Braun FMVSS NO. 403 User Manual

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Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Braun Corporation FMVSS No. 403

Quick Reference Installation Sheet 31312

“DOT — Private Use Lift”

NHTSA Vehicle Physical Requirements

OEM (Van) Chassis Floor Requirements

Nonmodied OEM full size van oors meet all requirements for NV05. Nonmodied OEM mini van oors meet all requirements for NMV05.

Door Opening Dimensions

Vehicle lift access door opening must meet specied dimensions.

Vehi cle

Door

Opening

Lowered (Drop) Floor Requirements

Must meet or exceed nonmodied OEM oor section.

“1992” and Newer Ford Slide Door

1. Remove the lower slide door stop.

2. With Power Door: Door stop not used.

Without Power Door: Drill (2) holes in the lower door stop at dimensions shown in Figure B.

3. Replace door stop, locating on the

(2) drilled holes (provides adequate clearance).

2-3/4"1-7/16"

Rev: A

Position Lift

Place lift in approximate position. Note: Hoist or other lifting device is recommended.

Position wedge plate(s) to achieve a 1/2" pre- load at right inboard corner of platform. See Figures C and D.

Clearances

Minimum 1" clearance

between lift and vehicle. See Figure E.

Maximum 1/2" between inboard locator and oor when locator is deployed. See Figure E.

Minimum 3/4" clearance between door and vertical arm. See Figures F and G.

Frame

Tube

Wedge

Plate

edge

Plate

Figure C

Figure D

Position wedges as needed for 1/2" preload.

Inboard Locator

Minimum 1" Clearance

Stepwell

Figure E

Maximum

1/2"

Floor

1/2"

Figure A

Dimension

Minimum Clear Door

Opening Height

Clear Door Opening

Width

Maximum

Floor-to-Ground

Minivan

42"

31-1/2"

29"

Ground Level

Full Size

Van

48"

39-1/2"

29"

Drill (2) 5/16" diameter holes.

Figure B

Figure F

Slide Door

Minimum 3/4"

Wall

Clearance

Floor

(ALIGNED) PARALLEL (ALIGNED)

Wall

Rear Swing Door

Figure G

Floor

(ALIGNED) PARALLEL (ALIGNED)

Minimum 3/4"

Clearance

Wall

Front Swing Door

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Secure Lift

1. Temporarily secure base plate by installing sheet metal screws in base plate slots.

2. Secure vertical mounting brace and upper mounting bracket to frame tube. See Figure I.

3. Temporarily assemble upper adjustment bracket and upper mounting channel. See Figure K. Position assembly and mark mounting holes on van wall (C pillar).

Carefully drill 5/16" diameter wall mounting holes. Secure upper mounting channel to wall (C pillar) using expanding Fab-Lock bolts (minimum 2). See Figure J.

4. Secure upper adjustment bracket and upper mounting channel assembly to vertical mounting brace.

5. Carefully operate lift through all functions checking for clearances (specied in Figures D-I). Adjust lift position and/or upper mounting hardware as needed.

6. Drill 3/8" diameter holes through oor using the corner holes in the base plate as a template. Refer to Figure H. Insert 3/8"-16 hex bolts and secure below oor as specied in Figure H (bolt lengths as required per application).

Tighten all mounting hardware securely. All fasteners must meet

FMVSS 571.403 Section 6.3.

7. Cut upper adjustment bracket off ush with mounting brace and install foam padded cover using cable ties. Note: Cover power unit before cutting bracket.

8. Position and secure docking bumper. See Figure L.

9. Position and secure warning sensor mat as specied in Figure M. Connect wiring harness to lift as shown in Figure P.

Position wedges as needed.

All Positions

3/8-16 x 3"

Mounting

5/16-18 x 3/4"

Flat Head

Screw

5/16"

Flat

Washe r

5/16"

Hex Nut

Plate

Hardware

Typical

Hex Bolt

Vertical

Brace

Upper

Mounting

Bracket

Washer

Frame

Tube

Wedge

5/16" Lock

• One in each corner.

• Lengths as required

Floor

Adjustment

Bracket

5/16" Flat

Washe r

ecarB

gn i

t nu

oM la

itre

Figure H

3/8-16 Hex Bolt

(Minimum 4)

per application.

5/16" Flat Washer

3/8" Body Washer

3/8" Lock Washer

3/8-16 Hex Nut

Upper

3/8" Lock

Washe r

3/8" Hex

Figure I

Nut

Frame

Tube

5/16" Lock

Washe r

5/16" Flat

Washe r

Fab-Lock Bolt Installation

1. Remove rubber washer and install 1/4" at washers.

5/8" Wrench

3. Place a 5/8" wrench onto bolt head and secure tightly

Hardware

typical

opposite side

5/16-18 x 7/8"

Button Head

Cap Screw

1/4" Flat Washers

Fab-Lock Bolt

5/16" Socket

Ratchet Wrench

Upper

Adjustment

Bracket

Vertical

Mounting

Brace

Note: Cut bracket off ush with mounting brace and install foam padded cover using cable ties.

