AMF-BRUNS Alu Ramp User manual

Operating Instructions
WHEELCHAIR ACCESS VEHICLE WITH REAR CUT-OUT
www.amf-bruns.de
CITROËN BERLINGO / PEUGEOT PARTNER WITH AMF-BRUNS ALU RAMP

Foreword
Alu Ramp Page 3 of 56
Foreword
Dear Reader,
these Operating Instructions serve to provide all information
required for the safe use of the Alu Ramp and the optional
Lowering Rear Suspension.
The Alu Ramp and Lowering Rear Suspension are designed
and constructed in accordance with state of the art tech-
nology and recognised safety standards. Persons and ma-
terials can however be endangered, as not all danger areas
can be eliminated if the functional capability is to be main-
tained. Accidents caused by these dangers can however be
prevented by strictly observing these Operating Instruc-
tions. Over and above this, the operational efficiency of the
Alu Ramp and Lowering Rear Suspension can be used to
the full and unnecessary faults can be prevented.
After reading these Operating Instructions for the first time,
keep them in a safe place for future reference over the en-
tire lifetime of the vehicle. If you sell the vehicle, hand these
Operating Instructions over to the new owner.
All details, figures and dimensions contained in these Oper-
ating Instructions are non-binding. No claims in any form
can be derived from these.
This document must not be reproduced or duplicated, in full
or in part, without the prior, written permission of the man-
ufacturer.
The Alu Ramp and Lowering Rear Suspension must not be
converted or modified in any way, without seeking the prior,
written permission of the manufacturer. The manufacturer
will not be held responsible in any way whatsoever if con-
versions or modifications are carried out without authorisa-
tion.
Use only original spare parts or spare parts which have
been approved of by the manufacturer. If spare parts other
than these are used, this can have a negative effect on the
specified characteristics, the functionality and safety of the
Alu Ramp and Lowering Rear Suspension. Using non-origi-
nal or unauthorised spare parts will render the guarantee
null and void.
Contact our customer services department to order spare
parts or accessories (see Chapter 12, page 55).

Foreword
Page 4 of 56 Alu Ramp
Explanation of symbols and signs
To improve understanding, the following conventions should
be met for these Operating Instructions:
1.
The following types of special note are used to highlight text
passages of an important nature.
DANGER!
 warns of a situation of immediate danger, which will lead
to serious or fatal injuries, if not avoided.
W
ARNING!
 warns of a potentially dangerous situation, which will lead
to serious or fatal injuries, if not avoided.
CAUTION!
 warns of a potentially dangerous situation, which will lead
to slight or minor injuries or material damage if not
avoided.
A
TTENTION!
...warns of a potentially dangerous situation, which can
cause material damage, if not avoided.
...contains general notes and useful information.
...gives a reference to important information in other sec-
t
ions and documents.

Foreword
Alu Ramp Page 5 of 56
2.
Some texts serve a particular purpose. These are identified
as follows:
 Lists
Ö Instructional text, e.g. a sequence of activities.
3.
Meaning of directions:
If directions are given in the text (in front of, front, behind,
rear, right, left), these directions relate to the normal direc-
tion of travel of the vehicle.

Contents
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Contents
Foreword................................................................. 3
Contents.................................................................. 6
1 Safety .................................................................. 8
1.1 Proper Use..............................................................9
1.1.1 Ramp............................................................9
1.1.2 Hydraulic Lowering Rear Suspension............9
1.2 Improper Use ........................................................ 10
1.3 Personnel Requirements ....................................... 10
1.4 Product Monitoring ................................................ 11
1.5 Danger Zone .......................................................... 11
1.6 Safety Devices ...................................................... 12
1.7 Safety and Accident Prevention Regulations ......... 12
1.8 Disposal ................................................................ 14
2 Description ........................................................ 15
2.1 Layout and Function.............................................. 15
2.1.1 Ramp.......................................................... 16
2.1.2 Floor section................................................17
2.1.3 Belts and belt anchorages.......................... 18
2.2 Hydraulic Lowering Rear Suspension .................... 19
2.3 Rating Plate........................................................... 19
2.4 Operating Controls................................................20
2.5 Technical Data ...................................................... 21
2.5.1 Alu Ramp.................................................... 21
2.5.2 Lowering Rear Suspension ......................... 21
3 Transportation...................................................22
4 Installation / Commissioning .............................22
5 Operation...........................................................23
5.1 Safety Regulations for Operation...........................23
5.2 Deploying the Ramp..............................................25
5.3 Embarking a Passenger/Loading a Wheelchair .....28
5.4 Disembarking a Passenger/Unloading
a Wheelchair .........................................................33

