II. FOLDOVER 1:6 RAMP INSTALLATION WARNING!
Contents
1. TABLE OF CONTENTS DECEMBER 2009 ER6 SERIES 1 6 SERVICE MANUAL INSTALLATION Il FOLDOVER 1 6 RAMP INSTALLATION A INSTALLATION GUIDELINES Careful installation of the Ricon FoldOver 1 6 ramp contributes to proper and safe operation Use the electrical wiring diagrams in Figures 3 5 1 and 3 5 2 to supplement this section 1 LOCATING MOUNTING BRACKETS ON BUS FRAME Use a rigid fixture that substitutes for the ramp assembly when positioning ramp mounting brackets on bus frame If the ramp assembly is used to position mounting brackets verify that it is correctly located relative to the vehicle floor etc Accurate positioning of brackets prevents twisting or warping of ramp frame when installing and tightening mounting hardware A warped frame may cause the ramp motion to be erratic Set height of ramp flooring surface flush to surrounding floor structure to prevent a tripping hazard 2 INSTALLING 1 6 RAMP IN FLOOR The location of the ramp depends on its path of motion The ramp must be positioned so it can move un obstructed through its required range of travel a rim away floor material to allow ramp assembly to drop into floor opening NOTE Do Not install ramp trim flange kit until ramp is installed in bus The ramp trim overlaps the perimeter gap between the sides of the enclosure and bus structure The typical gap between the sides of the enclosure and the bus structure is 1 82. WITHOUT LH amp RH TRIM GUPO NOTES DIMENSIONS IN INCHES MILLLIMETERS IN PARENTHESES REFERENCE MOUNTING BRACKET KIT P N 43936 OR 44754 PER SPECIFIED APPLICATION RSM0021500 FIGURE 2 2 RAMP INSTALLATION 2 2 m D Ricon ms 32DERG02 B A Wabtec company DECEMBER 2009 ER6 SEHRIES 1 6 SERVICE MANUAL INSTALLATION NOTE Refer to Figure 2 2 Ramp should sit securely and level on bus structure If ramp does not sit level on bus structure install appropriate shim spacers accordingly N CAUTION FOLLOW SEQUENCE FOR SECURING RAMP ONTO BUS STRUCTURE DEVIATION FROM THE INSTALLATION SEQUENCE CAN CAUSE RAMP WARPAGE e Refer to Figure 2 2 Install and tighten two 2 front bolts f Refer to Figure 2 2 Install and tighten three 3 rear mounting bracket bolts NOTE Mounting bracket kit is pre installed at the factory and is configured according to bus manufacturer Refer to mounting bracket kit i e Gillig Kit P N 43936 Orion Kit P N 44754 part number for vehicle in stallation g Inspect middle hardware installation If space is present between the ramp frame and bus structure in stall appropriate shim spacer then install and tighten two 2 middle bolts h Referto Figure 2 3 Install left and right trim pieces with attaching hardware provided SCREWS X14 TRIM LH MM RSM0021400 FIGURE 2 3 RAMP TRIM INSTALLATION 3 IN
3. a Verify that the ramp is completely stowed This establishes a reference position for ramp during target adjustment NOTE Use a straightedge as an artificial target to simulate ramp tray barrier when fully stowed b Refer to Figure 2 23 Loosen jam nuts on sensor body Adjust position of both nuts to achieve a gap between nose of sensor and outside diameter of target that is 060 030 gap is set on inside of ramp tray barrier Do not allow sensor to contact target Tighten jam nuts and recheck gap 32DE R602 B D Ricon 2 9 A Wabtec company INSTALLATION EHRO6 SEHRIES 1 6 SERVICE MANUAL DECEMBER 2009 SENSOR GAP 0 06 0 03 E d ad FIGURE 2 23 SENSOR GAP ADJUSTMENT RIGHT SIDE VIEW 5 FINAL INSPECTION a Visually inspect ramp for loose or missing hardware and fittings and confirm that pockets are free of debris Verify that slanted plated cover is secure and closed on ramp c Verify that non skid flooring is clean functional and securely fastened d Verify that manual operation strap is undamaged BACK TO TOP PRINT CHAPTER NEXT CHAPTER Ricon 32DER602 B A Wabtec company 2 1
