manual

4 Lay the seat on its back, with foam rubber

to stop any movement, and to avoid
damage.
5 Remove the screws locating the bottom
cover moulding and remove the moulding
(Fig. 54).

Remove the 2
screws retaining
the bottom cover
Fig. 54

6 Remove the micro switch.

7 Remove the seat stem retaining nut,
washer and collar seat stem retaining nut,
washer and collar (Fig. 55), and withdraw
the seat stem and spacing washer (Fig.
56).

Seat stem
retaining
nut, washer
and collar

Fig. 55 Micro switch

Spacing
washer

Seat
stem

Fig. 56

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Minivator 1000 series Installation Manual

8 Remove the circlips from the latching

levers (Fig. 57), and remove the levers.

Remove circlips
and withdraw
the latching
levers

Fig.57
6 Unbolt the reaction block (Fig. 58).
7 Unbolt the spring reaction bracket (Fig. 58).
8 Slide the latching bar out.

Reaction
block
Latching bar Spring
reaction
bracket.
Fig. 58
9 Remove the 4 countersunk Allen screws
retaining the seat mounting plate (Fig. 59),
and remove the plate.
10 Remove the micro switch loom from its
present inlet hole (Fig. 59).

C/sunk
Allen Micro switch
screws Loom
Fig. 59

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 Minivator 1000 series Installation Manual

10 Replace the plate in the required position,

and tighten the Allen screws to 20Nm.
(Fig. 60).

Fig. 60
11 Replace the micro switch in the position
indicated in Figure 61, and feed the loom Micro switch
through the moulded hole as shown in (Fig.
60 and 61) and reconnect the spade
terminals.

Fig. 61
12 Feed the latching bar, and reaction bracket
into the seat,
Note: The positions of the reaction bracket
and spring must be a mirror image of the
original assembly, so that the latching yoke
lines up with the latching plate (Fig. 62).
13 Fit the spring reaction bracket and tighten
to 20Nm. (Fig. 62).

Fig. 62

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Minivator 1000 series Installation Manual

14 Fit the latching levers into their bearings

and over the latching bar and replace the
circlips (Fig 63).
Ensure the latching mechanism operates
freely.

Fig. 63

15 Fit the nylon spacing washer with the inner

bevelled portion against the weld on the
plate and the seat stem in the position
shown, with the large notch rotated 90O
anti-clockwise (Fig. 64).
Note: Take care not to damage the micro
switch when assembling the seat stem.
Fit the seat stem retaining nut, washer and
collar (Fig. 61), and ensure the mechanism
operates smoothly prior to fitting the cover.
Nylon
spacing
washer

Fig. 64 Seat stem

16 Snap out the plastic covering the new

position required for the seat stem
(Fig. 65), and replace the cover (Fig. 66).

Snap out the new seat

stem cover moulding

Fig. 65

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 Minivator 1000 series Installation Manual

17 Fit the cover moulding using the two plastic

nuts (Fig. 66).

Fig. 66

18 Replace the seat in the required position

(Fig. 66), refer to page 11 and 12 (Fitting
the seat), for details of the sequence.
19 Replace the seat upholstery as detailed on
page 12.

Fig. 67

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Minivator 1000 series Installation Manual

Appendix 1 electrical diagram - right hand

Fig. 68 Appendix 1

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 Minivator 1000 series Installation Manual

Appendix 2 electrical diagram - Left Hand

Fig. 69 Appendix 2

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Minivator 1000 series Installation Manual

Appendix 3 electrical diagram - options. To build a standard left hand unit

Dip Numbered
switches collars
for setting
direction
and speed

Main Programming
motor button (Red)
connections
RED lead
Black lead

Fig. 70 Appendix 3

Appendix 4 To change the power unit hand

- Electrics
Note: Should the power unit require
changing hand, this must be done prior
to fitting to the track.
Then follow the sequence given in
schematically in Fig. 71 Appendix 3 and/
or Fig. 73 Appendix 4 to change the
electrics.
1 Lay the power unit with its front face down.
2 Take off the top and rear covers from the
power unit to reveal the main PCB and
wiring connectors (Fig. 16).
3 Follow the sequence stated in the schematic
electrical diagrams, Appendix 1
Note: All wires have numbered collars
for identification purposes.
A pair of pointed nose pliers will be
required to change the main motor leads
over; care must be taken to avoid
damaging the cover insulators when Fig. 71 Appendix 3
performing the operation.

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 Minivator 1000 series Installation Manual

Appendix 5 electrical diagram - options. To build a standard right hand unit

Dip Numbered
switches collars
for setting
direction
and speed

Main Programming
motor button (Red)
connections
RED lead
BLACK lead

Fig. 72 Appendix 4

Fig. 73 Appendix 5

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Minivator 1000 series Installation Manual

Fault Analysis

INDICATES FAULT POSSIBLE REMEDIES

Green LED Power ‘ON’ Battery charger connected
(On lift front panel) Permanently illuminated Battery charger not Check battery charger
Flashing with buzzer connected circuits
LED extinguished when Brake not connected Check brake circuits
direction selected
Red LED Holding switch (Key) OR Off Turn key ON
Final limit OR Lift has over-run it’s limit Wind lift off the cam on track
OSG OSG tripped Reset OSG

Red LED flashing Battery charger not connected

plus one or more of above
Yellow LED Battery condition Battery volts less than 21V Allow batteries to charge
when first connected
Battery volts fallen below
16.5V when running
Flashing yellow LED Brake not connected Check brake circuit
Relay fault Tap large black relay, if LED
still flashing replace control
board
Buzzer Short bleep on starting Normal
Continuous bleeping for 20 Battery charger not
seconds with flashing green connected
LED (front panel)
Extended bleep on start Battery has reached 30% of Possibly due to heavy
usable power usage if charger OK

Fault Analysis-other possible problems and tests

Lift dead Check key switch is ON before removing covers. Has lift overrun onto final limits?
No green LED indication LED will extinguish when final limit is actuated.
Lift dead With voltmeter, check battery volts across B+ & B- on control board. If more than 23V, pull
No LED indication out both green connector blocks. After approximately 5 seconds there will be a bleep and
the red LED will glow. This means there is a short circuit on the wiring.
If no bleep or LED replace board.
Lift running at half Very low battery volts, final stage before lift stops.
speed Check dip-switch settings.
Lift will run at half speed when immediately after power-up, the handset is used to move
the lift UP or DOWN.
Battery charger Connect voltmeter across B+ & B- on the control board.
information Momentarily press up or down button on remote control, lift will bleep and the volts will dip
down, then increase back to original voltage. If this happens the charger is OK
Also look for the Green LED on front panel to be permanently illuminated. If it’s flashing,
lift not receiving charge. Check charge contacts on track with voltmeter.(Should read
approximately 40V DC). Check polarity of charge contacts on rail. Lower contact should
be ‘+’, upper contact should be ‘-‘ on a left-hand track. Vice versa on right-hand track i.e.
lower ‘-‘, upper ‘+’.
Check continuity from lift charge contact butterfly to connection into controller for BOTH
positive & negative looms.
Are the butterfly contacts on the lift making contact with charge contacts on track?

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Minivator 1000 series Installation Manual

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Minivator Ltd. 82, First Avenue, Pensnett Estate, Kingswinford,
West Midlands. DY6 7FJ. England.
Tel. 44(0)1384 408700. Fax. 44(0)1384 408719 ‘E’ mail. sales@minivator.co.uk