Upper

Mounting

Channel

Adjustment

Bracket

2. Insert Fab-Lock bolts (minimum

2) fully through mounting channel and C pillar.

4. Place a 5/16" socket onto the inner screw and tighten (turn clockwise).

5. Turn socket until Fab-Lock has expanded against metal surface.

3/8-16 Slide Nut

Fab-Lock Bolt

3/8-16 x 1"

Hex Cap Screw

Lock Washer

(Qty: 2)

Wall (C Pillar)

Upper

Vertical

Mounting

Brace

Figure J

Upper

Mounting

Channel

with

Figure K

3/8-16 x 3"

Hex Bolt

with Lock Washer and Hex Nut

Figure L

Docking Bumper

3/8-16 x 2"

Hex Bolt

(Qty: 2)

Stepwell

Docking Bumper

Edge of Finished Floor

Note: Threshold warning

mat must be installed on a at, rigid surface.

Outer Pivot

Docking Bumper

Platform

Trim

Floor

5/16" Flat Washer 3/8" Lock Washer 3/8-16 Hex Nut

Threshold Warning

Figure M

#10-16 x 1-1/2"

Wafer Head Phillips

Self-Drilling Screw

(Qty: 4)

Min.

18"

Threshold

Warning

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Grommet

Ground

Cable

9/32" Diameter

Pilot Hole

Attach Power and Ground Cable

Figure N

Frame

ube

1. Drill 1-1/8” diameter grom-

met access hole. Check

under the vehicle for obstructions.

2. Insert grommet. Secure grommet with two self-tap screws.

Power Cable

3. Route ground and power cables through grommet.

Route cables clear of exhaust, other hot areas and moving parts.

4. Connect ground cable to vehicle framing member (see detail below).

5. Attach power cable to Auxiliary terminal of Circuit Sentry. Attach one end of 18" lead cable to the Battery Circuit Sentry terminal.

Lead

Cable

Pos.

Neg.

Circuit

Sentry

Bat.

Aux.

1/8" x 4" x 4"

Plastic

Locate Circuit Sentry within 12" of positive (+) battery terminal. Mount Circuit Sentry with four self-tap screws. Sandwich 1/8" x 4" x 4" plastic between Circuit Sentry and mounting surface.

6. Carefully connect opposite end of lead cable to Posi-

tive (+) post of battery.

12"

Max.

Connect Interlock

Vehicle and Lift Interlock

A 2-circuit lift/vehicle interlock interface harness is provided inside the tower cover. The Grey/Red wire is connected to the battery power stud. A butt connector is provided on the Yellow/Light Blue wire.

To meet minimum NHTSA requirements, connect vehicle interlock signal wires as detailed in Figure P (Steps 1-4):

BARRIER

LIFT

Door

Barrier

Limit

Down

Limit

Limit Fold

Floor

Limit

Limit Stow

Unfold

Limit

Deploy

Threshold

Limit

Sensor

W16

Optional Interlock Kits

Universal Interlock Kit 30940K is available for easy interface with vehicle OEM electronic signals.

Note: Detailed installation instructions are supplied with interlock kit(s).

INTERLOCK

100024-

REV

Y/LT. BU

GY/R

RNING

Install and verify proper operation of all NHTSA mandated interlocks as specied. Failure to do so will result in a non-compliant installation and may result in serious bodily injury and/or property damage.

Figure P

Chassis

5/16"

External Tooth

Star Washer

Figure O

Ground Cable Mounting

Thread Cutting

Screw

Ground Cable

Lift mounted ground cable ground cable must be mounted to a vehicle framing member to provide optimum ground.

Ground Cable Corrosion: When mounting ground cables, remove undercoating, dirt, rust, etc. from framing member around mounting holes (minimum 5/8” diameter area). Apply protective coating to mounting holes to prevent corrosion. Failure to do

so will void warranty of certain electrical components.

Door Cut-Out Switch Harness

Disconnect and discard.

Threshold Warning Sensor Harness

Connect vehicle

Cut

wire.

Install butt

connector.

interlock signal wires.

(Lift Stowed Signal)

LT. BU

GY/R

ehicle Secure Signal)

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Limit Switch Adjustment

Floor Level Cam Adjustment:

The oor level cam(s) are located on the lower drive arm shaft, on the rear side of the frame tube (under the cover). Adjust per application.