Contents
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6 Maintenance and Repair ...................................35
6.1 Safety Regulations for Maintenance and Repair....35
6.2 Routine Maintenance Work ...................................36
6.2.1 Maintenance schedule ...............................36
6.2.2 Maintenance record ...................................36
6.3 Functionally Testing
the Electrically Operated Belts ..............................37
6.4 Yearly Inspection...................................................38
6.5 Maintenance and Inspection Record.....................39
7 De-Commissioning and Conservation ..............40
8 Faults and Troubleshooting .............................. 41
8.1 Alu Ramp .............................................................. 41
8.2 Lowering Rear Suspension....................................42
9 Inspection Log...................................................43
9.1 Inspection Log Master Data Sheet ........................44
9.2 Inspection List.......................................................45
9.3 Inspection Results.................................................46
10 Electrical Circuit Diagram .................................53
11 Hydraulic Circuit Diagram .................................54
12 Customer Service .............................................55

Safety
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1 Safety
CAUTION!
There are a number of risks of suffering personal injury and
material damage involved in the operation and maintenance
of the Alu Ramp and Lowering Rear Suspension.
Therefore:
 it is imperative, that these Operating Instructions are read
thoroughly before operating the Lowering Rear Suspen-
sion. Always observe the notes and information con-
tained therein, in particular the safety instructions.
 If these Operating Instructions or parts thereof are lost
or become illegible, please request a new copy from the
manufacturer.
Prerequisite to the safe handling and trouble-free operation
of the Alu Ramp and optional Lowering Rear Suspension is
a thorough knowledge of the applicable safety information
and the safety regulations.
It is therefore imperative that this Chapter is read thoroughly
before operating the Alu Ramp and Lowering Rear Suspen-
sion and that the instructions and warnings herein are
strictly observed. The safety information and warnings,
given at the appropriate places in the following Chapters,
must also be strictly observed. The manufacturer will not be
held responsible if safety information and warnings are not
observed.
In addition to the information given in these Operating In-
structions, local legislative regulations must be taken into
consideration, in particular those regarding safety and acci-
dent prevention.

Safety
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1.1 Proper Use
1.1.1 Ramp
The Alu Ramp must only be used for transporting persons
in wheelchairs or empty wheelchairs. By using the Alu
Ramp, persons can be embarked into or disembarked from
the vehicle to which the Alu Ramp is fitted.
When doing so, the Alu Ramp is operated by an accompa-
nying person.
Wheelchairs must be equipped with the fittings necessary
to secure it by means of the belt restraint systems provided.
1.1.2 Hydraulic Lowering Rear Suspension
The hydraulic Lowering Rear Suspension is an optional ex-
tra. The hydraulic Lowering Rear Suspension is used exclu-
sively to temporarily lower and raise the vehicle's rear sus-
pension. By doing this, a gentler gradient for a one-piece
Alu Ramp is achieved via which persons in wheelchairs can
be embarked into or disembarked from the vehicle.
W
ARNING!
If the Alu Ramp or the hydraulic Lowering Rear Suspension
is used for any other purpose than that described above,
t
his may result in dangerous situations for persons or mate-
rial damage being caused.
Therefore:
 Only use the Alu Ramp or the hydraulic Lowering Rear
Suspension for the purpose for which was intended.
 Proper use also includes strictly adhering to the infor-
mation given in these Operating Instructions.
 Do not use the Alu Ramp for any other purpose, particu-
larly those given in Section 1.2. These are deemed to be
improper use.

Safety
Page 10 of 56 Alu Ramp
1.2 Improper Use
Any type of use, other than that mentioned in section 1.1 is
deemed to be improper use.
The Alu Ramp and the Lowering Rear Suspension are
deemed to be improperly used if for example
 the Alu Ramp is used to transport goods,
 the Alu Ramp or the Lowering Rear Suspension is used
when in a faulty condition or with safety-relevant malfunc-
tions,
 the Alu Ramp or the Lowering Rear Suspension is used
without protective cladding and safety devices,
 unauthorised modifications are made to the Alu Ramp or
the Lowering Rear Suspension,
 it is used to transport wheelchairs that can not be se-
cured by means of the belt restraint systems provided,
or
 it is used by incompetent persons.
1.3 Personnel Requirements
The Alu Ramp and the optional Lowering Rear Suspension
must only be handled by persons who:
 have been instructed in how to operate the Alu Ramp and
Lowering Rear Suspension,
 have read and understood these Operating Instructions,
 have proven their ability to operate the Alu Ramp and
Lowering Rear Suspension to the vehicle's owner,
 have been expressly assigned by the vehicle's owner to
operate the Alu Ramp and Lowering Rear Suspension,
 have the technical knowledge to operate the wheel-
chair's brakes and switch the motors of electrically driven
wheelchairs ON and OFF and
 who are in a position to adapt themselves to the particu-
lar behaviour and needs of disabled persons.
Transportation, installation, commissioning, maintenance,
repair, fault finding and disposal of the Alu Ramp, the Low-
ering Rear Suspension and the vehicle itself must only be
carried out by persons with the corresponding technical
training and experience.

