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2014 USER MANUAL TRANSIT RACKS

1. ENI F KWIKSTAND PIVOT PLATE ASSEMBLY Installation Fig 34 USES OF THE KWIKSTAND Use the Kwikstand for e presentation at meetings fairs and shows e training bus operators and mechanics e educating customers KWIKSTAND FEATURES Some Kwikstand features include e compact design hand adjustable fasteners steel tubing construction with durable powder coat finish accommodation of all Sportworks pivot plate assemblies and transit racks easy maneuverability 60 2014 USER MANUAL ASSEMBLY OF KWIKSTAND Refer to Figure 35 to assemble the Kwikstand The Kwikstand accommodates all Sportworks pivot plate assemblies and transit bike racks 2014 DLe BIKE PACK z BIKE RACK TO PIVOT PLATE ASSEMBLY r 4 sH Hef t g 5 ae cies FE Ge ITEM TY DESCRIPTION E 2 3 8 16 x 1 1 2 HEX BOLT wel nal F 4 z ASHER i z i G 2 FLANGE BUSHING 1 7O ae JE H 2 2 8 16 LOCKNUT Se 1 E mm de eo E Fi lal NA i Ie WV 1 i Hl a t D Of ro gt a E Py PIVOT PLATE ASSEMBLY ff c a P oN D an D _ a ba D Deo D hi PIVOT PLATE ASSEMBLY TO STAND A SN oi ITEM QTY DE
2. Installation Fig 19 8 Assemble each stand off to the bumper back structure using 1 2 x 2 1 2 bolts washers and locknuts Use a socket wrench with an extension to insert and tighten the bolts inside each stand off leg See Figure 19 Protect the bolt access path of each stand off leg by inserting a plastic cap into each leg The mounting bracket is now installed You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to RTS Bumper via Stand off Brackets 1 1 each Drill jig template 2 2 each 1 4 indexing dowel to secure the drill jig template 3 1 each Hole saw arbor with 1 4 pilot drill 4 1 each 1 1 2 hole saw 5 1 each 1 2 extension drill 12 length 24 2014 USER MANUAL GMC NEW LOOK BUMPERS The Sportworks bike rack easily interfaces with the GMC New Look coach The mounting bracket consists of a bracket set and support cross tube that bolt directly to existing bolt holes on the GMC coach The bike rack is then fastened to the mounting bracket BIKE RACK INSTALLATION TO GMC NEW LOOK BUMPER Follow the installation instructions below to install a Sportworks bike rack and mounting bracket to a GMC New Look coach 1 Loosely assemble the pivot plate assembly to the GMC bracket pieces as shown in Figure 20 Use the provided 3 8 16x1 1 2 hex bolts washers and locknuts GMC BRACKE
3. KoORROAIS ames Ve ASHER 172 13 LOCKNUT Installation Fig 25 PLUE BIFD TC CS BUMPER je DL PIVOT PLATE ASSEMBLY i p k T f D D ji I B i ar DE E hs D re pe A You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to Blue Bird TC CS Stock Bumper 1 1 each Drill jig template 2 1 each 1 4 transfer punch 3 1 each 1 4 pilot drill 4 1 each 17 32 drill 2014 USER MANUAL 29 CLASS III RECEIVER INTERFACE Install the Sportworks trailer hitch mounting bracket only to a Class III hitch receiver Verify that the receiver is a Class III hitch receiver before installation See Figure 26 for the complete bracket assembly Note Obtaining and proper installation of the Class III recieiver hitch is the sole responsibility of the customer Sportworks Northwest Inc does not supply the receiver hitch BIKE RACK INSTALLATION TO CLASS III HITCH 1 Insert the Sportworks trailer hitch mounting bracket with the riser tubes UP into the Class III hitch receiver and secure it in place with the provided 5 8 diameter hitch pin and cotter pin 2 Mount the pivot plate assembly to the trailer hitch mounting bracket using the provided 3 8 16 x 1 1 4 hex bolts washers and locknuts You are now ready to install the Sportworks bik
4. aware of this possibility Investigate approach angle requirements in your area before mounting the rack Footprint The footprint is the outline of a bike rack against the front of the bus when the rack is in the stored position D gt Installation Fig 2 Avoid obstructing headlights hi beam headlights and turn signal indicators See the section CHANGING THE POSITION OF THE RACK in this chapter for adjusting the footprint of the rack Protrusion Protrusion measures the distance from the front of the bumper to the front edge of the bike rack in the deployed position Once the bike rack is mounted to the coach the protrusion distance is fixed Protrusion is a measurement that needs attention for three important reasons 1 Many state DOTs Departments of Transportation have set limits for bike rack protrusion e g California has a set limit of 36 inches 2 The further a rack protrudes the more likely it will affect a coach s approach angle and turning radius 2014 USER MANUAL 3 The rack protrusion affects the stowed position of the rack up against the front face of the coach where interference with windshield wipers and a coach driver s visual field should be avoided Installation Kits Sportworks Northwest Inc offers for purchase install
5. rear tire base base DL2 and DL3 V2 and V3 aa No specified requirement 2 35 inches 3 00 inches Weight No specified requirement Recommended gross bicycle weight not to exceed 55 pounds per loadable position Overall Height No specified requirement No specified requirement Overall Width No specified requirement Racks w panniers on the rear of bike can be 16 wide 8 to either side 2014 USER MANUAL sportworks Sportworks Customer Change Notice CCN100352 Date 11 30 2010 Effective January 1 2011 Sportworks will replace mild steel black powder coated support arm housings with an all stainless steel anti glare finish support arm housing for all new racks and spare part orders Reason for Change 1 2 3 This change will improve product performance and eliminate potential rusting on the magnet arm catch This change simplifies replacement parts There will now be one main replacement support arm housing and one main replacement support arm assembly part number to order This provides arm housing consistency across our product line on our all stainless steel and mild steel powder coated rack offerings Description of Change 1 2 This change will replace mild steel black powder coated support arm housing assemblies with stainless steel anti glare finish support arm housing assemblies This change will phase out our mild steel black powder coated s
6. 16 18 Deployment Kit Black Pivot Plate Assembly Formed Plate Std Width 14 16 18 Deployment Kit White Pivot Plate Assembly Formed Plate Std Width 14 16 18 Magnetic Deployment Switch Pivot Plate Assembly Formed Plate Std Width 14 16 18 Magnetic Deployment Switch No decal NP Pivot Plate Assembly Magnetic Deployment Switch Black Pivot Plate Assy NP Width 14 18 Ctrs New Wash Guard Deployment Kit Black Pivot Plate Assembly with hardware recessed bumper Deployment Kit Pivot Plate Assy Std Width 23 Ctrs Travel Stop Deployment Switch Black Pivot Plate Assy Std Width ETI Bus O S 11 16 Holes w Deployment Switch Ten Second Bracket Swept 10 0 Deployment Kit w o Cable See LD Ten Sec Brkt Swept 10 0 w NP Tabs Dply Kit w o Cable Deployment Kit Hardware Recessed Bumper Pivot Plate Deployment Kit Hardware Complete Recessed Bumper Style PIVOT PLATE Chevy 5500 Std and NP Width Deployment Kit Deployment Rework Kit New Flyer Deployment Kit New Flyer Trolley Deployment Magnet Switch with Fasteners New Flyer Trolley Ford 2001 2010 E350 450 Vented Mounting Plate Assy Deployment Kit Black Ten Second Bracket Slide In 11 0 NP Compatible Deployment Kit w o Cable See LID Ten Second Bracket Swept 12 0 NP Tabs Deployment Kit w o Cable See LID 95 USER MANUAL Change Type Compatibility e The new magnet switches will not fit prior Sportworks cable wiring containing the origi
7. ECN 100659 H Date 5 11 09 Parts Affected Item ID lltemName C Cdr 100659 SPAN SP VeloPorter 3 Bike Rack 100659 SPAN DPLY _ VeloPorter 3 Bike Rack 100659 DPLY SP VeloPorter 3 Bike Rack 100659 DPLY VeloPorter 3 Bike Rack 100659 VeloPorter 3 Bike Rack 100659 SPAN SPR VeloPorter 3 Bike Rack 100659 SPAN DPLY VeloPorter 3 Bike Rack 100659 SAMPLE VeloPorter 3 Bike Rack 100659 SP VeloPorter 3 Bike Rack 100740 DPLY Custom VeloPorter Bike Rack Wide Frame 100740 TRDPLY SP Custom VeloPorter Bike Rack Wide Frame 100740 Custom VeloPorter Bike Rack Wide Frame 100740 TRDPLY Custom VeloPorter Bike Rack Wide Frame Reason for Change To allow easier field replacement of urethane trays Description of Change Replaced Phillips Head Fasteners with Hex Head and reduced the number of fasteners per tray from six to four Change Type Compatibility Class A Change New Trays and Frames will not fit previous versions of Trays and Frames Installation with Pivot Plate remains unchanged Effectivity of Change 1 All Shipments on or after May 1 2009 First shipments may include both six bolt and four bolt versions Tray Mounting Fasteners 100 2014 USER MANUAL 100701 100702 100822 100823 Service Part Number Reference Table Six Bolt Trays will continue to be available for repair or replacement Two new FGI Part Numbers have been created for the new four bolt trays All other hardware including Torsion
8. Installation Fig 27 CAUTION The lock bolts do not replace the 5 8 diameter hitch pin and cotter pin supplied with the mounting bracket The hitch pin must be used to anchor the mounting bracket and bike rack to the coach Tene 2014 USER MANUAL FLXIBLE NEW LOOK BUMPERS The Sportworks bike rack easily interfaces with the Flxible New Look coach The mounting bracket consists of two bracket pieces and a support cross tube that bolt directly to existing tow hook bolt holes and to two drilled holes in the Flxible coach front bumper The bike rack is then fastened to the mounting bracket BIKE RACK INSTALLATION TO FLXIBLE NEW LOOK BUMPER Follow the installation instructions below to install a Sportworks bike rack to a Flxible New Look coach with stock metal bumper 1 Examine both tow hooks on the front face of the Flxible New Look coach Each tow hook is anchored to the coach face via four bolts Remove the two bolts from each tow hook that are oriented INBOARD towards the bumper centerline UP ee TOW HOOK Q 1 SOD Ci Vy FWD FLXIBLE BUMPER Tee Lf A CQ OT M o BRACKET CRUSS TUBE N 14 Di o o Ne ITEM QTY DESCRIPTION Sc eae C N A Oe ig FT gh YX gt a L r Sh i e o PAS RIET a ANGLE NOTCH DOWN S 3 fete WAS mM OA mm OA D 4 1 2 13 LOCKNUT Q OR C a EN O OA Installation Fig 28 2 Place the
9. 100776 VeloPorter Mirror Ratchet Support Arm Assembly 100700 VeloPorter Mir Supt Arm Grip 100777 VeloPorter Mirror Ratchet Support Arm Grip Replacement Kit 3 arms 100799 V3 Rework Support Arm Set Replacement Kit 2 arms 100803 V3 Custom Wide Frame Rework Support Arm Set ray Required Actions Please update your ERP and other ordering systems to reflect the new VeloPorter 3 P N s provided above 2 Please contact us to receive a copy of the FRP Customer Agreement and to learn how to receive replacement VeloPorter 3 support arms with ratchet system through our Field Replacement Program Regards Jerry Stewart Vice President Engineering amp Quality Sportworks Northwest Inc 2014 103 USER MANUAL sportworks Product Change Notice Discontinuation of Electro Polished Bike Racks Date of Notice November 7 2008 Description of Change All Sportworks bicycle racks and related spare replacement parts currently available with an electro polished finish glossed silver color will be discontinued effective January 01 2009 and replaced with the anti glare finish matted silver color Reason for Change The electro polish process uses toxic and environmentally hazardous chemicals that are difficult to handle and increasingly expensive to manufacture Change Type Compatibility Class A Change All existing electro polished P N s will be replaced with equivalent anti glare P N s se
10. 2014 USER MANUAL 49 Ten Second Bracket Field Installation Instructions Kit 100722 Tools needed are Wrenches for Bumper removal and Mag Base Drill This Kit includes a router with router bit drill templates for Romeo Slide In and Swept Bumpers holes saw step drill and clamps used with the drill template router templates for Romeo Slide In and Swept Bumpers and a rivnut squeezer The templates are stamped identified as Slide In or Swept Be sure to indentify your bumper type and use the correct templates Use Kit P N 100801 Ten Second Bracket Field Install Slide In Bumper Set of Rivnuts and Clips for Slide In Bumpers and Kit P N 100802 Ten Second Bracket Field Install Swept Bumper Set of Rivnuts for Swept Bumpers Removal and disassembly of the bus bumper machining of the bumper module and back structure and re installation onto the bus will take 2 3 hours per bus 1 Remove bumper from coach and setup on table or work bench 2 Using tape measure square scribe or permanent marker mark center line of both the bumper back structure and the urethane module These two must line back up during re assembly 3 Remove the bumper module from the back structure Slide In First remove one corner module using a putty knife break off the heads of the plastic christmas tree clips then with a drift drive the clips down out of the module and back structure Slide off the corner module Repeat for the center module Reinstallation w
11. Align center marks j Test fit Ten Second Bracket to ensure that the Module and Back Structure are aligned properly k Install new christmas tree pins included in kit If new locations are necessary drill 3 16 diameter thru module using the back structure as a template Install new christmas tree pins m Install Corner module 6 Re mount bumper onto coach 7 Slide in Ten Second Bracket angled up slightly then drop down when legs engage with back structure 8 Tighten Hand Knobs just hand tight insert Hair Cotter Pins Your Ten Second Bracket Installation is now complete Figure 12 Bumper Complete 55 2014 USER MANUAL MOUNTING THE BIKE RACK Once a bracket has been properly mounted to a coach the bike rack can be quickly installed It only takes a few minutes to install the bike rack to the mounting bracket See Figure 32 for the assembly of the bike rack to the pivot points on the pivot plate H H H H V EIKE RACH r i T Dof h 5 ITEM PTY DESCRIPTION i P E A 2 3 8 1l6x1 1 2 HEX BOLT E 4 3 8 WASHER C Z FLANGE BUSHING T 2 3 8 16 LOCKNUT i E i i l3 comm L pn 4 TOF TE DL PIVOT PLATE ASSEMBLY Installation Fig 32 After mounting the bike rack at the pivot points make sure the bike rack locks hori
