AMF-BRUNS EasyPull User manual

www.amf-bruns.de
Operating Instructions
EasyPull

Foreword
EasyPull Page 3 of 52
Foreword
Dear Reader,
these Operating Instructions serve to provide all information
required for the safe use of the EasyPull.
The EasyPull is designed and constructed in accordance
with state of the art technology and recognised safety
standards. Persons and materials can however be endan-
gered, as not all danger areas can be eliminated if the func-
tional capability is to be maintained. Accidents caused by
these dangers can however be prevented by strictly ob-
serving these Operating Instructions. Over and above this,
the operational efficiency of your EasyPull 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 EasyPull. If you sell the EasyPull, 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 EasyPull must be converted or modified in any way,
without seeking the prior, written permission of the manu-
facturer. The manufacturer will not be held responsible in
any way whatsoever if conversions or modifications are car-
ried out without authorisation.
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
EasyPull. Using non-original 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 49).

Foreword
Page 4 of 52 EasyPull
Explanation of symbols and signs
To improve understanding, the following conventions should
be met for these Operating Instructions:
1.
The following conventions are used to highlight important
information:
DANGER!
 warns of a situation of immediate danger, which will lead
to severe or fatal injuries, if not avoided.
W
ARNING!
 warns of a potentially dangerous situation, which will lead
to severe 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
EasyPull Page 5 of 52
2.
Some texts serve a particular purpose. These are identified
as follows:
 Lists
 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
Page 6 of 52 EasyPull
Contents
Foreword................................................................. 3
Contents.................................................................. 6
1 Safety ................................................................. 8
1.1 Proper Use ............................................................9
1.2 Improper Use.........................................................9
1.3 Operator Requirements ....................................... 10
1.4 Product Monitoring .............................................. 10
1.5 Safety and Accident Prevention Regulations......... 11
1.6 Disposal ................................................................ 11
2 Description ....................................................... 12
2.1 Layout and Function ............................................ 12
2.1.1 Voltage transformer.................................... 12
2.1.2 Control unit ................................................. 13
2.1.3 Winch with belts ......................................... 14
2.1.4 Remote control........................................... 15
2.1.5 Rating plates............................................... 16
2.2 Technical Data ......................................................17
3 Transportation...................................................17
4 Installation ........................................................ 18
4.1 Safety Information for Installation ......................... 18
4.2 Fitting the Winch ..................................................20
4.3 Installing and Connecting the Electrical System ... 21
4.3.1 Fitting the voltage transformer.................... 21
4.3.2 Fitting the control unit .................................22
4.3.3 Laying the extension cable (optional) .........23
4.3.4 Laying the connection cable .......................23
4.3.5 Fitting the door contact switch ...................24
4.3.6 Making the connections .............................24
4.4 Tightening Torques ..............................................25
4.5 Carrying out a trial run .........................................26
5 Commissioning................................................. 27
5.1 Initial Setting......................................................... 27
5.2 Checking the Setting............................................30
5.3 Fine Adjustment ................................................... 31

Contents
EasyPull Page 7 of 52
6 Operation .........................................................32
6.1 Safety Regulations for Operation .........................32
6.2 Loading an Occupied or Unoccupied
Wheelchair...........................................................34
6.3 Unloading an Occupied or Unoccupied
Wheelchair...........................................................36
7 Maintenance and Repair ..................................38
7.1 Safety Regulations for Maintenance and Repair...38
7.2 Routine Maintenance Work..................................39
7.2.1 Maintenance schedule ...............................39
7.2.2 Maintenance record ...................................40
7.3 Maintenance and Inspection Record ...................40
8 De-Commissioning and Conservation ............. 41
9 Faults and Troubleshooting ............................. 41
9.1 Fitting a New Battery ...........................................43
9.2 Configuring a New Remote Control .....................44
10 Spare parts ......................................................46
11 Electrical Circuit Diagrams .............................. 47
12 Customer Service ............................................49
13 Declaration of Conformity................................50