• Stepwell Application (Figure Q)

1. Position platform at oor level.

2. Loosen the two cam screws.

3. Adjust the cam for proper switch activation.

4. Tighten the two cam screws.

• Dropped Floor Application (Figure R)

• Up-Stop Adjustment (inner cam and switch):

1. Position platform at original oor height (full up position).

2. Loosen screws A, B and C.

3. Adjust the inner cam for proper switch activation.

4. Tighten screw B.

• Floor Level Adjustment (outer cam and

switch):

Activated when the platform switches from the up/down positions to the stow/deploy positions.

1. Position platform at lowered oor level.

2. Loosen screws A and C.

3. Adjust the outer cam until the oor level switch activates.

4. Tighten screws A and C.

Deploy Limit Switch Adjustment (Figure S)

This switch adjusts the angle of the platform when positioned at oor level. The platform should be level with the van oor. The switch is located on the vertical arm where the switch arm pivots.

1. Position platform at oor level.

2. Loosen the screw that secures the cam to the vertical arm.

3. Level platform using a level (or as needed).

4. Adjust cam so the deploy limit switch activates.

5. Tighten screw.

6. Verify position and check level.

Stepwell Application

Figure Q

Screws

Dropped Floor Application

Figure R

Deploy Limit Switch

Figure S

Switch

Arm

Vertical

Arm

Deploy Limit Switch

FMVSS 403/404 Certiﬁcation Checklist

Audible

Threshold

Inboard Locator

Warning

Threshold

Warning Sensor

DOT — Private Use Lift

The operations listed below must be func-

Cam

Switch

Outer

Cam

Inner

Cam

Switch

Screw

Cam

tionally veried.

Switch Arm

Platform

Outer Barrier

Vehicle movement is prevented unless the lift door is closed, ensuring the lift is stowed.

Lift operation shall be prevented unless the vehicle is stopped and vehicle movement is prevented.

The platform will not fold/stow if occupied.

The inboard locator will not raise if occupied.

The outer barrier will not raise if occupied.

An audible warning will activate if the threshold area is occupied when the platform is at least one inch below oor level.

Lowering the platform beyond the inboard locator locking position is allowed only when the inboard locator is locked in position.

Lift platform movement shall be interrupted unless the outer barrier is deployed.

31312 Rev. A

Lift Operating Instructions

RNING

Whenever a passenger is on the platform, the:

• Passenger must face outward

• Wheelchair brakes must be locked

• Inboard locator and outer barrier must be UP.

Failure to do so may result in serious bodily injury and/or property damage.

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

TO UNLOAD PASSENGER:

Before lift operation, park the

vehicle on a level surface, away from vehicular trafc. Place the vehicle transmission in “Park” and engage the parking brake.

Photos appearing in the Lift Operating Instructions depict lift functions being activated by liftmounted control switches only.

Lift-posted Warnings and Lift Operating Instructions decal 31185 provides lift operating instructions. Replace any missing, worn or illegible decals.

Follow the Manual Operating Instructions in event of power or equipment failure. Do not use electrical override to operate the lift when a passenger is on the platform.

LEVEL Switch

1. Load passenger onto platform

facing outward and lock wheelchair brakes.

Note: Outer barrier must be UP

before loading passenger onto platform.

2. If necessary, press the switch arm LEVEL switch until platform is level.

DOWN Switch

TO OPEN DOOR(S):

Power Door Operator(s):

Press the DEPLOY switch until door(s) are fully open. Release switch.

Manual Door(s):

Manually open door(s) fully and secure.

TO DEPLOY PLATFORM:

1. Press DEPLOY switch until platform sections open (rotate) to full width. See Photos D and E. Release switch.

2. Press DEPLOY switch until platform until platform stops (reaches oor level) and the inboard locator unfolds. See Photos C and F. Release switch.

M N

3. Press DOWN switch until the

entire platform reaches ground level and outer barrier unfolds fully. Release switch. See Photo K.

TO UNLOAD PASSENGER:

4. Unlock wheelchair brakes and unload passenger from platform.

Note: Outer barrier must be fully unfolded until entire wheel-

chair has crossed the barrier. See Photos M and N.

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Lift Operating Instructions

TO LOAD PASSENGER:

1. Load passenger onto platform facing outward and lock wheelchair brakes. See Photos Q and R.

Inboard Locator

(unfolded)

5. Unlock wheelchair brakes and unload passenger from platform.

Switch

Note: Outer barrier must be fully unfolded until entire wheelchair

has crossed the barrier. See Photos O and P.