12. Rack for Buses if there are no bikes on the rack and no one else is waiting to load their bike The bike rack locks in place 5 Step away from the bus with your bike PLEASE NOTE THAT LOADING OR UNLOADING A BICYCLE FROM THE STREET SIDE MAY CAUSE INJURY OR DEATH 64 2014 USER MANUAL BUS WASHING The Sportworks Bike Rack For Buses has been designed to safely pass through bus wash facilities Before taking a newly mounted bike rack through a wash facility the operator should check to ensure that the wash facility is properly set up for washing the bus with a rack on it Most wash systems use either a top fixed or top and bottom fixed spinning brush system The Sportworks rack has been designed with round tubing and round edges so that the wash brushes address surfaces that will not catch or tear them Four types of conditions may cause excessive wear or harm to the bike rack or the wash system None of these conditions should exist when running a bus with a bike rack through the wash facility 1 The brushes are spinning at too slow of an RPM This condition may allow the brushes to hook on protruding objects such as rear view mirrors If the axle of the brush assembly pushes deep against the rack or any part of the bus that has any sort of ledge it aoe may become caught N i there a q _ 2 The bus is traveling too fast through the wash system This may cause the same type of damage as stated in Bus Was
13. Spring Pads and Deployment Kit Brackets have been modified to fit both four and six bolt frames Item Name O O ooo y y VeloPorter Wheel Tray Six Bolt Version VeloPorter Mirror Wheel Tray Six Bolt Version VeloPorter Wheel Tray Four Bolt Version VeloPorter Mirror Wheel Tray Four Bolt Jerry Stewart Vice President Engineering amp Quality Sportworks Northwest Inc 2014 101 USER MANUAL sportworks VeloPorter 3 Product Change Notice ECN 100659 G December 12 2008 Parts Affected 100659 SPAN SP VeloPorter 3 Bike Rack 100659 SPAN DPLY _ VeloPorter 3 Bike Rack 100659 DPLY SP VeloPorter 3 Bike Rack 100659 DPLY VeloPorter 3 Bike Rack 100659 VeloPorter 3 Bike Rack 100659 SPAN SPR VeloPorter 3 Bike Rack 100659 SPAN DPLY _ VeloPorter 3 Bike Rack 100659 SAMPLE VeloPorter 3 Bike Rack 100659 SP VeloPorter 3 Bike Rack 100740 DPLY Custom VeloPorter Bike Rack Wide Frame 100740 TRDPLY SP Custom VeloPorter Bike Rack Wide Frame 100740 Custom VeloPorter Bike Rack Wide Frame 100740 TRDPLY Custom VeloPorter Bike Rack Wide Frame Description of Change All VeloPorter 3 support arms have been revised to include a ratchet system secondary retainment device that significantly improves field performance Sportworks highly recommends updating all VeloPorter 3 bike racks affected by this change Note This product change does not apply to VeloPorter 2 bike racks and support arms NEW Ratchet System Release Handle VeloPorter 3 Supp
14. The mounting bracket is now installed 19 2014 USER MANUAL INTERMEDIATE BUMPER i ns INTERMEDIATE S WERT STAND OFF BRACKET DLA PIVOT PLATE ASSEMBLY E 7 Ir 1 E q IF LIF A f E E i l rg 4 om eee eee 7 4 nf _ Hm 8 ff _ A4 E 22 Z F ITEM QTY DESCEIPTION N E A 4 3 8 16x1 1 2 HEX BOLT Se ee E 2 3 8 WASHER i C 4 3 8 16 LOCKNUT gt D 4 1 2 13x2 1 2 HEX BOLT E 8 1 2 SAE WASHER Se ERE F 4 1 e 13 LOCKNUT SWEPT INTERMEDIATE BUMPER Installation Fig 15 You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to Intermediate Swept Intermediate Bumper via Stand off Brackets 1 1 each Drill jig template 2 2 each 1 4 indexing dowel to secure the drill jig template 3 1 each Hole saw arbor with 1 4 pilot drill 4 1 each 1 1 2 hole saw 5 1 each 1 2 extension drill 12 length SO 2014 USER MANUAL RTS BUMPERS The RTS bumper presents a very simple interface for the Sportworks bracket and bike rack The method of bike rack installation is to insert a bracket set consisting of two stand offs into the front face of the bumper via 1 1 2 holes sawn typically at 18 a
15. The Help Slide In bumper can be identified by its aluminum extruded back structure and its 2 black urethane pieces that slide in onto the back structure and meet at the bumper centerline There are two different methods of installing a Sportworks bike rack to coaches with a Slide In bumper The method depends on the type of mounting bracket you choose either the C Bracket or Stand off mounting bracket The Stand off mounting bracket is ideal for buses with minimal clearance between the top of the Slide In bumper and coach body SLIDE IN BUMPER C BRACKET METHOD The C Bracket mounting bracket is intended to mount to the extruded back structure of the Slide In bumper at four locations two at the top and two at the bottom of the bumper No modifications to a coach with a Slide In bumper are typically required to install the Sportworks C Bracket and bike rack However clearance problems may be encountered with each C Bracket arm and its mounting hardware fitting between the bumper and the coach body Check this clearance before installing a bracket and bike rack Caution Before proceeding with the bracket and bike rack installation check that each C Bracket arm and its mounting hardware has enough clearance to fit between the bumper and the coach body If there is a clearance problem either 1 Modify the body of the coach as required to fit the C Brackets and its hardware or 2 Re mount the bumper low enough to achieve neces
16. be done so every 30 days If there are problems with the bike rack or mounting bracket replace or repair them to proper working order and return them to service Contact Sportworks for parts SERVICING THE DL2 BIKE RACK Service every 30 days 1 D oOo cc 2 If the bike rack is not raising and lowering with ease check the two pivot bolt assemblies for incorrect installation or wear Replace the assemblies if damaged Check that the pivot tabs are straight and aligned to properly pivot the bike rack Straighten the tabs as required Check the pivot plate for correct alignment and damage Remove and straighten the pivot plate if it is not straight If the bike rack magnet does not properly mate with the support arm check the alignment of the magnet arm the steel strap securing the magnet to the bike rack Tweak the magnet arm as required Make sure the fasteners holding the magnet assemblies to the magnet arm are tight Examine the magnet and magnet housing for wear Replace if damaged Examine the structural integrity of the main loops saddle pieces and the rectangular tubing of the main frame Repair or replace the bike rack if damaged 79 2014 USER MANUAL SERVICING THE DL2 LATCH MECHANISM Service every 30 days J PF ltem PART NAME DESCRIPTION Latch Handle Handle 100180 DL2 Latch Handle with Roll Pin taich Handle Pin 100179 Rotor Clip DL2 Latch Pin Assy 1 Check that the relea
17. brackets to be mounted are correct for the bumper style FIGURE 1 BOLT HOLE PATTERN ON A 96 MCI HELP BUMPER BRACKET ARM oar TAB USE THESE TWO i I BOLT HOLES 18 00 THIS BOLT IS ON I CENTERLINE ON A 96 BUMPER 1 Assemble the C brackets to the pivot plate and use this assembly to locate the slot positions Fig 2 Cut four 2 1 8 x 1 2 access slots with centers located 9 each side of the bumper centerline The slots should be flush with the top and bottom edges of the steel backing beam Use a keyhole saw spiral cut saw or jigsaw to cut the slots FIGURE 2 OT PLATE DS SON Ky ASSEMBLY OF PIVOT PLATE TO C BRACKETS Pid 40 2014 USER MANUAL MCI FLIP DOWN ENERGY ABSORBING BUMPERS BIKE RACK INSTALLATION TO MCI FLIP DOWN BUMPER 2 Remove the existing bolts in the top and bottom of the backing beam and slip the C Bracket arms through the slots Line up the mounting holes Slip the supplied spacers between the C bracket arms and the beam and attach using 2 13 x 3 long mounting MOI FLIP DOWN BUMPER C BRACKET ASSEMBLY INSTALLED VIEW with HELP energy absorbing bumper MCI HELP BUMPER MCI HELP BUMPER p i CUT SLOTS UNIVERSAL C BRACKET 264 UNIVERSAL C BRACKET 2E4 STEEL BACKING BEAM E CUT SLOTS EXISTING BUMPER CUP EXIS
18. each locator pin of the template on the TOP edge of the protruding bumper trim Match the center of the template with the center of the front of the bus Hold or tape the template firmly in position See Figure 13 Swept Intermediate Bumper Place each semi cylinder piece of the template into the bumper groove Match the center of the template with the center of the front of the bus Hold or tape the template firmly in position See Figure 13 Using a 1 4 pilot drill drill through ONLY ONE of the upper template bushings just through the urethane bumper Insert a 1 4 dowel into the drilled hole to index the template in place Drill a 1 4 hole through the other upper bushing and insert a 1 4 dowel into it With the template indexed to the bumper at two places drill the two lower 1 4 holes on each side of the bumper 4 holes total The template must not move during this step 17 2014 USER MANUAL INTERMEDIATE BUMPER DRILL TEMPLATE PLACEMENT b gt PLACE EAC H TEMPLATE En ATOR PIN ON THE EDGE OF THE PROTRUDING BUMPER TRIM CIF NECESSARY ATTACH THE EXTENSION ARMS TO THE STEMRCA TE AND USE THE LOCATOR PINS ON THE ENBS OF THE EXTENSION ARMS 2 gt USE THE MARKED TEMPLA TEL CENTERLINE TO CENTER THE TEMPLATE TO THE FRONT FACE OF THE COACH 3 gt DRILL 1 4 PILOT HOLES AS INDICATED IN THE INSTALLATION INSTRUCTIONS LOCATOR PIN LOCATOR FIN EXTENTION AFM EXTENSION ARM FOMEO
19. 00434 NP DL2 Bike Rack Black N A 100434 SPAN NP DL2 Bike Rack w Bilingual Decals Black N A 100434 SPAN QR NP DL2 Bike Rack w Bilingual Decals and Quick Release Hardware Black N A 100434 SPAN QR NP DL2 Bike Rack w Bilingual Decals Quick Release Hardware DPLY and Deployment Kit Black N A 100434 DPLY NP DL2 Bike Rack w Deployment Kit Black N A 100434 DPLY SPAN NP DL2 Bike Rack w Deployment Kit Bilingual Decals Black N A 100434 DPLY QR NP DL2 Bike Rack w Deployment Kit Quick Release Hardware Black N A 100434 QR NP DL2 Bike Rack w Quick Release Hardware Black N A 100434 FRNCH NP DL2 Bike Rack French English Decals Black N A 100434 FRNCH DPLY NP DL2 Bike Rack French English Decals Deployment Kit Black N A Support Arm Spares Part Numbers Affected Part Number Description Replacement Part Number 100111 SPARES Support Arm Housing Black 100594 100308 SPARES MIRRORED Hook Supp Arm Assy Black 100322 100109 SPARES Support Arm Assembly Black 100588 100109 SPAN SPARES Support Arm Assembly Bilingual Decals Black 100588 SPAN 100594 SPARES Support Arm Housing SS NP DL2 and Middle Position Trilogy No Change 100322 SPARES MIRRORED Hook Support Arm Assembly All S S No Change 100588 SPARES Support Arm Assembly DL2 DL3 Middle Pos SS Anti Glare No Change 100588 SPAN 2014 SPARES Support Arm Assembly D
20. 425 483 7000 Fax 425 488 9001 www sportworks com salesandsupport sportworks com gmo ame oao r d 7 e nn SiGe ae
21. ATION TO FORD E 350 E 450 BUMPER Late Model Bumper With Vent Openings 6 Place the four 1 1 2 diameter standoffs through the sawn holes and vent opening until they contact the backing plate Use the four 3 8 16 x 6 1 2 bolts to assemble the standoffs and mounting plate to the backing plate as shown 7 You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section NOTE The mounting method for non vented bumpers is similar except that two additional holes must be made to facilitate the two lower stand offs See steps 2 and 3 above FIGURE 3 Optional Romeo Bumper on Ford E350 450 37 2014 USER MANUAL GOSHEN SENTRY COACH OEM STEEL BUMPER BIKE RACK INSTALLATION TO GOSHEN SENTRY STEEL OEM BUMPER VIA A CLASS Ill RECEIVER HITCH The recommended method for mounting the Sportworks bike rack to the Goshen Sentry Coach is to use a Class 3 receiver hitch bracket Fig 1 This method requires the installation of a 2 square class 3 receiver hitch directly to the frame of the vehicle This receiver hitch can be custom fabricated and installed by a qualified trailer hitch shop HITCH MOUNT HITCH RECEIVER ON VEHICLE FIGURE 1 The edge of the 2 square hitch receiver should be mounted flush with the front of the bumper and not more than 1 2 below the bumper Fig 3 It is recommended that tabs be welded onto the receiver to allow
22. Assemble the pivot plate assembly to the two stand offs using 3 8 x 1 1 2 bolts washers and locknuts See Figure 14 This assembly is the mounting bracket The pivot plate assembly will be used as a drill brace for step 6 ie 2014 USER MANUAL 6 Using a 1 2 extra long drill and using each stand off as a drill jig drill through the bumper back structure at four locations two locations per stand off by inserting the drill down into each stand off leg Use cutting oil lubricant on the tip of the drill Clear any chips from the drilling operation You will need to move and remount the pivot plate assembly to the two stand offs as required to gain clearance to drill all 4 holes The pivot plate assembly should be used as a drill brace in this step TINTERMEDIATE SWEPT INTERMEDIATE STAND OFF BRACKET C DLe UADRANT a S GAS DLe PIVOT PLATE vi DL2 SUPPORT STRAP E F ITEM QTY DESCPIPTION p ROA SA A 4 3 8 16x1 1 2 HEX BOLT as ao E 3 3 8 ASHER A A C 4 3 8 16 LOCKNUT Installation Fig 14 7 Assemble each stand off to the bumper back structure using 1 2 x 2 1 2 bolts washers and locknuts Use a socket wrench with an extension to insert and tighten the bolts inside each stand off leg Protect the bolt access path of each stand off leg by inserting a plastic cap into each leg See Figure 15 8 Remount the pivot plate assembly to the two stand offs See Figure 15
23. CROSS TUBE E E z gt F F F em T J 7 e H b r C E B A Ed Ao be A c 6 i E P Be Ba cy D N i i e 3 i i i ITEM TY DESCFIPTION 7 eles a i GMC BRACKET PIECE A 2 3 8 16 X 2 3 4 HEX BOLT l E pee B 4 3 8 WASHER i ape T C 3 8 16 LOCKNUT en e ILE PIVOT PLATE ASSEMBLY D 6 1 2 13 X 2 HEX BOLT i ei E le 1 2 WASHER Ni pile F 6 12 12 LOCKNUT INES NE L vs al E AN D D Installation Fig 23 You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to GMC New Look Coach Stock Bumper 1 1 each GMC Cross tube Hole Locator Template 2 1 each 1 4 transfer punch 3 1 each 13 32 drill 27 2014 USER MANUAL BLUE BIRD TC CS STOCK BUMPERS Installing a Sportworks bike rack to a Blue Bird TC CS coach with stock bumper involves drilling four holes in the front steel bumper BIKE RACK INSTALLATION TO BLUE BIRD TC CS STEEL BUMPER Follow the installation instructions below to install a Sportworks bike rack and mounting bracket to a Blue Bird TC CS coach 1 Locate the Blue Bird drill jig template on the Blue Bird coach front bumper Place the locator screws of the jig so that they catch on the top edge of the bumper and allow the template to rest against the bumper surface Match the center of the template with the center of the bumper Hold or tape the template f