Safety
Page 8 of 52 EasyPull
1 Safety
CAUTION!
Risk of injury if the EasyPull is not operated correctly.
Therefore:
 It is imperative, that these Operating Instructions are read
thoroughly before operating the EasyPull. Always ob-
serve the notes and information contained therein, in par-
ticular 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 EasyPull 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 EasyPull and that the instructions and
warnings herein are strictly observed. The safety infor-
mation 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 infor-
mation 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
EasyPull Page 9 of 52
1.1 Proper Use
The operational reliability of the EasyPull is only guaranteed
if it is put to proper use. It must therefore only be used for
the purpose for which it is intended.
The EasyPull is only deemed to be in proper use when it is
used to pull wheelchair-bound persons or unoccupied
wheelchairs into vehicles that are specifically designed or
converted to transport disabled persons. The vehicle must
be fitted with an access ramp for this purpose. The EasyPull
only secures the front of the wheelchair. For transportation,
the wheelchair must be secured with additional belts at the
rear. The passenger in the wheelchair must wear a safety
belt.
Proper use also includes strict adherence to the information
given in these Operating Instructions.
W
ARNING!
If the EasyPull is used for any other purpose than that de-
scribed above, this may result in dangerous situations for
persons or material damage being caused.
Therefore:
 Only use the EasyPull for the purpose for which it was
intended.
 Always adhere to information given in these Operating In-
structions.
 Do not use the EasyPull for any other purposes, particu-
larly those given in Section 1.2. These are deemed to be
improper use.
1.2 Improper Use
Any use other than that described in Section 1.1 is deemed
to be improper use.
These include in particular:
 Pulling any objects other than wheelchair-bound persons
or unoccupied wheelchairs.
 Allowing operation by incompetent operators.
 Making unauthorised modifications to the EasyPull.
 Operating the Swivel Lift when it has safety-relevant faults
or is in a faulty condition.

Safety
Page 10 of 52 EasyPull
1.3 Operator Requirements
The EasyPull must only be handled by persons who:
 have read and understood these Operating Instructions
and
 have the technical knowledge to operate the parking
brakes on wheelchairs
Over and above this, the following applies if the EasyPull is
used commercially or communally:
The EasyPull must only be operated by persons who:
 are of legal age,
 have been instructed in how to operate the EasyPull,
 have been expressly assigned to do so by
the owner and
 are in a position to adapt themselves to the particular be-
haviour and needs of disabled persons.
Transportation, installation, commissioning, maintenance,
repair, fault finding and disposal of the EasyPull must only
be carried out by persons with the corresponding technical
training and experience.
1.4 Product Monitoring
Please contact AMF-Bruns GmbH & Co. KG immediately if
faults or problems are encountered when operating the
EasyPull or if accidents 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 EasyPull must only be carried out
with the prior agreement of AMF-Bruns GmbH & Co. KG.
The costs of such work will not be accepted by AMF-Bruns
without prior agreement.

Safety
EasyPull Page 11 of 52
1.5 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 EasyPull must only be used for the purpose for which
it is intended, otherwise dangerous situations, with re-
sultant 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 EasyPull is only operated
by authorised persons.
 If the EasyPull is used commercially or as a public utility,
the owner must ensure that operating personnel are fa-
miliar with the operation of the EasyPull under all operat-
ing conditions by providing training courses.
 Proper use of the EasyPull also includes adherence to the
specified maintenance and repair work, in particular strict
adherence to the maintenance intervals. If such work is
not carried out, trouble-free operation can not be guar-
anteed. Risks of personal injury and material damage can
occur.
 The EasyPull must not be operated in a faulty condition,
as serious injuries may be caused by this. If faults occur,
do not use the EasyPull until repairs have been effected.
 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.
1.6 Disposal
When the EasyPull's useful life has expired, it must only be
disposed of by qualified specialists. The manufacturer will
accept no liability for damage caused by incorrect disposal.