4. STALLING VEHICLE WIRING HARNESS Route wiring harness from vehicle ramp controls to rear of ramp Use the supplied electrical installation kit Ricon P N 44204 to connect vehicle control wiring to the ramp interface connector Ricon P N 4391 1 oee Table 2 1 for pin layout and signal descriptions a Disconnect vehicle battery Be sure that harness does not interfere with any moving parts or binds against any parts or is pinched in any way 32D E R602 B D Ricon 2 3 A Wabtec company INSTALLATION ER6 SERIES 1 6 SERVICE MANUAL DECEMBER 2009 Install Main Circuit Breaker Kit P N 36267 Avoid installing near a heat source Refer to Chapter 3 6 Electrical Diagrams and Figures 3 5 1 3 5 2 Route and install black ground cable P N 43929 to ground connection and red power cable P N 43928 to positive connection block Route and install ramp interface harness supplied by bus manufacturer to ramp interface connection Pin Wire color Description _ Vots 1 Re PMV HV High Voltage P24V 6 Yelow HV High Voltage P24V e Cycle ramp a few times to ensure ramp is working properly B FOLDOVER 1 6 RAMP ADJUSTMENTS 1 CHAIN SPRING ASSEMBLY INSTALLATION AND ADJUSTMENT FOR MOTOR DRIVE SYSTEM Removal and installation of the chain spring assembly may be necessary Unequal tension on the springs may c
5. ause different torques on ramp tray sprockets and will possibly cause ramp tray asymmetry error a Refer to Figure 2 4 Install motor drive assembly into enclosure before installing chain spring assem bly NOTE Do not completely tighten bolts for motor drive system to allow some movement when installing chain spring assembly Bolts will be tightened after chain spring assembly is installed FIGURE 2 4 INSTALLED MOTOR DRIVE ASSEMBLY Refer to Figure 2 5 and 2 6 Install left hand and right hand chain guides C Ricon M 32DER602 B A Wabtec company DECEMBER 2009 _ EHR6 SEHIES 1 6 SERVICE MANUAL INSTALLATION p FRONT CHAIN GUIDE REAR CHAIN GUIDE G me NS FIGURE 2 5 and 2 6 FRONT AND REAR CHAIN GUIDES LH SIDE SHOWN c Refer to Figure 2 7 and 2 8 Install pre assembled chain spring assembly by routing onto small sprocket NOTE Pull chain spring assembly until spring is flush against spring supports wey FIGURE 2 7 2 8 ROUTE CHAIN SPRING LH SIDE SHOWN d Refer to Figure 2 9 and 2 10 Install spacer onto drive shaft then install self aligning bearing e Install two washers and two bolts then tighten 27 SPACER SELF ALIGNING BEARING FIGURE 2 9 and 2 10 ROUTE CHAIN SPRING LH SIDE SHOWN f Refer to Figure 2 11 Install Chain Spring Assembly by pushing spring rod DOWN and INWARD into enclosure until Chain Spring Assembly is install
6. ed against the two spring supports in enclosure NOTE Ensure that Chain Spring Assembly is securely installed against spring supports 32DE R602 B D Ricon 2 5 A Wabtec company INSTALLATION ER6 SERIES 1 6 SERVICE MANUAL DECEMBER 2009 aes PUSH DOWN Es FAW yi SPRING SUPPORT FIGURE 2 11 SPRING ASSEMBLY LH SIDE SHOWN g Refer to Figure 2 12 and 2 13 Locate and mark an alignment mark on sprocket for reference to main tain sprocket hole at 5 inboard NOTE Ensure that spring is securely installed against spring supports l REFERENCE MARK FIGURE 2 12 and 2 13 LARGE SPROCKET ALIGNMENT LH SIDE SHOWN h Referto Figure 2 13 Ensure that sprocket maintains 5 inboard reference i Wrap chain around sprocket then install onto enclosure j Tighten pivot screw but leave a little slack on chain k Referto Figure 2 14 Insert turnbuckle into rod Do not completely tighten Install Front Chain Cover with screw TURNBUCKLE FIGURE 2 14 SPROCKET AND TURNBUCKLE ADJUSTMENT LH SIDE SHOWN 2 6 Hicon M 32DER602 B A Wabtec company DECEMBER 2009 EHR6 SERIES 1 6 SERVICE MANUAL INSTALLATION m Referto Figure 2 15 Tighten bolts to secure drive module TIGHTEN BOLTS FIGURE 2 15 MOTOR DRIVE SYSTEM BOLTS LH SIDE SHOWN n Refer to Figure 2 14 T