24. CS Latch Pin 4 7098 1 LATCH PIN RIVET 5 7068 1 SPRING Compression for DL2 Latch Stainless 6 3584 1 PIN ROLL 5 32 X 75 SS 7 7014 1 PIN ROLL3 16 X 1 SS 1 Check that the release handle operates smoothly 2 Examine the wear of the plastic insert in the tip of the latch pin Replace the insert if the latch quadrant is being marred by the latch pin 3 Examine the components inside of the latch housing a x Remove the roll pin attaching the latch stem to the latch pin b After removing the roll pin pull on the release handle to separate the latch stem from the latch pin c Check the wear on the spring Clean the spring and replace it if it is distorted or not functioning properly d Remove any dirt and debris from inside the latch housing e Re assemble the latch mechanism in the reverse order of steps a c DO NOT LUBRICATE NOTE PLEASE ASK SALES FOR 6 DIGIT FINISHED GOODS P N 91 2014 USER MANUAL TECHNICAL INFORMATION Bicycle Dimensional Requirements For DL2 DL2 NP DL3 V2 and V3 Bike Racks for Buses Minimum Requirement Maximum Tolerance DL2 and DL3 V2andV3 oF Gone V2 and V3 Wheel Diameter 2006 current 29 inches as indicated on tire i a f design 29 700c 20 inches 16 inches 700c Wheel Base DL2 and DL3 V2 and V3 measured from ground contact point of front tire to ground contact point of No specified requirement 44 inch wheel 46 inch wheel
25. Clean the rack surface thoroughly isopropyl alcohol before replacing Pay particular attention to the chain guard sticker 11 If surface rust develops on stainless steel use naval jelly to remove 88 2014 USER MANUAL Servicing the Apex Support Arm Service every 30 days ITEM QTY PART TITLE 1 1 3810 Pin Clevis 1 4 x 1 75 SS 2 1 7302 RING SPLIT 670 O D X 051 WIRE DIA SS 3 1 poe Weldment Apex Support Arm Housing Shot Peened 4 2 3608 CS Upper Bushing 5 1 9662 SUPPORT ARM SPRING 6 1 4492 Support Arm Spar Apex 7 2 3609 Apex Lower Bushing 8 1 4557 PIN ROLL 5 32 X 75 SS 9 2 4493 Shank Support Apex Support Arm Hook 15 2 4571 SHCS 250 20 X 1 75 17 1 4494 Support Arm Grip Apex 18 2 9893 NUT 1 4 20 DEFORMED THREAD SELF LOCKING SST NOTE PLEASE ASK SALES FOR 6 DIGIT FINISHED GOODS P N 2014 USER MANUAL 89 1 Examine the components inside of the support arm a b c 2 2 gt i oo Remove the split ring from the clevis pin in the support arm pivot Remove the split ring 2 from the clevis pin 1 at the bottom of the support arm housing Remove the clevis pin Remove the fasteners 15 from the support arm grip and remove the grip from the top of the spar Carefully slide the stainless steel spar out the bottom of the support arm housing Make note of how the two sets of nylon bushings 4 and 7 fit in the
26. ES FOR 6 DIGIT FINISHED GOODS P N e 73 2014 USER MANUAL 1 Examine the components inside of the support arm assembly a b O 2 2 w oo Remove the bolts attaching the support arm assembly to wheel stop Remove the support arm grip Note The lower Phillips screw fixes one end of the spring Remove the roll pin from the base of the support arm housing This fixes the other end of the spring Carefully slide the support arm spar out from the bottom end of the support arm housing Make note of how the two nylon slider bushings fit at the base of the support arm spar Also note that the four upper bushings engage into the four holes in the housing Re assembling the upper bushings may require some practice Remove the roll pin on the support arm housing to free the support arm spring Clean the spring and examine it for wear overstress and cyclical fatigue Pay special attention to the end hooks of the spring Replace the spring as necessary Clean the inside of the stainless steel support arm housing using a stainless steel brush Do not use a non stainless wire brush Examine the upper and lower bushings Replace them if they are excessively worn or marred Replace them if the support arm spar is not tracking correctly i e there is too much twist Re assemble the support arm assembly in the reverse order of steps a d Use a simple hook made of stiff wire or similar tool to pu
27. FIM INTERMEDIATE BUMPER URETHANE STRUCTURE DCATOF PIN ON EDGE OF PROTRUDING BUMPER TFIM PILOT DRILL PILOT DRILL 4 p LOCATOR PIN LOCATOR PINT anii CENTERLINE BACK STRUCTURE j genot wi PILOT LG g H DRILL TEMPLATE 16 EPT INTERMEDIATE BUMPER DRILL TEMPLATE PLACEMENT 1 gt PLACE THE TEMPLATE ON THE BUMPER WITH EACH SEMI CYLINDER t EDs ae JEE BUMPER GROOVE eo USE THE MARKED TEMPLATE CENTERLINE TO CENTER THE TEMPLATE ONT FACE OF THE COACH 30 DRILL 1 4 PILOT HOLES AS INDICATED IN THE INSTALLATION INS TAE TINS Fol IEO FIM SWEPT INTERMEDIATE BUMPER URETHANE STRUCTURE DRILL BUSHING 4 TOTAL TEMPLATE le ee ae i el BL UMINYH EXTRUDED Loos basas CK STRUCTURE SEMI CYLINDER DRILL BUSHING l6 Installation Fig 13 3 Remove the template from the bumper Use a 1 1 2 hole saw with a 1 4 pilot drill to saw four holes just through the front surface of the urethane bumper at the same four locations drilled in step 2 Use care to insure that the holes are sawn perpendicular to the surface of the bumper back structure 4 Insert on each side of the bumper a stand off into the holes sawn in step 3 Orient the 3 8 holes of the stand offs DOWN for a lower bicycle loading height Work each stand off into the 1 1 2 holes until the stand off legs contact the aluminum extruded back structure of the bumper The friction fit of the stand off legs in the bumper holes should hold them in place 5
28. INTERMEDIATE bumpers are similar bumpers The Swept Intermediate bumper is just a later version of the Intermediate bumper with characteristic smooth rounded curves UWPETHANE STRUCTURE URETHANE STRUCTURE a es i l TT x E BUMPER BACK STRUCTURE BUMPER BACK STRUCTURE pL INTERMETIATE BUMPER SWEPT INTERMEDIATE BUMPER Installation Fig 12 The method of bike rack installation and type of mounting bracket are the same for both the Intermediate and Swept Intermediate bumper A bracket set consisting of two stand offs is inserted into the front face of each bumper via four holes sawn through the urethane bumper structure and four corresponding holes drilled through the bumper back structure Bolts secure each stand off to the bumper back structure The Intermediate and Swept Intermediate bumpers each have internal urethane ribs as part of the bumper structure which gives it strength and stability The key toa smooth successful installation of stand off brackets is to place the stand off legs between the urethane ribs Placing the stand offs 16 apart and centered to the front face of the coach i e each stand off is placed 8 on either side of the bumper centerline typically avoids interference with the ribs The Intermediate bumper may be found on coaches of different widths Different coach widths can affect the rib spacing of the urethane structure For this reason be sure to
29. ION Sa 378 px 1 4 HEX BOLT 378 WASHER Sa WeS 7e LOCKNLIT Figure 7 6 Orient the pivot plate assembly and C Brackets as shown below and loosely assemble together See Figure 7 This assembly is the mounting bracket SLIDE IN C BPAECT CPES SLIDE M BJMPEF DL PIVOT PLATC ASSEWRLY ITEM TY DESCRIPTION d 2 12 1 172 1 E 13x1 1 2 IZ WASHER 2 12 LOGKNLIT Figure 8 7 Assemble the mounting bracket to the bumper back structure at 4 places using 1 2 x 1 1 2 bolts washers and locknuts Tighten any loose bolts of the mounting bracket 11 2014 USER MANUAL 8 Remount the bumper with the attached mounting bracket to the coach frame Tighten all bumper to frame bolts after the bumper has been adjusted level to the coach body and the centerlines marked in step 1 mate back together NOTE Placing spacers between the top of the bumper back structure and the coach body makes positioning of the bumper easier You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to Slide In Bumper via C Brackets 1 1 each Rigid transfer punch template 2 1 each 1 4 transfer punch 3 1 each 1 4 drill 4 1 each 17 32 drill 12 2014 USER MANUAL SLIDE IN BUMPER STAND OFF METHOD The Stand off mounting bracket mounts to the front of the Slide In bumper via four holes sawn through the urethane stru
30. L2 DL3 Middle Pos SS Anti Glare Bilingual Decals USER MANUAL No Change 94 sport MMT Deployment Kit Connector Change Notice Date 09 01 2010 Notification of Change All deployment kit connectors used in Sportworks Pivot Plate assemblies part numbers listed below are being replaced with their respective Weather Pack connector counterparts beginning September 1 2010 Reason for Change The Weather Pack connectors provide improved protection from the environment and corrosion versus the original molded style connector currently being used Table 1 Deployment Kit Part Numbers Affected by Change to Weather Pack Connectors 100502 100584 100462 100718 100720 100440 DPLY WPK 100517 MAG ND 100530 DPLY 100530 WHT DPLY 100530 Mag 100530 MAG ND 100517 mag 100517 DPLY 100630 DPLY 100386 DPLY 100491 DPLY 100637 DPLY 100641 DPLY 100654 100682 100616 DPLY 100679 100680 100681 100737 DPLY 100626 DPLY 100668 DPLY 2014 SPARES Deployment Pivot Plate Kit with Standoffs Deployment Kit DL2 amp DL3 ONLY Complete Deployment Kit with light amp faceplate amp Sheet Metal Bracket Old Quadrants V2 Deployment Alarm Kit Complete Deployment Kit V2 amp V3 Complete Pivot Plate Assy Std amp NP Width Nova BUS Low Floor Black w travel stop Deploy Switch w wpk con NP Pivot Plate Assembly Deployment Switch No Decals Black Pivot Plate Assembly Formed Plate Std Width 14
31. Machining Figure 5 Rivnut Tool h Use Rivnut Installation Tool to install two 12 13 x Grip Rivnuts suppllied with kit i Install Rivnuts two places with Rivnut Flange seated onto 0 937 Diameter Spot Face j Install Rivnuts until swaged tight in place Figure 6 Rivnut Installation 52 2014 USER MANUAL Figure 7 View of Backside of Rivnut Installed ESE Figure 8 Pilot Drill for Routing Operation 5 Module Routing a b C Use hand drill and 3 8 diameter drill to spot drill for routing Spot drill in 2014 Secure Urethane Module Sliding it back into the back structure works well Install template Line up centerline mark on module with template centering block Use strap or other method to secure template to the module the center of the template cutouts The slots in the module will be much smaller than the template cutouts 53 USER MANUAL Figure 9 Routing the Module e Use 4 Diameter Router Bit supplied with kit and the router base Attach the router base to your router You may need to drill 3 3 16 diameter holes to mount the base f Start routing in spot drill locations to rout all four slots in module g Use sand paper or other device to remove burrs along routed edges h Remove template Figure 10 View of Routed Module Figure 11 Test Fitting Ten Second Bracket 54 2014 USER MANUAL i Slide Center Module onto Back structure
32. N Y ITEM QTY DESCRIPTION SHEA A gt He x Bole oe z l G 2 ci o E 3 i E a S ne ee a a PIVOT PLATE ASSEMBLY C he 17 2 ASHER S D 6 IZAI LOCKNUT cre ST ca M i amp eI Sep ao KON E 4 3 8 16x1 1 2 HEX BOLT E a E ERN LNE F 2 8 l6x2 3 4 HEX BOLT i z G 12 E ASHER IE 6 3 8 16 LOCKNUT BS i R G e5 E gt r Installation Fig 31 You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section Ye 2014 USER MANUAL FORD OEM STEEL BUMPERS VENTED OPENING BIKE RACK INSTALLATION TO FORD E 350 E 450 BUMPER The custom mounting bracket for the Ford Cutaway Van E 350 E 450 consists of a formed steel backing plate four 1 1 2 diameter stand offs a mounting plate and a pair of stabilizer struts The backing plate is bolted to the vehicle frame ends sandwiched between the bumper and frame Four standoffs pass through holes in the bumper face and the mounting plate is attached to the backing plate with bolts passing through the stand offs Two stabilizer struts connect from the lower corners of the mounting plate to the frame of the vehicle FIGURE 1 Exploded View of Ford with OEM Bumper Installing the Bike Rack for Buses mounting bracket to the Ford chassis involves removing the bumper and sawing four holes through the steel bumper 1 Remove the bumper from the vehicle Lay the bumper face down and support it with blocks as necessary to
33. SALES FOR 6 DIGIT FINISHED GOODS P N 1 Check that the latch handle for damage Replace if necessary 2 Check the latch handle tube for straightness Straighten or replace if necessary 3 Examine the wear of the plastic insert in the tip of the latch pin Replace the insert if the quadrant is being marred by the latch pin 4 If the latch pin does not properly track on the quadrant check that the quadrant is attached tightly and squarely to the pivot plate Replace the quadrant if damaged 5 Examine latch components a Check that the roll pin fixing the return spring is fully engaged b Check the wear on the spring Clean the spring and replace it if it is distorted or not functioning properly c Check the latch pin housing for damage 72 2014 USER MANUAL FIG 4 SERVICING THE VELOPORTER SUPPORT ARM ASSEMBLY Assembly Parts List ITEM PART TITLE PTE S O pe ee RING SPLIT 670 O D X 051 WIRE DIA Ss 2 1 7299 PIN CLEVIS 3 16 X 1 1 4 SS ee SS Pan Head Phillips Machine Screw 10 32 Thread 1 3 8 Length 4 1 9644 VeloPorter Support Arm Spar _ 5 2 9646 VeloPorter Lower Bushing 4 9645 ___ VeloPorter Upper Bushing 7 1 9641 PEN VeloPorter Support Arm Housing Anti Glare 10 9 9662 CUSTOM SS SPRING 12 1 9647 _ VeloPorter Support Arm Grip _ e i 18 8 Stainless Steel Toplock Locknut Hex 10 32 Screw Size 3 8 Width 1 8 Height NOTE PLEASE ASK SAL
34. SCRIPTION 1 1 A a S 4 SHES W KNOB i i E 4 2 SHCS KNOB C 12 3 8 WASHER T 6 3 8 16 WINGNUT aani STAND LEG la ig a O o f B e HEEL p STAND FOOT AN AD le 5 Installation Fig 35 USER MANUAL 6402 MANEUVERING THE KWIKSTAND To maneuver the Kwikstand lift up on the attached bike rack and push in the preferred direction as illustrated in Figure 36 HAZ SERT 1 H EB SD MOVE MOVE HREL k Installation Fig 36 62 2014 USER MANUAL OPERATION OF BIKE RACK The Sportworks Bike Rack for Buses has been designed to make as low an impact as possible on transit operations All loading and unloading of bicycles can be done by the bicycle rider Sportworks suggests that loading of children s bicycles be done by an accompanying adult but the rack can be easily loaded by young children These are the steps that should be followed when using the rack Loading Bikes 1 2014 Prepare your bike for loading Remove water bottles pumps and other loose items that could fall off while the bus is in motion Inform the bus driver that you will be loading your bike You must load your bike from the curb or in front of the bus Do not step into oncoming traffic to load your bike Squeeze handle up to release latch then fold down the bike rack You only need to use one hand to unlatch and pull the bike rack down so you can hold your bike with your other hand It is not necessary to lean y