Description
Page 12 of 52 EasyPull
2 Description
Wheelchairs are pulled into a vehicle by the EasyPull. To en-
able this, the vehicle must be equipped with an access ramp
2.1 Layout and Function
The EasyPull comprises the following main components:
 Voltage Transformer
 Control Unit
 Winch with belts
 Remote Control
2.1.1 Voltage transformer
The voltage transformer (see Figure 1) generates the power
supply voltage (24 V DC) for the control system and winch
from the vehicle’s battery voltage. The primary and second-
ary sides of the voltage transformer are protected by fuses.
Figure 1: Voltage Transformer
Fuses
Heat sink

Description
EasyPull Page 13 of 52
2.1.2 Control unit
The control unit (see Figure 2) contains the receiver for the
remote control and the electronics to control the winch. The
door contact switch connected to the control unit switches
the power supply to the EasyPull OFF when the tailgate /
rear doors is / are closed and simultaneously resets the
control unit. The LED’s indicate the various operating sta-
tuses of the EasyPull.
Figure 2: Control Unit
LED
Operating Status
gree
n red
OFF OFF Tailgate / rear doors closed: EasyPull is
switched OFF by the door contact switch.
ON ON Tailgate / rear doors open: belts reeled in
(magnets switch the proximity sensors).
ON OFF Tailgate / rear doors open: belts reeled out
(magnets do not switch the proximity sen-
sors).
blinks OFF Belts are being reeled in or out.
All other sta-
tuses Fault
Antenna
Green LED
Red LED

Description
Page 14 of 52 EasyPull
2.1.3 Winch with belts
The winch (see Figure 3) pulls the wheelchair into the vehi-
cle. It comprises the winch housing with the motor and in-
terlocks. Two sensors in the winch housing signal the con-
trol unit when the adjustable magnets on the belts are in
their proximity. As soon as at least one of the magnets is in
the proximity of a sensor, the winch stops and the belts are
latched in position. Each belt is equipped with a belt lock
and a loop to attach it to the wheelchair.
Figure 3: Winch with Belts
Winch housing
Sensors
Magnet
Belt lock
Loop
Belt

Description
EasyPull Page 15 of 52
2.1.4 Remote control
The push-buttons on the remote control are used to control
the EasyPull functions.
The red LED blinks whenever a push-button is pressed.
If the LED blinks without a push-button having been
pressed, the battery must be replaced (see Section 9.1,
page 43).
Figure 4: Remote Control
Push-button Function
A Reels the belts out slowly, in order to pull
the wheelchair out of the vehicle.
B Reels the belts in.
C Reels the belts out quickly, in order to
pull the belts out of the vehicle.
D Resets the control unit in case of a fault
(press button D for at least 15 seconds).
NOTE
The belts are not driven when they are reeled out. The belts
reel out slowly or quickly by braking the winch to a greater
or lesser extent. If necessary, the operator must pull the
wheelchair out of the vehicle.
LED

Description
Page 16 of 52 EasyPull
2.1.5 Rating plates
A rating plate, which contains the fundamental data, is at-
tached to the EasyPull (see Figure 5). The rating plate is at-
tached to the motor.
Figure 5: EasyPull Rating Plate
The remote control’s rating plate is attached to the rear of
the remote control (see Figure 6). It contains the type and
serial numbers.
Figure 6: Remote Control Rating Plate
Type number Meaning
EPS.510 Hardware type number
433 Frequency
01 Modification state (downwards com-
patible)
Serial number Meaning
06 Year of production
11 Month of production
0000001 consecutive number
Designation
Serial number
Year of
manufacture
Manufacturer’s
details
Serial number
Type number

Transportation
EasyPull Page 17 of 52
2.2 Technical Data
Designation EasyPull
Dimensions: Width 520 mm
Depth 158 mm
Height 110 mm
Connection voltage 12 V DC
Weight approx. 16 kg
Current consumption approx. 25 A
Rated pulling power approx. 160 kg
Designation Remote Control
Voltage source Button cell CR2032
Power supply voltage 1.8 to 3.3 V DC
Quiescent current < 10 nA
Temperature range -40 to + 85 °C
Transmission fre-
quencies
Japan 426 MHz
All other re-
gions
433 MHZ
3 Transportation
The EasyPull is either shipped by the manufacturer or by a
logistics company assigned by the manufacturer.