7. ighten turnbuckle to adjust stiffness on chain spring assembly NOTE Turn CCW counter clockwise to tighten Ensure a little slack on chain SLACK IN CHAIN Ka 22AD 22 3 5 W wv dae ACE EOM L a Tw FIGURE 2 16 SLACK ON CHAIN LH SIDE SHOWN 2 COUPLER ADJUSTMENT As noted in the Chain Spring Assembly Installation unequal tension on the springs may cause different tor ques on ramp tray sprockets and will possibly cause ramp tray asymmetry error The adjustable coupler will allow for adjustment and alignment of chain sprocket a Refer to Figure 2 17 Loosen three bolts and nuts of the adjustable coupler 32DER602 B Ric on 2 7 A Wabtec company INSTALLATION EHRO6 SEHRIES 1 6 SERVICE MANUAL DECEMBER 2009 FIGURE 2 17 ADJUSTABLE COUPLER NOTE Do not completely remove bolts and nuts Only loosen enough to be able to adjust coupler Nuts will need to be torque adjusted before completing procedure b Adjust Chain Sprocket to align and balance chain tension Settorque wrench to 143 inch lbs NOTE Ensure the torque wrench is calibrated before each use d Refer to Figure 2 18 Torque each of three coupler nuts to 143 inch lbs 6 E ae Pp a 7 FIGURE 2 18 Torque Each Nut FIGURE 2 19 Torque Value NOTE Secure bo
8. inch Use shims to fill gap EYE BOLTS LEFT I EYE BOLTS RSM0021300 FIGURE 2 1 RAMP LIFTING EYE BOLTS TAKE EXTREME CARE WHEN POSITIONING RAMP INTO BUS BE SURE TO FOLLOW PROPER OPERATION AND SAFETY INSTRUCTIONS WHEN USING LIFTING DEVICE b Refer to Figure 2 1 Attach lifting device hooks to pre installed eye bolts c Use lifting device to place ramp into bus 32DER602 8 D Ricon 2 1 A Wabtec company INSTALLATION 6 1 6 SERVICE MANUAL DECEMBER 2009 d Lower ramp onto bus floor Ensure that rear ramp flange rests on bus floor MOUNTING BRACKET BOLTS X3 BUS STRUCTURE SHIM SPACER BUS STRUCTURE SUPPLIED BY BUS MANUFACTURER REAR RAMP FLANGE FRONT REAR SC RENS Z Ny fa AL Ot MD EE E I aa 3 BUS FLOOR SURFACE FRONT BOLTS X2 MIDDLE BOLTS X2 SUPPLIED BY BUS SUPPLIED BY BUS FACTORY INSTALLED MANUFACTURER MANUFACTURER MOUNTING BRACKET 8 29 17 13 21 90 WIT BEOCK 211 435 556 51 66 nn 1312 RIGHT SIDE VIEW 14840 40 1 4 MAX 1280 1 8 MIN 7 12 00 E 09 21 25 24 00 33 76 540 Y 610 858 J I e 2 1 8 MIN Aas TOP VIEW BUS FLOOR BUS FLOOR SHOWN
9. lt with a box end wrench to prevent bolt from rotating while torque is applied e Usea black fine point marker and write torque value near each of three nuts that have been torque as shown in Figure 2 19 3 RAMP TRAY ADJUSTMENT Removal and installation of the chain spring assembly must be completed without the presence of the ramp tray Re installation of the ramp tray must be installed as follows a Refer to Figure 2 20 Mark alignment holes of ramp tray to sprocket 2 8 Hicon M 32DER602 B A Wabtec company DECEMBER 2009 EHR6 SEHIES 1 6 SERVICE MANUAL INSTALLATION FIGURE 2 20 RAMP TRAY ALIGNMENT FIGURE 2 21 RAMP TRAY INSTALLATION NOTE Hole closest to inner edge of ramp must attach to hole of sprocket closest to outer edge of enclo sure b Refer to Figure 2 21 Attach ramp tray and install screw through aligned holes c Refer to Figure 2 22 Position ramp tray in vertical position NOTE Ramp tray should be installed 5 outboard OUTBOARD FIGURE 2 22 RAMP TRAY INSTALLATION d When ramp tray is correctly positioned 5 outboard install screws through ramp tray and in through large sprocket e Ensure that spring is relaxed and that spring is flush against both spring supports f Tighten five screws to securely fasten ramp to enclosure 4 SENSOR TARGET ADJUSTMENT FOR POSITION AND GAP
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