35. T PIECE C B DLE BJADEFANT Te Die PIVOT PEATE DL2 SUPPORT STRAP pE l B IEM OT DESCRIPTION BOA BOA A 4 3 8 16x1 1 2 HEX BOLT i E E 3 8 ASHER A DA E 4 2 8 16 LOCKNUT Installation Fig 20 2 Expose two existing bumper bolt holes on the GMC coach front bumper by removing the two carriage bolt assemblies typically centered and spaced 22 apart on the lower portion of the front bumper 3 Examine both tow hooks on the front face of the GMC coach Each tow hook is anchored to the coach face via four bolts Remove the two bolts from each tow hook that are oriented INBOARD towards the bumper centerline 25 2014 USER MANUAL ML an REMOVE TOW HOOK BOLTS 4EA gt o o o o S CROSS TUBE A Be D F mi SR Ls REMOVE EXISTING BUMPER E t CARRIAGE BOLTS ZEA MARK WHERE BRACKET PIECES INTERFACE WITH CROSS TUBE 2 PLACES SS i i i 1 EN 41 p BRACKET PIECES Installation Fig 21 Place the assembly of step 1 and the cross tube on the GMC coach as shown in Figure 21 Orient the notches of the cross tube angle pieces DOWN The notches provide clearance for the front bumper Use a felt tip pen to mark on the cross tube where the top hole of each bracket piece rests at the center wid
36. TING BUMPER CLIP D ENGAGES HEX BOLT 4 PLACES ENG4GES HEX BOLT 4 PLACES ITEM OTY_ DESCRIPTION 2 13 x 3 HEX BOLTI 2 LOCKWASHER PACER 71 1 sS bolts Fig 3 FIGURE 3 3 Sportworks NW recommends mounting a safety chain between the bumper and frame Fig 4 This will prevent the bumper from opening far enough to allow the deployed bike rack to contact the road surface in the event that the bumper latch fails or is released accidentally FRONT OF COACH SAFETY CHAIN FIGURE 4 4 Tighten all bolts securely You are now ready to install the bike rack Refer to MOUNTING THE BIKE RACK at the end of this section 41 2014 USER MANUAL NOVA LOW FLOOR COACHES These instructions apply to the Nova Low Floor Coach fitted with the 102 inch TRANSPEC Energy Absorbing Bumper The bike rack attaches to a pivot plate spanning two C brackets which are bolted to the coach body The complete bracket assembly includes two C brackets one extra long pivot plate assembly two threaded tow eye adapters and the associated bolt kits See Fig 1 BIKE RACK INSTALLATION TO NOVA LOW FLOOR BUMPERS 1 Remove the tow eyes or hooks from the screw in mounting points on the front of the coach 2 Insert the threaded tow eye adapters into the tow eye mounting points A inch hole near the outer end of the adapters allows insertion of a rod to turn the adapters The 2 13 threaded hole in one end
37. Y l n l N z pS i ALNO LA NY XO lo sj 14 1 gt I ji t lt I TI Re FLXIBLE NEW LOOK COACH is I iit I IP TALL STOCK METAL BUMPER Ge I CA L T na CF H Ae H AF FLOOBLE BRACKET PIECE A C 5 K A z AN N INSTALLATION ie 2 PIVOT PLATE ASSEMBLY eco EE SE p n A gt RA 2 gt MARK HERE THE LOW HOLE OF EACH BRACKET PIECE oh C RESTS ON THE FLXIBLE NEW LODK COACH STOCK BUMPER ay i a LOW HDLE FLXIBLE BRACKET PIECE 7 i Bs eh Y cut 5 gt DN N a R m B J as Installation Fig 30 2014 33 USER MANUAL 5 Center punch the two marks made in step 4 and drill through the front bumper using a 1 4 pilot drill then enlarge the holes using a 17 32 drill 6 Remount the bracket pieces with the attached pivot plate assembly to the cross tube Fasten the lower portion of the bracket pieces to the bumper via the newly drilled holes of step 5 using the provided 1 2 13 x 1 1 2 hex bolts washers and locknuts The Flxible New Look mounting bracket is now installed See Figure 31 Flxible Dp FLXIBLE NEW LOOK 10 TALL A ARS STOCK METAL FRONT BUMPER a EHA one l C D D i j F gt E i a 1 M ie E N i i e s CFDS5 TUB p c ee A Ge E wise SB igs o FLXIBLE BRACKET PIECE ZEA z Sane HS aI HE
38. ace plugs if missing or damaged 3 VBOLTS ARE PRESENT SECURE ARMS TO FRAME 4 PLACES Replace missing bolts 4 MAGNETS ARE PRESENT 2 PLACES Replace if missing These magnets stow the hook arms 5 VHOOK ARMS SLIDE IN OUT 2 PLACES Hooks move smoothly in out and self stow on magnet DO NOT LUBRICATE 6 VLATCH HANDLE WORKS Latch is easy to release and does not get stuck 7 BIKE RACK SWINGS FREELY AND LOCKS IN TWO POSITIONS Rack pivots and locks in both the deployed and stored positions 76 2014 USER MANUAL DL2 MAINTENANCE The DL2 and its accompanying brackets require very little service Regular suggested maintenance checks are included below 2 gt Ee 4 SOOO SI ml c i E _15 y pS rE 5 gt DO PD ie _ 77 2014 USER MANUAL 30 DAY GENERAL MAINTENANCE INSPECTION amp SERVICE Check every 30 days to insure that 1 2 _ _ 13 The rack swings freely and smoothly between the deployed and stored positions The release latch easily unlatches and does not stick in the release position The release latch automatically locks the rack in place when moved to the deployed or stored positions Each support arm hinge allows the support arm to raise and lower without undue constraint Each support arm magnet properly mates with and holds the support arm Each support arm hook pulls out smoothly stops at the stop screw easily slides bac
39. aising and lowering with ease check the two pivot bolt assemblies for incorrect installation or wear Replace the assemblies if damaged Check that the pivot tabs are straight and aligned to properly pivot the bike rack Straighten the tabs as required Check the pivot plate for correct alignment and damage Remove and straighten the pivot plate if it is not straight Check the stow latch and the support arm grip latching teeth If they are broken or worn replace the necessary parts Check the wheel stop for damage Replace if necessary Check the urethane wheel wells for cracks or damage Replace if necessary To replace remove the six screws attaching the tray to the frame The tray engages with two sleeves in the location of the wheel stop Use a screw driver or small pry bar to spread the tray flanges off the two sleeves Slide the wheel stop off of the tray Reverse steps for installation of the new tray Examine the structural integrity of the round tubing of the main frame Repair or replace the bike rack if damaged 71 2014 USER MANUAL FIG 3 SERVICING THE VELOPORTER LATCH HANDLE Service every 30 days Assembly Parts List TITLE LATCH PIN RIVET 7072 PIN ROLL 5 32 X 75 SS 9657 Spring 0 626 ID x 0 750 OD x 1 250 x 062 SS Wire 9650 VeloPorter Latch Handle Tube 1 1 19661 VeloPorter Latch Handle 1 9668 Type 420 Stainless Steel Spring Pin 3 16 Diameter 1 Length NOTE PLEASE ASK
40. assembly Pull the shank support 9 out the top of the spar to free the support arm spring Clean the spring and examine it for wear overstress and cyclical fatigue Pay special attention to the end hooks of the spring Replace the spring as necessary Clean the inside of the stainless steel support arm housing 3 using a stainless steel brush Do not use a non stainless wire brush Examine the two nylon bushings 7 that are inserted in the base of the spar Replace them if they are excessively worn or marred Re assemble the support arm in the reverse order of steps a d Use needle nose vise grips similar tool to pull the spring into position when re inserting the clevis pin 1 through the base of the support arm housing and the end hook of the spring Check the operation of the support arm once again Each support arm hook should pull out smoothly easily slide back into the stored position and properly self stow on the magnet when it is released Replace the spar tube if it is bent The arm may bind if bent DO NOT LUBRICATE Examine the support arm pivot Check clevis pin for wear Replace if damaged or worn 4 Examine the rubber grip Replace it if ripped gouged or bent 2014 OG USER MANUAL SERVICING THE APEX3 LATCH MECHANISM Service every 30 days PART ITEM NUMBER QTY DESCRIPTION 1 9661 1 VeloPorter Handle Latch Bar Plastic 2 4487 1 DL2 LATCH HANDLE TUBE 3 3603 1
41. ation kits for a number of bumper installations These include the necessary supplies for an accurate and efficient bracket installation These kits include but are not limited to the following items 1 Hole Saw bit for bumper module modification 2 Drill bit extension and arbor for bumper back structure drilling 3 Easy to use reusable drill template for easy hole location If you have this bracket Use this installation kit 100241 100268 Install Kit RTS 100495 100531 100665 100269 Install Kit Slide In C Frame 100243 100374 100646 100270 Install Kit Slide In Stand Off 100242 100271 Install Kit Intermediate 100242 100406 100272 Install Kit Swept Intermediate 100245 100244 100273 Install Kit GMC New Look 100246 100274 Install Kit Blue Bird TC CS 100361 100363 Install Kit Blue Bird Q 100242 100406 100378 Install Kit Swept Intermediate Vented 100447 100449 Install Kit Neoplan LF Swept Bumper 100499 100484 Install Kit MCI Drop down bumper 100407 100646 100506 Install Kit Transpec 100492 100566 Install Kit Slide In Neoplan Metroliner 100514 100629 100657 100578 Install Kit Slide In Stand Off Orion VII Swept 100607 100613 Install Kit 102 Swept Transit Bumper 100647 100758 100723 Install Kit Slide In 20 94 Spacing 100759 100760 Install Kit Chevy G3500 2014 USER MANUAL If you have a b
42. ched to the pivot plate both vertically and horizontally on the bumper Use 1 2 inch drill and bracket as a template to spot drill the urethane Use 3 hole saw to create two holes thru urethane to expose back structure of the bumper Insert the brackets still attached to the Pivot Plate into the two 3 inch holes Note bracket may be tight fitting in the urethane Use long 1 2 inch bit and bracket as a template to drill thru the bumpers back structure Attach brackets to bumper with supplied 2 Hex Head Cap Screws Re attach Pivot Plate to bracket in their proper locations 8 Torque 2 13 to 100 120 ft lb torque 3 8 16 to 30 40 ft Ib You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE RACK at the end of this section D DU g 6 7 48 2014 USER MANUAL CHANCE OPUS LF BIKE RACK INSTALLATION 1 2 3 Remove tow eye receiver cover from front bumper Remove tow hooks from receivers Place left and right brackets into tow eye receivers Note hex head cap screws pointing downwards Secure to bus using tow eye hitch pins Loosely mount pivot plate to brackets using supplied hardware Tigheten anti wobble bars torque to 100 120 ft lb Secure pivot plate to brackets and torque to 50 60 ft lb x n 4 5 6 x xn You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE RACK at the end of this section
43. cture and four corresponding holes drilled through the bumper back structure This method is ideal for buses with minimum clearance between the top of the Slide In bumper and coach body No modifications to a coach with a Slide In bumper are typically required to install the Sportworks Stand off bracket and bike rack STAND OFF METHOD BIKE RACK INSTALLATION TO HELP SLIDE IN BUMPER If you are installing a Sportworks bike rack to a coach equipped with a wheelchair lift you may have to deploy the lift and remove the wheelchair lift pan cover in order to gain clearance for installation You may also have to remove the bumper from the coach to gain bolt access 1 Locate the provided drill jig template on the bumper Align each semi cylinder piece of the drill template against the curved profile of the front bumper face The template should be well indexed Match the center of the template with the center of the front of the bus Hold or tape the template firmly in position See Figure 9 SLUVOMUR SUMPLR BACe STRUCT UPI LETHE WLP SI PLOTLEE SUMI COLINDEP PICCE DRILL TEMPLATE OPAL BUSHING a Figure 9 2 Using a 1 4 pilot drill drill through ONLY ONE of the upper template bushings just through the urethane bumper Insert a 1 4 dowel into the drilled hole to index the template in place Drill a 1 4 hole through the other upper bushing and insert a 1 4 dowel into it With the template indexed to the bumper at two places drill
44. determine the required distance between stand offs to clear the internal ribs of the urethane bumper structure either 16 or 18 to be compatible with the installation jig This rib spacing check should not be required for the Swept Intermediate bumper stand offs 16 apart should miss any urethane rib 16 2014 USER MANUAL Before installing a bike rack on an INTERMEDIATE bumper Check the rib spacing of the bumper for stand off leg clearance at 16 and 18 apart and centered relative to the front face of the coach NOTE Each stand off leg is 1 1 2 in diameter Use the 16 spacing between stand offs for the coach provided that the stand off legs miss the internal ribs Use the 18 spacing as a possible alternative to avoid ribs The drill template clearly indicates which drill bushings to use for either the 16 or 18 spacing between stand offs The bike rack will easily install with either the 16 or 18 spacing After the spacing between stand offs has been established follow the installation instructions below The installation procedure is the same for either the 16 or 18 spacing The only difference is which set of drill template bushing holes to drill through 16 or 18 Consult Sportworks at 425 483 7000 if neither the 16 or 18 spacing will work for your application BIKE RACK INSTALLATION TO INTERMEDIATE SWEPT INTERMEDIATE BUMPER 1 Locate the drill jig template on the bumper Intermediate Bumper Align
45. drill the two lower 1 4 holes on each side of the bumper 4 holes total The template should not move during this step RTS DRILL JIG TEMPLATE 1 APPLY THE JIG TO THE BUMPER FACE BY INSERTING THE TOP LOCATOR SCREWS IN THE LOWER V GROOVE OF THE BUMPER TRIM STRIP 2 ADJUST THE TEMPLATE UNTIL IT IS CENTERED TO THE BUMPER AND PERPENDICULAR TO THE ROAD 3 gt DRILL FOUR 1 74 PILOT HOLES IN THE URETHANE STRUCTURE VIA THE TEMPLATE URETHANE STRUCTURE lt ADJUST TOP LOCATOR SCREW OPILOT DRILL O PILOT DRILL CENTERLINE TOP LOCATOR SCREW 2EA TOP Sees LOCATOR SCREW PILOT DRILL O PILOT DRILL O ADJUST T DRILL JIG TEMPLATE ADJUSTING SCREW lt 2EA gt Installation Fig 17 RTS BUMPER L TRIM STRIP VA LOWER V GRDOVE OF TRIM STRIP BUSHING BUSHING NU ALUMINUM EXTRUDED BACK STRUCTURE 4 Remove the template from the bumper Use a 1 1 2 hole saw with a 1 4 pilot drill to saw four holes just through the front surface of the urethane bumper at the same four locations drilled in step 3 Use care to insure that the holes are sawn perpendicular to the surface of the bumper back structure 5 Insert on each side of the bumper a stand off into the holes sawn in step 4 Orient the 3 8 holes of the stand offs DOWN for a lower bicycle loading height Work each stand off into the 1 1 2 holes until