Installation
Page 18 of 52 EasyPull
4 Installation
NOTE
The vehicle manufacturer's body fitting guidelines must be
adhered to when installing the EasyPull.
The installation company itself is responsible for adherence
to the safety regulations when installing the EasyPull.
Installation is insofar carried out at the sole risk installation
company. The manufacturer will accept no liability whatso-
ever for damage caused during installation of the EasyPull.
Unless such damage is caused by grossly negligent or in-
tentional breach of contract on the part of the manufacturer.
In addition to the information given in these Installation In-
structions, local legislative regulations must be taken into
consideration, in particular those regarding safety and acci-
dent prevention.
The EasyPull must only be installed in vehicles with a 12 V
DC electrical system
4.1 Safety Information for Installation
DANGER!
Risk of injury through incorrect installation.
A
number of risks of personal injury and material damage
can be caused if the EasyPull is incorrectly installed in the
v
ehicle.
Such risks can not only occur during installation but also as
a result of installation not being carried out correctly.
Therefore:
 The EasyPull must only be installed in the vehicle b
y
trained, specialist personnel.

Installation
EasyPull Page 19 of 52
DANGER!
Danger through screws becoming loose.
If screws / bolts are not tightened to the specified torque,
t
hey can become loose during operation of the EasyPull.
This can result in accidents being caused.
Therefore:
 Tighten all fastening screws / bolts to the torque specified
in Section 4.4, page 25.
 If any of the vehicle's original screws are loosened or re-
moved for installation of the EasyPull, they must be re-
tightened to the torque specified by the vehicle manufac-
turer.
DANGER!
Danger through incorrect installation of the power supply
cable.
If the power supply cable is not installed correctly, there is
a
risk of fire. This can result in cause serious injuries to the
passengers in the vehicle and material damage.
Therefore:
 Secure the cables adequately, such that they will not
chafe at any point.
 Do not secure cables to the brake lines.
A
TTENTION!
Risk of material damage.
The control unit can suffer damage when connecting or dis-
connecting the starter battery or the power supply cable to
t
he voltage transformer or control unit, if the door contact
switch is not activated at this point in time.
Therefore:
 Close the rear doors / tailgate of the vehicle before you
connect or disconnect the starter battery.
 Always disconnect the starter battery before carrying out
any work on the EasyPull's electrical system.

Installation
Page 20 of 52 EasyPull
4.2 Fitting the Winch
 Remove the winch housing (see Figure 3, page 14).
 Place the winch in the position where it is to be installed.
 Inspect the underside of the vehicle, to check whether
the position in which the EasyPull is to be installed is suit-
able to bolt it to the floor of the vehicle and make a con-
nection to the vehicle’s chassis.
NOTE
The vehicle manufacturer's body fitting guidelines must be
adhered to when installing the winch.
The fastening holes that will be drilled later, must be posi-
t
ioned such that a positive, metal to metal connection to the
v
ehicle’s chassis can be made.
The fastening holes must not be positioned above cavities,
beams, seams or similar parts. This must be ensured by the
position of the EasyPull on the vehicle's floor. Otherwise the
EasyPull can not be bolted down correctly.
 Correct the position of the EasyPull if necessary.
 Mark the position of the fastening holes.
 Drill the Ø = 10.5 mm fastening holes.
 Check once again that the position of the fastening holes
for the EasyPull is suitable.
 Deburr all holes.
 Remove all drilling swarf, e.g. using a vacuum cleaner.
 Remove underseal from the underside of the vehicle, at
the points to which the EasyPull will be secured.
 Apply rust-proofing paint to all bare metal surfaces.
 Allow the corrosion protection to dry.
 Bolt the EasyPull to the vehicle’s floor and chassis.
 Tighten the bolts to the torque specified in Section 4.4,
page 25.