Safety
Alu Ramp Page 11 of 56
1.4 Product Monitoring
Please contact AMF-Bruns GmbH & Co. KG immediately if
faults or problems are encountered when operating the Alu
Ramp or the optional Lowering Rear Suspension or if acci-
dents or "near-misses" occur.
AMF-Bruns will effect a solution to the problem with your
help and the knowledge gained will flow into future projects.
NOTE
Guarantee work on the Alu Ramp and the Lowering Rear
Suspension must only be carried out with the prior agree-
ment of AMF-Bruns GmbH & Co. KG.
The costs of such work will not be accepted by AMF-Bruns
without prior agreement.
1.5 Danger Zone
The danger zone is the area behind the Alu Ramp that is
being deployed, in which a person can be injured through
the movement of the Alu Ramp.
CAUTION!
Risk of injury and danger of material damage when deploy-
ing the Alu Ramp.
There is a risk of injuries to the legs and feet if the Alu Ramp
is allowed to fall to the ground. The Alu Ramp can suffer
damaged.
Therefore:
 Keep a firm hold of the Alu Ramp until it is fully in contact
with the ground.
 Allow the Alu Ramp to deploy slowly.

Safety
Page 12 of 56 Alu Ramp
1.6 Safety Devices
Electrically operated belts
Electrically operated belts, with which the wheelchair is se-
cured when driving, are attached to the front area of the
vehicle's floor. These electrically operated belts can only be
pulled out when the Alu Ramp has been fully deployed and
the indicator lamp in the rocker switch is lit (refer to Section
2.4, page 20). The electrically operated belts retract auto-
matically when the rocker switch is in either position. Before
the wheelchair can be pushed or driven up the Alu Ramp,
the electrically operated belts must be attached to the
wheelchair and the rocker switch must be operated such
that the indicator lamp goes out. This will prevent the wheel-
chair from rolling back out of control.
1.7 Safety and Accident Prevention
Regulations
Adhere to the following notes in order to prevent personal
injuries and material damage. For commercial use, also ad-
here also to the relevant safety and accident prevention
regulations laid down by the trade associations.
 The Alu Ramp must only be operated if all safety and pro-
tective devices are correctly fitted (see Section 1.6). Such
devices must only be removed in order to enable mainte-
nance and repair work to be carried out. All safety and
protective devices must be replaced immediately after
such work has been completed. If they are not replaced
correctly, there is a high risk of injury.
 The Alu Ramp must only be used for the purpose for
which it is intended, otherwise dangerous situations, with
resultant injuries, may occur (Proper Use: see Section 1.1,
page 9).
 The owner is responsible for ensuring that proper use is
adhered to, in particular that the Alu Ramp is only oper-
ated by authorised persons.

Safety
Alu Ramp Page 13 of 56
 If the Alu Ramp is used commercially or as a public utility,
the owner must ensure that operating personnel are fa-
miliar with the operation of the Alu Ramp and Lowering
Rear Suspension under all operating conditions by giving
training and familiarisation courses.
 Proper use of the Alu Ramp and Lowering Rear Suspen-
sion also includes adherence to the specified mainte-
nance and repair work, in particular the strict adherence
to the maintenance intervals. If such work is not carried
out, trouble-free operation can not be guaranteed. Risks
of personal injury and material damage can occur. We
recommend that maintenance records be kept.
 If the Alu Ramp and the optional Lowering Rear Suspen-
sion is used commercially or as a public utility, it must be
inspected by a technical expert at intervals of not more
than 1 year after commissioning. During inspection, faults
affecting the safety should be systematically identified
and remedial action taken (see "Inspection Log Book",
page 43).
 The Alu Ramp and Lowering Rear Suspension must not
be operated in a faulty condition, as serious injuries may
be caused by this. If faults occur, do not use the Alu
Ramp or Lowering Rear Suspension until repairs have
been effected.
 Before carrying out maintenance or repair work, this in-
cludes cleaning work, switch the vehicle's engine OFF
and prevent the vehicle from rolling away by applying the
handbrake. Make certain that no other person can start
the vehicle (e.g. by removing the ignition key). If this is
not done, there is a risk of injury.
 Use only original spare parts or spare parts which have
been approved of by the manufacturer. If non-original or
unauthorised replacement parts are used, this will render
the guarantee null and void.