46. e Table 1 0 The anti glare P N s will be available with the same features kits and options as the existing electro polished product line Effectivity of Change Orders for electro polished products will be accepted and processed through December 31 2008 in accordance with Sportworks annual pricing policy Orders for electro polished products received on or after January 1 2009 will not be accepted Required Actions Customers and OEM resellers are required to update their procurement systems and documentation to reflect the conversion from electro polished to anti glare P N s as outlined in Table 1 0 below DL2 amp DL2 NP TRILOGY 104 2014 USER MANUAL Table 1 0 Electro Polished to Anti Glare P N Conversion Chart Electro Polish j et NEW Anti Glare Electro Polish Item Description 100306 S S DL2 Santa Cruz Electropolished 100804 100306 DPLY ata Santa Cruz Electropolished w Deployment 100804 DPLY 100307 S S DL2 Santa Cruz Body Only Electropolished 100808 100460 S S NP Bike Rack Electropolished 100540 S S NP DL2 Bike Rack w Extended Reach Support Arm Electropolished S S NP DL2 Bike Rack w Deployment Kit Electropolished S S NP DL2 Bike Rack w Deployment Kit Quick eee ae Release Hardware Electropolished LOSS 100460 dply qr S S NP DL2 Bike Rack w Deployment Kit Quick 100540 dply qr 100460 16 100540 16 100460 DPLY 100540 DPLY span Release Hardware Bilingual Decal
47. e 32 Page 35 Page 38 Page 40 Page 42 Page 44 Page 46 Page 48 Page 49 Page 50 oooh ND Page 56 Page 58 Page 59 Page 60 Page 61 Page 63 Page 65 Page 67 Page 75 Page 85 Page 92 Installation Overview The installation is crucial to the safety and performance of the Sportworks Bike Rack for Buses system There are several factors that need to be addressed when mounting the rack These factors include the e Load Height e Approach Angle e Footprint e Protrusion Carefully read and understand the following information regarding the positioning of the rack on the bus before beginning the installation process Load Height The load height is the vertical distance a bicycle must be lifted for placement in a deployed bike rack If the rack is mounted too high some riders may have difficulty loading the rack zA 3 CORNER OF WHEELCHAIR LIFT ql 4 USt_iAU_ dl io h L LOAD HEIGHT go ee lean I ANGLE Pa 1 PROTRUSION Installation Fig 1 Approach Angle The approach angle is the angle created by a line from where the front tire contacts the pavement to the first obstruction ahead of the front tire This obstruction would first touch the pavement on a very steep hill The bike rack will limit the approach angle if it is installed on the bumper in a low enough position The bike rack installer should be 2 2014 USER MANUAL
48. e rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section FORD E 350 VAN DL2 BIKE RACK DLA PIVOT PLATE ASSEMBLY 3 8 16 LOCKNUT 4 EAD 7 mI mm J 5 SS e ES are E a 7 s H4 t 8 3 8 16 x 1 1 4 HEX BOLT 4 EA X 4 reine P44 E N 7 pspazsb s COTTER PIN ASHER 8 EA Da SZ I Lae TRAILER HITCH MOUNTING BRACKET S CLASS 3 RECEIVER 95 8 HITCH PIN Installation Fig 26 30 2014 USER MANUAL SPECIAL NOTE In some cases the fit between the Sportworks trailer hitch mounting bracket and the Class III receiver hitch is loose enough to cause the bike rack to rest at an angle or rock back and forth during use This will not impair the use of the rack If this movement is unacceptable we recommend modifying the coach s Class III receiver hitch as illustrated in Figure 27 This modification consists of adding two lock bolts by drilling and tapping two holes on the side of the receiver With this modification the trailer hitch mounting bracket and bike rack can be trimmed and locked in place COTTEP PIN S CLASS 3 RECEIVER HITCH 05 8 HITCH FIN 2 3 8 16 JAM NUT Ce EOI 378716 1 1 4 GR 8 HEX BOLT 2 EA 3 8 l6 THREAD 2 PLACES y CLASS 3 RECEIVER gt HOLE LOCATION
49. e recommended torque values are For 2 13 Grade 8 110 130 FT LB For 3 8 16 Grade 8 50 60 FT LB For the rack pivot bolts 3 8 16 Stainless 30 40 FT LB 2014 USER MANUAL 58 CHANGING THE POSITION OF THE RACK TYPICAL HEIGHT ADJUSTMENT FOR ALL BUMPER TYPES To change the position of the rack remove the bike rack from the pivot plate Remove the pivot plate from the C Brackets or other bracket pieces and position the pivot plate up or down as required Remount the pivot plate to the bracket pieces and the rack to the pivot plate Some bracket assemblies may not have multiple height adjustment holes If this is the case the bracket assembly is designed for an optimum position in terms of minimal headlight interference and proper loading height Height adjustment is not required IK OO O10 OO DAN OO VOI RRO o 9 o O GS 10 OS x 3 N L z F A ea aT A at a Height Adjustment Holes Installation Fig 33 59 2014 USER MANUAL DISPLAYING THE BIKE RACK The Sportworks Bike Rack for Buses can be easily displayed using the Sportworks KWIKSTAND This bike rack show stand allows one to quickly and easily demonstrate the use and operation of the bike rack The hands on experience benefits all those investigating the bike rack TLe BIKE RACK
50. e vehicles Users standing in or near a lane of moving traffic when loading unloading bikes Headlight and turn signal blockage A wider than normal turn radius may be required to safely maneuver the vehicle Rack damage including breakage caused by excessive vibration and undue stress on the critical weld points For additional information and to learn more about the rack models Sportworks recommends for use with smaller transit vehicles please contact our Sales and Support Department at 425 483 7000 or salesandsupport sportworks com Thank You Sportworks Northwest Inc 97 2014 USER MANUAL sportworks Sportworks Product Change Notice ECN 100616 Date 2 25 10 P N s Affected 2011 Price 100615 BRACKET Chevy 5500 includes 2 130 00 100616 PIVOT PLATE Chevy 5500 Std and NP Width 163 00 or 6 PIVOT PLATE Chevy 5500 Std and NP Width Deployment Kit 232 00 100846 New Strut Kit Chevy 5500 required as of 2 25 2010 78 00 New Heavy Duty Pivot Bolt Kit installs one rack 100839 Rae da 26 00 Travel Stops Added to Pivot Plate Reason for Change 100846 New Strut Kit 100839 Pivot Bolt Kit Firm Suspension of the Chevy 5500 Chassis combined with flexible bumper mount and flexible Pivot Plate results in excessive bouncing of the Sportworks Bike Rack in both the stowed and deployed position leading to premature failures of rack bushings and frame 1 Excessive bouncing may dislodge bicycle Descrip
51. ents 5 Slide grip until it bottoms out on end of hook tube being careful not to compromise the end of the grip by stretching it too tightly 6 Allow 1 hour for solution to evaporate and grip to tighten Always test the grip before putting into service to ensure proper adhesion 84 2014 USER MANUAL Service and Maintenance Guide APEX3 BIKE RACK VISUAL INSPECTION Top View Side View 85 2014 USER MANUAL BIKE RACK VISUAL INSPECTION Sportworks recommends the following quick visual inspection to ensure an operable bike rack Use this page as an inspection sheet for your transit operators Examine the 7 items below before operating your coach If the bike rack does not function properly service it before putting it into operation 1 VPIVOT BOLTS ARE TIGHT Tighten if required 2 VENDPLUGS ARE PRESENT 2 PLACES Replace plugs if missing or damaged 3 VCLEVIS PINS AND SPLIT RINGS ARE PRESENT SECURE ARMS TO FRAME 3 PLACES Replace missing parts 4 VMAGNETS ARE PRESENT 3 PLACES Replace if missing These magnets stow the support arms 5 VSUPPORT ARMS SLIDE IN OUT 3 PLACES Hooks move smoothly in out and self stow on magnet DO NOT LUBRICATE 6 VLATCH HANDLE WORKS Latch is easy to release and does not get stuck 7 BIKE RACK SWINGS FREELY AND LOCKS IN TWO POSITIONS Rack pivots and locks in both the deployed and stored positions 86 2014 USER MANUAL APEX3 MAINTENANCE The Ape
52. her amp Position Trilogy Nut 5 Standard Support Arm Hook Stainless 6 100112 Grip Molded Support Arm Hook 7 Acetal Slider Piece 8 Stop Plate 9 Spring 10 Pin Roll 3 16 x 1 S S 11 100110 Pin Clevis 3 16 x 1 1 4 Support Arm Spring Kit S S 12 Ring Split S S 82 2014 USER MANUAL 1 Examine the components inside of the support arm w oo a b c 2 Remove the bolts attaching the support arm hinge to the bike rack Remove the stop screw at the top washer end of the support arm housing Remove the roll pin from the base of the support arm housing Carefully slide the stainless steel hook arm out from the support arm housing Make note of how the two nylon slider keys and stop plate fit at the base of the hook arm Remove the roll pin on the hook arm to free the support arm spring Clean the spring and examine it for wear overstress and cyclical fatigue Pay special attention to the end hooks of the spring Replace the spring as necessary Clean the inside of the stainless steel support arm housing using a stainless steel brush Do not use a non stainless wire brush Examine the two nylon slider keys that rest at the base of the hook arm Replace them if they are excessively worn or marred Replace them if the support tube is not tracking correctly i e there is too much twist Examine the stop plate that rests at the base of the hook arm Replace it if excessively w
53. hing Fig 1 number one above 4 NN 3 The brush density is too low There is less than the recommended number of brushes on the brush arm assembly This is usually found when well worn brushes are used for too long of a period 65 2014 USER MANUAL 4 The brushes are being turned into the bus path Make sure the brushes are spinning so that they tend to climb up and over any protrusions they could catch on See Figure 1 The illustration shows the recommended rotation for the brush assemblies If the brush assembly is fixtured to the driver s side the brush needs to rotate counter clockwise as viewed from the top If the brush assembly is mounted on the curb side the brush assembly would need to rotate clockwise When operating the wash facility in the recommended way one should find no deterioration above regular wear and tear to the bus the bike rack and the wash system lf this is not so take time to examine the rack setup on the bus and the setup of the wash facility Please consult Sportworks at 425 483 7000 if you are experiencing any further problems 66 2014 USER MANUAL SERVICE AND MAINTENANCE GUIDE FIG 1 VELOPORTER BIKE RACK VISUAL INSPECTION Top View ED SUPPORT ARM GRIP 5 WHEEL STOP Side View 7 2014 USER MANUAL VELOPORTER BIKE RACK VISUAL INSPECTION Sportworks recommends the following quick visual inspection to ensure an operable bike rack Use this page as an inspection
54. ill require new Christmas tree clips included in the fastener kit P N 100801 Swept Remove one corner module then remove the center module Both modules are attached with four 14 Self Tapping Screws Re use the screws 4 Back Structure Machining Figure 1 Step Drilling Back Structure a A Mag Base Drill is required for this machining Sportworks Kit 100722 includes the 7 Diameter Dowel Pin 0 687 0 937 Diameter Step Drill and the 1 15 16 Hole Saw needed b Secure to bench install template on top surface and center to centerline mark with L shape center block Use C Shaped Clamp Blocks to secure template to Back Structure See Figure 1 c Use 0 687 0 937 Diameter Step Drill and drill bushings to located Mag Base Drill 50 2014 USER MANUAL d Drill 0 687 Diameter thru and spot face 937 Spot face should be 80 100 cleanup with minimal depth See Figure 1 e Repeat for second hole location Use dowel and setup plate to locate the Mag Base Drill in the proper location for hole sawing lock drill in place Figure 2 Aligning Mag Base Drill Figure 3 Hole Sawing Back structure g Use 1 15 16 Diameter Hole Saw supplied with kit Saw hole thru one wall of back structure h Re locate Mag Base Drill and saw 1 15 16 Diameter in second location i Remove template j Debur holes with sandpaper file or other deburing tool 51 2014 USER MANUAL Figure 4 Back structure After
55. ion AR 2014 USER MANUAL INTERNATIONAL NAVISTAR OEM STEEL BUMPER VENTED OPENING BIKE RACK INSTALLATION TO INTERNATIONAL NAVISTAR OEM STEEL BUMPER The custom mounting bracket for the International 3200 3400 consists of both top and bottom custom laser cut bracket plates four 1 diameter by 7 8 long aluminum spacers and four 60mm M12 bolts with washers Both the top and bottom mounting brackets are affixed using both the 60mm bolts supplied and existing bolt holes in the bumper The 60mm bolts replace the stock bolts as the stock bolts are not long enough to accommodate the added thickness of the brackets and spacers 60mm bolt Spacer o o oo Installing the Bike Rack for Buses mounting bracket to the International chassis does not involve completely removing the bumper 1 Remove both of the existing upper bumper attachment bolts 2 Install the top bracket using the 60 mm bolts and washers provided being sure to insert a spacer between the face of the bumper and the back of the bracket see figure 1 Use of thread locking compound is recommended 3 Leave bracket snug but not completely tight until installation of both the bottom bracket and Pivot Plate Assembly have been completed 44 2014 USER MANUAL INTERNATIONAL NAVISTAR OEM STEEL BUMPER BIKE RACK INSTALLATION TO INTERNATIONAL NAVISTAR OEM STEEL BUMPER continued 4 Remove both of the existing lower bumper attachment bolts 5 Install the botto
56. irmly in position See Figure 24 HEADLIGHT TURN SIGNAL Va J X BUMPER BOLT NT x awe WN f By N EN N F a Z x z j YY y N N N x N Q NG LOCATOR SCREW a ras BLUE BIRD TC CS COACH ME 7 BLUE BIRD BUMPER DRILL JIG a N BUSHING GL le Installation Fig 24 2 Transfer punch four deep marks on the front bumper via the drill bushings of the drill jig template Remove the template from the bumper Drill a 1 4 pilot hole at each of the transfer punch marks through the front bumper Maintain a low drill motor RPM and use drill lubricant as required Next enlarge the four pilot holes using a 17 32 drill 28 2014 USER MANUAL 3 Loosely assemble each Blue Bird bracket piece to the bumper via the newly drilled holes Assemble the pivot plate assembly to the Blue Bird bracket pieces Tighten all bolts once together This assembly is the mounting bracket See Figure 25 The mounting bracket is now installed BLUE BIRD 17 32 DRILLED HOLE 4 PLACES BLUE EIFI BRACKET PIECE a ITEM Q DESCRIPTION 3 8 16 1 142 HEX BOLT Tod 37 8 ASHEF 38 16 LOCKNUT Ve 13 x 1 1 2 HEX BOLT
57. it to be bolted to the bottom flange of the bumper for stability Fig 2 38 2014 USER MANUAL An example hitch configuration is shown for reference FIGURE 2 EXAMPLE CONFIGURATION FOR GOSHEN CENTURY CLASS 3 HITCH RECEIVER With the hitch receiver installed the Sportworks hitch bracket is inserted into the receiver and pinned in place The pivot plate assembly is bolted to the two uprights using the supplied hardware Fig 3 With the pivot plate assembly securely in place the rack can be mounted as shown in Section 3 of the owners manual ye wane STOWED POSITION BIKERACK DEPLOYED POSITION GOSHEN gine FORMED STEEL BUMPER sPORTWORKS RECEIVER HITCH BRACKET RECEIVER RECEIVER MOUNTED FLUSH WITH CL4SS 3 HITCH FRONT OF BUMPER WITHIN 1 4 INCH BY OTHERS FIGURE 3 39 2014 USER MANUAL MCI FLIP DOWN ENERGY ABSORBING BUMPERS BIKE RACK INSTALLATION TO MCI FLIP DOWN BUMPER This bracket attaches to the bumper using four of the existing threaded holes in the bumper steel backing beam Access slots are cut through the plastic bumper face at the locations of the bracket arms The existing bolts two top and two bottom at the bracket arm locations are removed Spacers are placed between the bracket and the backing beam and the arms are attached using the supplied longer bolts Figure 1 shows the most common bumper bolt spacing and the bracket type used f Double check that the
58. k into the stored position and properly self stows on the magnet when it is released Both pivot bolt assemblies are tight If you see excessive wear or cracks in the bronze oilite bushings you must replace them immediately Some cutaway vehicles tend to cause the bushings to wear more quickly You can replace the originals with our heavy duty pivot bolt kit P N 100839 for longer life All fasteners are tight on the mounting bracket including the hardware for the support strap quadrant pivot plate to bracket pieces and bracket pieces to bumper or coach body There are two black plastic endplugs inserted into the main frame of the rack located near the ends of the lowering tube the tube one grabs to engage the release latch Replace if missing Check Torsion Spring Wear Pad for excessive wear or loose attachment to frame Torsion Spring Pivot Bolts are tight The instruction labels on the rack are intact Replace if shredded partially removed non readable or not adhering properly Clean the rack surface thoroughly isopropyl alcohol before replacing Pay particular attention to the chain guard sticker If surface rust develops on stainless steel use naval jelly to remove 78 2014 USER MANUAL SERVICING In addition to the 30 day general maintenance and service inspections there are more specific service guidelines to follow in maintaining the Sportworks bike rack The guidelines are easy to follow and should
59. keep the bumper level and stable Lay the backing plate inside the bumper over the captured studs The bent edges of the backing plate should face up with the shorter bent edge toward the bottom edge of the bumper The backing plate should rest level and straight within the bumper The two parts can be bolted together temporarily to ensure positioning 95 lt 2014 USER MANUAL FORD OEM STEEL BUMPERS VENTED OPENING BIKE RACK INSTALLATION TO FORD E 350 E 450 BUMPER 2 Using the backing plate as a template to locate mark the positions of the two holes to be sawn though the bumper Drill two pilot holes at the marked locations from the back of the bumper through the front These holes will allow the stand offs to pass through the bumper to the backing plate The one pair of stand offs will pass through the vent opening in the bumper Using a 1 5 8 to 1 7 8 diameter hole saw with a 4 pilot saw two holes through the metal bumper and the plastic facing De burr the edges of the holes Reinstall the bumper to the vehicle with the backing plate sandwiched between the bumper and the frame ends The bent edges of the backing plate face rearward with the shorter bent edge at the bottom To allow alignment leave the bumper bolts loose enough to allow shifting of the backing plate while attaching the standoffs and the mounting plate FIGURE 2 Ford with OEM Bumper 36 2014 USER MANUAL BIKE RACK INSTALL
60. ll the spring into position when re inserting the roll pin through the base of the support arm housing and the end hook of the spring Check the operation of the support arm assembly once again Each support arm hook should pull out smoothly stop at the stop screw easily slide back into the stored position and properly self stow when it is released If the support arm spar is bent it should be replaced Examine the support arm assembly mounting pivot Check the pivot for side play Side play can be adjusted by tightening the 3 8 16 nylock nut Do not over tighten The pivot should be free with a small amount of play With the support arm assembly vertical and fully retracted lightly push the grip towards the front of the bus and then away from the bus If total movement exceeds 2 replace the worn parts DO NOT LUBRICATE 2014 74 USER MANUAL Service and Maintenance Guide DL2 BIKE RACK VISUAL INSPECTION Top View e A E Side View 75 2014 USER MANUAL BIKE RACK VISUAL INSPECTION Sportworks recommends the following quick visual inspection to ensure an operable bike rack Use this page as an inspection sheet for your transit operators Examine the 7 items below before operating your coach If the bike rack does not function properly service it before putting it into operation 1 VHEX CAP IS TIGHT Tighten by hand preferably by tool if required 2 VENDPLUGS ARE PRESENT 2 PLACES Repl
61. m bracket in the same manner as the top using the 60 mm bolts and washers provided see step 2 and figure 1 Use of thread locking compound is recommended 6 Install Pivot Plate Assembly to upper and lower brackets moving brackets as required to achieve proper bolt hole alignment 7 Torque Pivot Plate Assembly attachment bolts to 50 60 Ft Lb 65 80 Nm 8 Torque bumper bracket attachment bolts to 65 80 Ft Lb 90 110 Nm You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE RACK at the end of this section 45 2014 USER MANUAL Chevy GMC 4500 5500 OEM STEEL BUMPER BIKE RACK INSTALLATION TO Chevy GMC OEM STEEL BUMPER The custom mounting bracket for the Chevy GMC consists of both Left and Right custom laser cut formed bracket plates and four 40mm Hex Head Cap Screws with washers Both the left and right mounting brackets are affixed using both the 40mm Cap Screws supplied and existing bolt holes in the bumper The 40mm bolts replace the stock bolts as the stock bolts are not long enough to accommodate the added thickness of the brackets and spacers Left curb side bracket Part 100616 Pivot Plate Assy 40mm Hex Head Cap Screw w washer FIGURE 1 Installing the Bike Rack for Buses mounting bracket to the Chevy GMC chassis does not involve completely removing the bumper 1 Remove both of the existing CURB SIDE bumper attachment bolts 2 Install the CURB SIDE b
62. mounting bracket cross tube piece so that it spans between the two tow hooks Orient the notches of the cross tube angle pieces DOWN Assemble the cross tube to the coach using the 1 2 13 x 2 1 2 hex bolts washers and locknuts See Figure 28 32 2014 USER MANUAL BRACKET PIECE OTY DESCRIPTION 4 3 8 16x1l 1 2 HEX BOLT 8 3 8 WASHER 4 3 8 16 LOCKNUT ws A FWD Ne 5 Ne hed ns Lon N i VE DN i k ll STN N S gl X Nian S k K 3A l uy PIVOT PLATE ASSEMBLY N a Si i as Qe al AS R OF OF Installation Fig 29 Fasten the pivot plate assembly to each Fixible bracket piece at the desired height location using the 3 8 16x1 1 2 hex bolts washers and locknuts provided See Figure 29 Mount the Flxible bracket pieces with the attached pivot plate assembly to the cross tube using the provided 3 8 16 x 2 3 4 hex bolts Use a felt tip marker to mark where the lower hole of each bracket piece contacts the front bumper This mark will indicate the drill hole location 2 ea on the front bumper to anchor each bracket piece See Figure 30 i ITEM QIY DESCRIPTION FR Fo a tes PENTEL G J y F 2 2 3 4 HEX BOLT i l G 8 ASHER H 4 16 LOCKNUT FLXIBLE COACH TOW HOOK A ak i GW b6 FLXIBLE CROSS TUBE ASSEHEL
63. nal style molded connector e These Deployment kit connector changes will be transparent to you when ordered as a complete kit Effectively of Change 1 All deployment kit shipments on or after September 1 2010 will contain our new Weather Pack connectors only 2 A limited quantity of spares inventory will be maintained by Sportworks for instances where the original molded style connector is required to support existing deployment kit maintenance Service Part Number Reference Table The spares kits containing the original molded style connector will remain available for repair or replacement Three new Part Numbers have been created for new spares kits constructed with the new Weather Pack connectors only Table 2 Deployment Wiring Spares Definition Old Molded Style Connector Spare New Weather Pack Connector Spare 100853 SPARES CABLE 9 with Original 100887 SPARES CABLE 9 with Weather Pack Connector Molded Connector 22 ga 2 conductor 1 End 20AWG 2 Conductor 100832 SPARES Magnetic Switch with 100885 SPARES Magnetic Switch with Weather Pack Original Molded Connector and Fasten Connector Standard and Fasteners 100670 Deployment Switch Cable with Origing 100886 Deployment Cable 20 ga 2 conductor with Weather style Molded connector and Weather Pack Connectors Pin and Socket 7 Length Pack Connector 7 length a Molded style Connector Weather Pack Connector Shroud Weather Pack Co
64. nd proceed in a workmanlike fashion If the answer is NO to any of these questions repair the bus or the bumper before mounting the bracket to the bus Mounting a bracket without making these requested repairs especially modifying a bracket to fit on a bus that is damaged voids all Sportworks warranties and creates potentially unsafe conditions 2014 USER MANUAL HELP UNIVERSAL 96 and 102 BUMPERS The 96 denotes bus width in inches as does the 102 The Help Universal 96 102 bumper can be identified by an array of exposed bolts on the top and bottom of the bumper These bolts hold the bumper s three black urethane pieces to the bumper back structure The Sportworks mounting bracket C Brackets is intended to mount to the bumper at four of the existing bolt locations Typically no modifications to a coach with the Universal 96 or 102 bumper are required to install the Sportworks bracket and bike rack However clearance problems may be encountered with each C Bracket arm and its mounting hardware fitting between the bumper and the coach body Check this clearance before installing a bracket and bike rack Caution Before proceeding with the bracket and bike rack installation check that each C Bracket arm and its mounting hardware has enough clearance to fit between the bumper and the coach body If there is a clearance problem either 1 Modify the body of the coach as required to fit the C Brackets and its hardwa
65. nnector Tower Figure 1 Comparison of original molded connector top and new Weather Pack connectors Aaron Rozeboom Design Engineer Sportworks NW Inc 96 2014 USER MANUAL sportw TECHNICAL BULLETIN 102 To OEM Transit Customers From Sportworks Northwest Inc RE 3 Position Racks amp Small Transit Vehicles Models Trilogy Bicycle Racks Item ID 100546 100567 100648 and VeloPorter 3 Bicycle Racks Item ID 100659 Issue Date February 17 2010 Dear Customers and Resellers Sportworks has received an increased number of customer inquiries regarding the use of 3 position bike racks on smaller sized transit vehicles While we cannot control how customers decide to install and use our products in the field there are some important safety and warranty issues to consider when choosing to install 3 positions racks on smaller bus types built on truck chassis which may include but are not limited to cut aways shuttles and paratransit vehicles Sportworks recommends the use of 3 position bike racks on full size 96 and 102 wide transit vehicles only Using 3 position racks on smaller buses and buses built on truck chassis may create unsafe conditions for cyclists and vehicle operators and may void the products limited 1 year warranty The following concerns can be directly attributed to the narrow profile small truck chassis and stiff suspension commonly found in cut away shuttle and paratransit typ
66. of the adapters should face forward Screw both adapters in so that they protrude about one inch from the face of the bus They can be adjusted later to set the angle of the C bracket NOVA LOW FLOOR FIG 1 THRE4DED Th EYE MOUNTING POINT TOW EYE ADAPTER PN 100442 TMOLNTING BRACKET PN 1JD43B fy z PIVDT PLATE 4SSEMBL PN 100440 Any BLS BIKE P4ck FoOR BUSES gt Ky ia BUMPER BRACKET VOUNTING LOCATION BOLTING PLATE 42 2014 USER MANUAL NOVA LOW FLOOR COACHES continued 3 Remove the two lower bolts at each bumper mounting bracket located behind the bumper and about 22 inches each side of center 4 Bolt the C Brackets loosely into the tow eye adapters with the lower bolting plate tucked behind the bumper over the existing bumper bolt holes Adjust the tow eye adapters so that the bolting plate contacts the bumper bracket face and the front of the C bracket is vertical and plumb 5 Replace the lower bumper mounting bolts loosely bolting the bottom of the C brackets into place 6 Bolt the pivot plate assembly to the C brackets Two vertical positions are possible Generally the lower position is used unless there is a clearance problem 7 Adjust the bolted assembly so that it is level centered and plumb Tighten all bolts You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE RACK at the end of this sect