Safety
Page 14 of 56 Alu Ramp
1.8 Disposal
When the Alu Ramp, the Lowering Rear Suspension and ve-
hicle's useful life has expired, they must only be be disposed
of by qualified specialists. The manufacturer will accept no
liability for damage caused by incorrect disposal.

Description
Alu Ramp Page 15 of 56
2 Description
Persons who are wheelchair-bound can be embarked into
or disembarked from a vehicle via the Alu Ramp.
The main components of the Alu Ramp are:
 the ramp,
 the floor section,
 belts and belt anchorages for securing the wheelchair.
The aim of this chapter is to illustrate the construction and
function of the Alu Ramp. To this end, the individual assem-
blies and components are described in the following sec-
tions.
2.1 Layout and Function
Figure 1: Two-Piece Ramp in The Deployed Position
Ramp Floor section

Description
Page 16 of 56 Alu Ramp
2.1.1 Ramp
The Alu Ramp is available in two different versions.
If supplied together with a Lowering Rear Suspension,
the passenger gains access to the vehicle via a one-piece
ramp.
Vehicles without the Lowering Rear Suspension are pro-
vided with a two-piece ramp. The extension created by this
second section effectively lessens the gradient of the ac-
cess ramp when it is extended.
In the deployed position, the access ramp provides a slope,
via which wheelchairs can be easily pushed or driven into
the vehicle (see Figure 1, page 15).
In the vertical, folded position the access ramp leaves
sufficient space for a passenger or empty wheelchair. In this
position, the frame of the ramp fills the gap in the vehicle's
rear bumper. The vehicle's rear doors can be closed (see
Figure 2).
Figure 2: Ramp in the Vertical Position
Frame
Ramp

Description
Alu Ramp Page 17 of 56
2.1.2 Floor section
The floor section of the Alu Ramp offers sufficient space for
the passenger in the wheelchair. The surface of the floor
section is lower than the floor of the vehicle. This ensures
that the passenger has sufficient headroom during embar-
kation, disembarkation and when riding in the vehicle (see
Figure 3).
Figure 3: Floor section
Floor
section
Electrically
operated
belts
Belt Reels
Fittings

Description
Page 18 of 56 Alu Ramp
2.1.3 Belts and belt anchorages
Two electrically operated belts are fitted to the front area of
the floor section (see Figure 3, page 17). The electrically op-
erated belts can be pulled out when the ramp is fully de-
ployed and the indicator lamp in the rocker switch is lit (see
Figure 6, page 20).
Fittings, to which the retractor belts can be attached, are
provided on the rear area of the floor section (see Figure 3,
page 17 and Figure 4). The rear end of the wheelchair is se-
cured by the retractor belts.
Figure 4: Retractor Belts and Fittings
Retractor
belts
Fittings
Floor
section

Description
Alu Ramp Page 19 of 56
2.2 Hydraulic Lowering Rear Suspension
If an Alu Ramp with one-piece ramp is fitted, the vehicle is
also equipped with a hydraulic Lowering Rear Suspension.
The rear axle is pulled upwards relative to the vehicle by
means.
of two hydraulic cylinders, thus lowering the rear end of the
vehicle.
The hydraulic Lowering Rear Suspension lessens the gradi-
ent of the ramp. This allows the use of a shorter, one-piece
ramp. This reduces the amount of free space required at
the rear of the vehicle for loading or disembarking a pas-
senger in wheelchair.
2.3 Rating Plate
A rating plate, which contains the fundamental data, is at-
tached to the Lowering Rear Suspension (see Figure 5). The
rating plate is located on the hydraulic aggregate.
Figure 5: Lowering Rear Suspension Rating Plate
Type
Year of
manufacture
Manufacturer’s
details
Serial
number
Aggregate
number
Cylinder
number
Designation

Description
Page 20 of 56 Alu Ramp
2.4 Operating Controls
Figure 6: Rocker Switch for the Electrically Operated Belts
Figure 7: Positions of the Operating Elements
Designation Function
Rocker switch for the
electrically operated belts
Allows the electrically oper-
ated belts to be pulled out.
Rocker push button for
Lowering Rear Suspension
Lowers the vehicle's rear
suspension.
Unlatching button, left Allow the access ramp to
be deployed.
Unlatching button, right
Unlatching button, left Unlatching button, right
OFF ON
Rocker push
button for
Lowering Rear
Suspension
Rocker switch for
the electrically
operated belts