67. orn marred cracked or has any broken corners Re assemble the support arm in the reverse order of steps a d Use a simple hook made of stiff wire or similar tool to pull the spring into position when re inserting the roll pin through the base of the support arm housing and the end hook of the spring Check the operation of the support arm once again Each support arm hook should pull out smoothly stop at the stop screw easily slide back into the stored position and properly self stow on the magnet when it is released Straighten the support arm hook if it is bent especially the portion of the hook that rests inside of the support arm housing the hook may freeze up until it is straightened properly DO NOT LUBRICATE Examine the support arm hinge Check the hinge for side play and warpage With the support arm vertical and the hook fully retracted lightly push the hook towards the front of the bus and then away from the bus If total movement exceeds 2 replace the support arm housing Examine the grip on the hook of the hook arm Replace it if ripped gouged or worn thin 2014 83 USER MANUAL INSTALLATION INSTRUCTIONS FOR SUPPORT ARM GRIPS 1 Secure Hook Support Arm Assembly 2 Use a 20 30 Palmolive Water or equivalent dish soap solution 3 Apply solution to hook tube and to inside of foam grip 4 Slide grip onto hook it will be necessary to twist and work grip past bend in short incremental movem
68. ort Arms NEW Ratchet System 402 2014 USER MANUAL Reason for Change To increase bicycle retention on VeloPorter 3 and custom VeloPorter bike racks Date of Change All VeloPorter 3 Bike Racks delivered after May 1 2008 include the new ratchet support arm features installed by the manufacturer prior to shipment All VeloPorter 3 Bike Racks delivered on or before April 30 2008 will require field replacement to obtain the new ratchet support arm features Field replacement will be offered directly to all VeloPorter 3 end customers in accordance with Sportworks VeloPorter 3 Field Replacement Program Field Replacement Program FRP As a courtesy to our VeloPorter 3 end customers Sportworks will rework and replace all VeloPorter 3 support arms purchased and delivered prior to May 1 2008 at no charge For additional information about this program including a copy of the Customer Agreement please contact Beata Zayas Kat Anthony FRP Primary Contact FRP Support 425 483 7000 x12 425 483 7000 x29 beataz sportworks com kathya sportworks com Replacement P N Cross Reference Table All old P N s mentioned below have been discontinued and are no longer available Old P N Description New P N Description 100676 VeloPorter Support Arm Assy 100778 VeloPorter Ratchet Support Arm Assembly 100699 VeloPorter Support Arm Grip 100779 VeloPorter Ratchet Support Arm Grip 100696 VeloPorter Mir Supt Arm Assy
69. our bike against the bus Lift your bike onto the bike rack fitting wheels into proper wheel slots Each wheel slot is clearly labeled for the front wheel The purpose of the directional placement is to make the bike nearest the bus easier to unload Raise the Support Arm over the front tire The Support Arm s number one purpose is to add lateral support for the bicycle when the bus is in motion or at rest Many bikes will sit in the wheel well without the use of the Support Arm but the rack must not be used without the Support Arm Bikes with especially thin rims and tires will sway back and forth without its use 63 USER MANUAL The handle should be placed as close to the front brake and head tube as ossible to ensure safety and security of the bike and in all cases the handle must be closer to the head tube than the highest point of the tire OK 6 Board the bus and enjoy the ride Choose a seat near the front of the bus to keep an eye on your bike DON T FORGET you have a bike with you when you get off at your stop New riders often do Unloading Bikes 1 Inform the bus driver that you will be unloading your bike as you approach your stop Use the front door to exit the bus Unload your bike from in front of the bus or from the curb not from the street 2 Raise the Support Arm off the tire The Support Arm automatically folds down to a secure position 3 Lift your bike out of the bike rack 4 Fold up the Bike
70. part in the urethane bumper structure The stand off legs contact the aluminum extruded back structure of the bumper Bolts hold each stand off to the bumper back structure RTS BUMPER PROFILE RTS BUMPER LICENSE PLATE CAVITY Installation Fig 16 BIKE RACK INSTALLATION TO RTS BUMPER Use the installation instructions below to install a Sportworks bike rack and mounting bracket to an RTS coach 1 Locate and mark the center left to right of the RTS bumper on the black typically black bumper trim strip 2 Locate the drill jig template on the bumper Align the top two locator screws of the template in the lower V groove of the black bumper trim strip Make sure the locator screws touch the top and bottom of the V groove Match the centerline of the template with the centerline of the bumper Turn the bottom two leveling screws adjusting screws by hand or with an allen wrench until the template is perpendicular to the ground and cannot rock See Figure 17 HOLD OR TAPE THE TEMPLATE FIRMLY IN POSITION THE TEMPLATE SHOULD NOT MOVE Soji 2014 USER MANUAL 3 Using a 1 4 pilot drill drill through ONLY ONE of the upper template bushings just through the urethane bumper Insert a 1 4 dowel into the drilled hole to index the template in place Drill a 1 4 hole through the other upper bushing and insert a 1 4 dowel into it With the template indexed to the bumper at two places
71. r back structure at four locations two locations per stand off by inserting the drill down into each stand off leg Use cutting oil lubricant on the tip of the drill Clear any chips from the drilling operation 7 Assemble each stand off to the bumper back structure using 1 2 x 2 1 2 bolts washers and locknuts Use a socket wrench with an extension to insert and tighten the bolts inside each stand off leg Protect the bolt access path of each stand off leg by inserting a plastic cap into each leg Now you may conveniently adjust the 14 2014 USER MANUAL loading height of the bike rack by moving the pivot plate to a higher or lower position if desired The mounting bracket is now installed SLIDE JM BUMPER SLIGE JN STHNG OFF BRAGRET SEA gt GLE FIVOT FLATE ASSEPIELY EAEEREN pl MEPER 40 f E F j a Ses Ho 4 3 GESiRIFTION 2 2 2 1 2 HEX BOLT lve SAE WASHER 12 12 LOCKNUT Figure 11 You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section INSTALLATION KIT Install to Slide In Bumper via Stand off Brackets 1 1 each 2 2 each 3 1 each 4 1 each 5 1 each 2014 Drill jig template 1 4 indexing dowel to secure the drill jig template Hole saw arbor with 1 4 pilot drill 1 1 2 hole saw 1 2 extension drill 12 length 15 USER MANUAL HELP INTERMEDIATE BUMPERS The INTERMEDIATE and SWEPT
72. racket that is not listed above there is not currently an installation kit available For most bracket installations templates and specialized tools are not required Please contact Sportworks Northwest Inc should you have specific questions about your installation We are happy to assist in any way possible Bracket Mounting The Sportworks Bike Rack for Buses system consists of two separate but integrated devices The bike rack is the main piece to this pairing The bracket which secures the rack to the bus is the other piece to this pairing Both contribute to the safe and correct function of the rack The bracket system typically attaches to the existing bumper The brackets are designed to mount to specific parts of the bumper but may also be required to attach to the coach as well Carefully follow all mounting instructions for the type of bumper you are working with Before installing any bumper bracket inspect the front of the coach for the following conditions 1 Is the bumper mounted correctly 2 Are the bumper and the frame of the bus in good repair Check to ensure that they are not bent or twisted from collision or from damage incurred during towing 3 Is the bus free of any other device that will inhibit the function of the bus or the rack 4 If the bumper must be removed to install the rack it is up to the installer to determine if the bumper to bus bolts can be re used Please examine all fasteners carefully a
73. racket using the 40 mm bolts and washers provided see figure 1 Use of thread locking compound is recommended 3 Leave bracket snug but not completely tight until installation of both the street side bracket and Pivot Plate Assembly have been completed 46 2014 USER MANUAL Chevy GMC 4500 5500 OEM STEEL BUMPER BIKE RACK INSTALLATION TO Chevy GMC OEM STEEL BUMPER continued 4 Remove both of the existing STREET SIDE bumper attachment bolts Install the STREET SIDE bracket in the same manner as the curb side using the 40 mm bolts and washers provided see step 2 and figure 1 Use of thread locking compound is recommended 2 Install Pivot Plate Assembly part 100616 to left and right brackets moving brackets as required to achieve proper bolt hole alignment 2 7 Torque Pivot Plate Assembly attachment bolts to 50 60 Ft Lb 65 80 Nm 8 Torque bumper bracket attachment bolts to 65 80 Ft Lb 90 110 Nm You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE RACK at the end of this section 47 2014 USER MANUAL AMERICAN BUS INDUSTRIES ABI BIKE RACK BRACKET INSTALLATION ABI TSV h Attach bottom bracket mounting holes to top Pivot Plate mounting holes at 18 mounting location align square Locate brackets against bumper Use of a stand or adjustable rest is recommended in this step for one person installations Center the brackets still atta
74. re or 2 Re mount the bumper low enough to achieve necessary clearance 2014 USER MANUAL BIKE RACK INSTALLATION TO HELP UNIVERSAL 96 102 BUMPER Follow the installation instructions below to install a Sportworks bike rack to a coach with a Universal 96 or 102 bumper Make sure you are installing the correct bracket on the bus Unlike the 102 C Brackets the 96 C Brackets have welded ear tabs on the ends of the C Bracket arms 1 Orient the pivot plate assembly and C Brackets as shown below and loosely assemble together See Figure 3 This assembly is the mounting bracket UNIVERSAL 96 C BRACKET UNIVERSAL 96 BRACKET N w AS DL QUADRANT SON 4 ye DLe PIVOT PLATE N y oO N N N Q N SN s LNN i R S a ks B Sa NN B DL SUPPORT STRAP BOS Ye A W N ITEM QTY DESCRIPTION eB A o A A 4 3 8 16x1 1 4 HEX BOLT Y AS B 8 378 WASHER A A 4 378 16 LOCKNUT UNIVERSAL 102 C BRACKET UNIVERSAL 102 BRACKET N N w AS DL QUADRANT X x JEA PIVOT PLATE N N N N N N N N N R D Re R kS N O L a IS x5 D LN i Ne ORES SON XS B SSeS ONS B DL2 SUPPORT STRAP IN Ye i Ne ITEM QTY DESCRIPTION eB A Na A A 4 3 8 16x1 1 4 HEX BOLT Y AS B 8 3 8 WASHER A A C 4 3 8 16 LOCKNUT Installation Fig 3 2014 USER MANUAL 2 Identify
75. s Electropolished span 100460 DPLY S S NP DL2 Bike Rack w Deployment Kit Bilingual 100540 DPLY SPAN Decals Electropolished SPAN S S NP DL2 Bike Rack French Decals Electropolished S S NP DL2 Bike Rack w Quick Release Hardware Electropolished S S NP DL2 Bike Rack w Bilingual Decals Electropolished S S NP DL2 Bike Rack w Trolly Deployment Kit Electropolished 100460 Frnch 100540 Frnch 100460 QR 100540 QR 100460 SPAN 100540 SPAN 100460 trdply 100540 trdply S S DL2 NP w 4 loop supports body only 100809 100461 l Electropolished 100512 S S DL2 Bike Rack Stainless Steel Electropolished 100536 S S DL2 Bike Rack Stainless Steel w Deployment Kit Electropolished S S DL2 Bike Rack Stainless Steel w Deployment Kit w Quick Release HW Electropolished S S DL2 Bike Rack Stainless Steel w Quick Release Hardware Electropolished S S DL2 Bike Rack Stainless Steel w Bilingual Decals Electropolished S S DL2 Bike Rack Stainless Steel w Trolle 1005 ta Dee Deployment Kit Electropolished r 100536 TRDELY 100550 S S DL2 w 4 loop supports Van Hool Electro Polish 100805 DL2 Bike Rack SS Recessed Bumper 100638 DPLY Electropolished doly p 100806 DPLY 100512 DPLY 100536 DPLY 100512 dply qr 100536 dply qr 100512 QR 100536 QR 100512 SPAN 100536 SPAN 105 2014 USER MANUAL works Sportworks Northwest Inc 15540 Woodinville Redmond Rd NE Suite A 200 Woodinville WA 98072 Phone
76. s with and holds the support arm grip Each support arm grip pulls out smoothly to the end stop and easily slides back into the stored position and properly self stows on the stow latch when it is released DO NOT LUBRICATE Both pivot bolt assemblies are tight If you see excessive wear or cracks in the bronze oilite bushings you must replace them immediately Some cutaway vehicles tend to cause the bushings to wear more quickly You can replace the originals with our heavy duty pivot bolt kit P N 100839 for longer life All fasteners are tight on the mounting bracket including the hardware for the quadrant pivot plate to bracket pieces and bracket pieces to bumper or coach body The instruction labels on the rack are intact Replace if shredded partially removed non readable or not adhering properly Clean the rack surface thoroughly isopropyl alcohol before replacing 270 2014 USER MANUAL SERVICING In addition to the 30 day general maintenance and service inspections there are more specific service guidelines to follow in maintaining the Sportworks bike rack The guidelines are easy to follow and should be done so every 30 days If there are problems with the bike rack or mounting bracket replace or repair them to proper working order and return them to service Contact Sportworks for parts SERVICING THE VELOPORTER BIKE RACK Service every 30 days 1 D Er 2 2g If the bike rack is not r
77. sary clearance 2014 USER MANUAL C BRACKET METHOD BIKE RACK INSTALLATION TO HELP SLIDE IN BUMPER 1 Using the aluminum bumper back structure as the reference mark the bumper centerline on the top and bottom surface of the aluminum bumper back structure as well as on the front face of the coach The centerline mark on the top of the bumper and on the front face of the coach should mate These two centerline marks will help in re aligning the bumper to the coach later 2 Remove the Slide In bumper from the coach frame by unfastening the bumper to frame bolts 3 Place and firmly hold the provided transfer punch template on the top surface of the bumper back structure with the template centerline aligned with the bumper centerline and the template dowels contacting the TOP REAR edge of the back structure The words BUMPER PUNCH should be visible Transfer punch two holes one on each side of the centerline See Figure 6 ALIGN TEMPLATE CENTERLINE WITH BUMPER CENTELRLINE BUMPER PUNCH TEMPLATE BUMPER BACK STRUCTURE BUMPER URETHANE STRUCTURE Figure 6 4 Mark two holes on the BOTTOM of the bumper back structure using the same procedure of step 3 5 Drill a 1 4 hole through each mark produced in step 3 and 4 drill 4 holes total Next enlarge the 1 4 holes with a 17 32 drill Drill perpendicular to the bumper surface 10 2014 USER MANUAL SLIDE 1N EF KET DL2 PIVOT PLATE sl N wE EM DESCRIPT
78. se handle and handle stem are straight Straighten them if they are bent out of line 2 Examine the wear of the plastic insert in the tip of the latch pin Replace the insert if the latch quadrant is being marred by the latch pin 3 If the latch pin does not properly track on the latch quadrant check that the quadrant is attached tightly and squarely to the pivot plate Replace the quadrant if damaged 4 Examine the components inside of the latch housing a Remove the roll pin attaching the latch stem to the latch pin b After removing the roll pin pull on the release handle to separate the latch stem from the latch pin 80 2014 USER MANUAL 2014 Unscrew the latch capnut and remove the components from inside the latch housing Check the wear on the spring Clean the spring and replace it if it is distorted or not functioning properly Check the snap ring on the latch pin Replace the snap ring if it is cracked broken or warped Remove any dirt and debris from inside the latch housing Re assemble the latch mechanism in the reverse order of steps a c DO NOT LUBRICATE 81 USER MANUAL SERVICING THE SUPPORT ARM Service every 30 days Parts amp Service Fig 5 ITEM PART NAME DESCRIPTION 1 Arm Housing Weldment 2 Washer Nylon Support Arm Housing SS 3 100594 PHCS 6 32 x 5 16 S S NP DL2 and Middle 4 14 20 SS Screw Was
79. sheet for your transit operators Examine the items below before operating your coach If the bike rack does not function properly service it before putting it into operation 1 VBOLTS ARE PRESENT SECURE SUPPORT ARMS TO FRAME 2 PLACES Replace missing bolts 2 STOW LATCH IS PRESENT 2 PLACES Replace if missing These Latches stow the hook arms 3 VSUPPORT ARMS SLIDE IN OUT 2 PLACES Handles move smoothly in out and self stows on latch DO NOT LUBRICATE 4 VLATCH HANDLE WORKS Latch is easy to engage and release 5 VWHEEL STOP IS SECURE Tighten Phillips 5 16 18 screws as necessary 6 BIKE RACK SWINGS FREELY AND LOCKS IN TWO POSITIONS Rack pivots and locks in both the deployed and stowed positions 68 2014 USER MANUAL VELOPORTER MAINTENANCE Fig 2 The V2 and its accompanying brackets require very little service Regular suggested maintenance checks are included below 69 2014 USER MANUAL 30 DAY GENERAL MAINTENANCE INSPECTION amp SERVICE Check every 30 days to insure that 1 2 The rack swings freely and smoothly between the deployed and stowed positions The latch handle easily unlatches and does not stick in the release position The latch handle automatically locks the rack in place when moved to the deployed or stowed positions Each support arm hinge allows the support arm to raise and lower without undue constraint or too much play Each support arm stow latch properly mate
80. th of the cross tube The marks should be spaced 20 apart and should clearly indicate the soon to be attachment point of each GMC bracket piece to the cross tube variations from coach to coach do not allow pre drilled holes to be made in the cross tube Remove the GMC bracket pieces with the pivot plate assembly from the bumper Remove the cross tube from the tow hooks Place and firmly hold or tape the GMC Cross tube Hole Locator Jig on the top surface of the cross tube and transfer punch two marks onto the cross tube at the two felt tip marks The template may be indexed off either edge of the top surface of the cross tube See Figure 22 Drill at the two transfer punch marks made in step 6 from the top surface of the cross tube directly into the bottom surface using a 13 32 drill 26 2014 USER MANUAL GMC CROSS TUBE HOLE LOCATOR JIG CROSS TUBE TOP SURFACE ere IN j XF y eey N fl mi TAN D 7 T z ALIGN INDEXING DOWELS AGAINST EITHER TOP EDGE OF THE CROSS TUBE Installation Fig 22 8 Assemble the cross tube to the tow hooks Assemble the GMC bracket pieces with the attached pivot plate assembly to the coach See Figure 23 The mounting bracket is now installed gt I AGM OIK F gE 5 TOw HOO p qa E E
81. the locations of the four existing bolts on the bumper two on the top and two on the bottom of the bumper which will be used in attaching the mounting bracket to the bumper Remove these four bolts See Figure 4 BOLT HOLE FATTERN ON A BOLT HOLE PATTERN ON Ide UNIVERSAL BUMPER 36 UNIVERSAL BUMPER 4 T USE THESE TWO THERE IS NO BOLT ON ed BOLT HOLES CENTERLINE ON A 102 UNIVERSAL BUMPER we e a E E E e E E BUMPER CENTERLINE BE ae ae C ile UNIVERSAL BUMPER 102 i TOP VIE 26 Installation Fig 4 3 Attach the mounting bracket to the bumper using 1 2 13x3 hex bolts lockwashers and spacers See Figure 5 Ul UNIVERSAL C BRACKET ILE PIVOT PLATE ASSEMELY if E Ge _ t J C y a EXISTING BUMPER CLIF ENGAGED HEX BOLT 4 PLACES es B UNIVERSAL BUMPER Be oF ITEM QTY DESCRIPTION T 4 1 2 13x3 HEX BOLT E 4 1 2 LOCKWASHER F 4 SPACER D Installation Fig 5 4 Tighten all mounting bracket fasteners after correctly seating the mounting bracket on the front bumper The mounting bracket is now installed You are now ready to install the Sportworks bike rack to the mounting bracket Refer to MOUNTING THE BIKE RACK at the end of this section 2014 USER MANUAL HELP SLIDE IN BUMPERS
82. the stand off legs contact the aluminum extruded back structure of the bumper The friction fit of the stand off legs in the bumper holes should hold them in place 6 Orient the pivot holes of the pivot plate UP and OUT and assemble the pivot plate assembly to the two stand offs using 3 8 x 1 1 2 bolts washers and locknuts This assembly is the mounting bracket See Figure 18 2014 USER MANUAL pE RTS STANDOFF BRACKET BS gS C Q 3g C amp g gt B B SOOM DL2 QUADRANT N N a al Ds x Sei N Ae B DLe SUPPORT STRAP Sl SS s ITEM QTY DESCRIPTION eB A A 4 3 8 16x1 1 2 HEX BOLT A B 8 3 8 WASHER A c 4 3 8 16 LOCKNUT Installation Fig 18 7 Using a 1 2 extra long drill and using each stand off as a drill jig drill through the bumper back structure at four locations two locations per stand off by inserting the drill down into each stand off leg Use cutting oil lubricant on the tip of the drill Clear any chips from the drilling operation 23 2014 USER MANUAL RTS BUMPER RTS STAND OFF BRACKET DLe PIVOT PLATE ASSEMBLY TL mI wW fi O C ITEM QTY DESCRIPTIDN 4 172 13xe 1 2 HEX BOLT B 8 172 WASHER 4 172 13 LOCKNUT
83. the two lower 1 4 holes on each side of the bumper 4 holes total The template must not move during this step 13 2014 USER MANUAL 3 Remove the template from the bumper Use a 1 1 2 hole saw with a 1 4 pilot drill to saw four holes just through the front surface of the urethane bumper at the same four locations drilled in step 2 Use care to ensure that the holes are sawn perpendicular to the front bumper surface If you encounter a urethane rib continue to saw through the rib until a pathway to the bumper back structure is produced 4 Insert on each side of the bumper a stand off into the holes sawn in step 3 Orient the five 3 8 holes of the stand offs INBOARD towards the bumper centerline Work each stand off into the 1 1 2 holes until the stand off legs contact the aluminum extruded back structure of the bumper The friction fit of the stand off legs in the bumper holes should hold them in place SLIDE IN STANDOFF BRACKET f s RON DLE SUPPORT STRAF JO ee sah ta pS Y X DESCRIPTION A BOA F w8 lexl 1 e HEX BOLT k a 3 8 WASHER Da A 378 16 LOCKMLIT Figure 10 5 Orient the pivot plate assembly with the pivot holes UP and fasten it to the two stand offs at the middle height adjustment using 3 8 x 1 1 2 bolts washers and locknuts See Figure 10 This assembly is the mounting bracket 6 Using a 1 2 extra long drill and using each stand off as a drill jig drill through the bumpe
84. tion of Change Two additional Travel Stops have been added to the 100616 Pivot Plate 2 100846 Strut Kit has been created to increase rigidity of the installation The Kit mounts to existing chassis plates 3 100839 Heavy Duty Pivot Bolt Kit has been created to address extended bushing life Change Type Compatibility All new Pivot Plates include the additional Travel Stops 98 2014 USER MANUAL Sr Field installation to older Pivot Plates is possible but requires drilling four mounting holes in the Pivot Plate Use Kit P N 100818 All new Chevy 5500 Installations will be required to use the new 100846 Strut Kit Field Installation to older Pivot Plates is possible but requires drilling two mounting holes thru Pivot Plate Wash Guard Changes Effective 2 25 2010 100616 and 100616 dply include travel stops for additional stability New part 100846 is a required part to be ordered with 100616 and 100616 dply to assist with rigidity of installation 100839 Heavy duty bolt kit is recommended to extend bushing life Full pivot plate assembly will now require part numbers 100615 100616 or 100616 dply and 100846 with recommended 100839 Heavy Duty Pivot Bolt Kit Please update your internal Ordering Systems to reflect these new parts and associated pricing Jerry Stewart Vice President Engineering Quality Sportworks NW Inc 2014 99 USER MANUAL sportworks VeloPorter 3 Product Change Notice
85. upport arm assemblies and support arm housing spares upgrading to the all stainless steel anti glare finished version Change Type Compatibility Class B Change New revision is backward compatible and adds increased functionality for future orders Effectivity of Change 1 This change will be effective on all new bike rack assemblies for all deliveries after 1 1 2011 2 Existing spares part numbers for the black powder coated support arm housings will be phased out 6 31 2012 Customers are strongly encouraged to fully migrate to the stainless steel anti glare finish support arm housings prior to the June 2012 date Refer to support arm spares table for the proper part numbers to order Jerry Stewart Vice President Engineering Quality Sportworks NW Inc All stainless steel 2014 support arms 93 USER MANUAL Rack Assembly Part Numbers Affected Part Number Replacement Description Part Number 100352 DL2 Bike Rack Black N A 100352 DPLY DL2 Bike Rack w Deployment Kit Black N A 100352 SPAN DL2 Bike Rack w Bilingual Decals Black N A 100352 SPAN ID DL2 Bike Rack w Bilingual Decals and ID Tag Black N A 100352 SPAN QR DL2 Bike Rack w Bilingual Decals and Quick Release Hardware Black N A 100352 DPLY OR DL2 Bike Rack w Deployment Kit w Quick Release Hardware Black N A 100352 qr DL2 Bike Rack w Quick Release Hardware Black N A 1
86. works 2014 USER MANUAL TRANSIT RACKS This information is owned and distributed by Sportworks Northwest Inc 15540 Woodinville Redmond Road NE Bldg A 200 Woodinville WA 98072 The information provided herein is for use as a compendium to the installation operation and maintenance of the Sportworks Bike Rack for Buses Sportworks specifically prohibits the unauthorized distribution of this information None of the information or knowledge contained herein may be copied or distributed without written consent of Sportworks 2014 Sportworks U S patented and other patents pending 2014 CONTENTS Installation Overview Installation Kits Bracket Mounting HELP Universal Bumpers HELP Slide In Bumpers HELP Intermediate Bumpers RTS Bumpers GMC New Look Bumpers Blue Bird TC CS Stock Bumpers Class Ill Receiver Interface FLXIBLE New Look Bumpers FORD OEM Steel Bumpers Goshen Sentry Steel Bumpers MCI Flip Down Bumper Nova LF Bumper International Navistar Chevy 4500 and 5500 ABI TSV Chance Opus LF Tow Eye Ten Second Bracket Bumper Field Installation Mounting the Bike Rack Torque Specifications Changing the Position of the Rack Displaying the Bike Rack Assembly of Kwikstand Operation of bike rack Bus washing Service and maintenance VP2 Service and maintenance DL2 Service and maintenance Apex 3 Technical information USER MANUAL Page Page Page Page Page Page 16 Page 21 Page 25 Page 28 Page 30 Pag
87. x3 and its accompanying brackets require very little service Regular suggested maintenance checks are included below Side View 87 2014 USER MANUAL 30 DAY GENERAL MAINTENANCE INSPECTION amp SERVICE Check every 30 days to insure that 1 2 The rack swings freely and smoothly between the deployed and stored positions The release latch easily unlatches and does not stick in the release position The release latch automatically locks the rack in place when moved to the deployed or stored positions Each support arm hinge allows the support arm to raise and lower without undue constraint Each support arm magnet properly mates with and holds the support arm Each support arm hook pulls out smoothly easily slides back into the stored position and properly self stows on the magnet when it is released Both pivot bolt assemblies are tight If you see excessive wear or cracks in the bronze oilite bushings you must replace them immediately All fasteners are tight on the mounting bracket including hardware for the quadrant pivot plate to bracket pieces and bracket pieces to bumper or coach body There are two black plastic end plugs inserted into the main frame of the rack located at either end of the lowering tube the tube one grabs to engage the release latch Replace if missing 10 The instruction labels on the rack are intact Replace if shredded partially removed non readable or not adhering properly
88. zontally in the deployed position and locks vertically in the stored position Check that the bike rack has free motion Refer to the Installation Overview section of this chapter on page 2 to confirm the proper installation height of the Sportworks bike rack 56 2014 USER MANUAL Mounting the Apex3 Apex 3 Installation Instructions Note Standoffs can shift during service because of impacts When installing the Apex pivot plate on pre installed standoffs it may be necessary to loosen the standoffs from the back bumper structure in order to align them to the 14 and 18 hole pattern Bolt the pivot plate to standoffs and tighten standoff bolts 1 Install pivot plate using supplied hardware 73 74 and 14 or 18 hole pattern 2 Install pivot tab bushings 66 in rack with flanges inside 3 Place rack on pivot plate in stowed up position The pivot plate will support the rack while you insert the fasteners 4 Insert the supplied fasteners 79 67 67 68 5 Insert the supplied fasteners and torsion spring 78 67 80 76 67 68 The bent end of the torsion spring hooks into the pivot plate and the large end of the torsion spring mount 76 should be toward the nut 6 Torque 1 2 13 bolts to 75 ft Ibs 57 2014 USER MANUAL General Torque Specs Most of our brackets are attached to the bus bumper using Grade 8 12 13 HHCS Our standard pivot plates are attached to the brackets using Grade 8 3 3 16 HHCS Th

2014 USER MANUAL TRANSIT RACKS

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