2. Press UP switch until platform raises just above ground level. Release switch.

3. If necessary, press the switch arm LEVEL switch until platform is level.

4. Press UP switch until platform stops (reaches oor level) and inboard locator unfolds (see Photo W). Release switch.

LEVEL Switch

TO STOW PLATFORM:

1. Press STOW switch until platform stops (fully stowed - vertical). Release switch.

2. Press STOW switch (Photo Y) until platform sections close (rotate) to locked position. See Photos AA-CC.

TO CLOSE DOOR(S):

Power Door Operator(s):

Press the STOW switch until door(s) are fully closed. Release switch.

Manual Door(s):

Manually close door(s) fully.

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Manual Operating Instructions

RNING

Do not use electrical override to operate lift when a passenger is on the platform. Doing so may result in serious bodily injury and/or property damage.

PLATFORM LATCH

Locked

Unlocked

Figure A Figure B Figure C Figure D

TO OPEN DOOR(S):

Manually open door(s) fully and secure.

TO DEPLOY PLATFORM:

1. Unlock (disengage) latch under middle platform section. See Figure A.

2. Manually open (rotate) the three platform sections to full width.

3. Engage latch under middle platform section to lock platform sections at full width. See Figure A.

4. Remove cap from top of vertical arm actuator. See Figure C.

5. Place crank handle on actuator shaft and turn counterclockwise until platform reaches oor level. See Figure C. Remove crank handle.

If you experience power or equipment failure, refer to the Manual Operating Instructions to operate the lift. Do not use electrical override to operate lift when a passenger is on the platform.

Refer to the Lift Operating Instructions for all normal lift operation procedures (such as loading and unloading passengers). Follow all Lift Operation

Safety Precautions!

INBOARD LOCATOR

Hairpin

Inboard Locator

Link

TO DEPLOY INBOARD LOCATOR:

1. Remove hairpin cotter from inboard locator link pin. See Figure B.

2. Remove link from inboard locator pin. See Figure B.

3. Lower (unfold) inboard locator to vehicle oor.

TO STOW INBOARD LOCATOR:

1. Raise (fold) inboard locator to vertical position.

2. Place link on inboard locator pin. See Figure B.

3. Insert hairpin cotter into inboard locator link pin. See Figure B.

TO LOWER PLATFORM:

1. Remove plug from top of motor cover. See Figure D.

2. Place crank handle on motor shaft and turn clockwise until platform reaches ground level. See Figure D. Remove crank handle.

ACTUATOR

Stow

Hand Crank Note:

For easier operation of the hand crank, press and hold the electrical override MANUAL/BRAKE RELEASE switch in the MANUAL position while turning crank.

Note: If turning crank is difcult, reset (press) manual reset circuit breaker and try again (see photo below).

Cap

Deploy

Down

TO RAISE PLATFORM:

1. Remove plug from top of motor cover. See Figure D.

2. Place crank handle on motor shaft and turn counterclockwise until platform reaches oor level. See Figure D. Remove crank handle.

TO STOW PLATFORM:

1. Remove cap from top of vertical arm actuator. See Figure C.

2. Place crank handle on actuator shaft and turn clockwise until platform stops (reaches full vertical position). See Figure C. Remove crank handle.

3. Unlock (disengage) latch under middle platform section. See Figure A.

4. Manually close (rotate) the three platform sections

5. Engage latch under middle platform section to lock platform sections. See Figure A.

TO CLOSE DOOR(S):

Manually close door(s).

MOTOR

Plug

Electrical Override Instructions

The Electrical Override feature is provided as a diagnostic procedure to reset the system and as an alternative method of operating the lift without a

RNING

• Do not use electrical override to operate lift when a passenger is on the platform.

• Override switches must be released to stop lift at desired position.

Failure to follow these rules may result in serious bodily injury and/or property damage.

TO OPEN DOOR(S):

Manually open door(s) fully and secure.

TO DEPLOY PLATFORM:

1. Unlock (disengage) latch under middle platform section. See Figure A.

2. Manually open (rotate) the three platform sections to full width (unfolded).

3. Engage latch under middle platform section to lock platform sections at full width. See Figure A.

4. Rotate the access cover to expose the override switches. See above photo.

5. Press the two override rocker switches to OVERRIDE.

6. Press the left toggle switch to DEPLOY until platform reaches oor level. Release switch.

7. Press the right toggle switch to DOWN until platform reaches ground level. Release switch.

8. To deploy (unfold) the outer barrier, press the left toggle switch to DEPLOY until barrier unfolds fully. Release switch.

passenger only. Do not use the electrical override to operate the lift when a passenger is on the platform. Lift functions operate at higher rate of speed when using the electrical override. When using the electrical override, the operator must stop pressing the applicable override switch when the lift reaches the desired position (limit switches

Locked

Unlocked

Figure A

TO OPEN DOOR(S):

Manually open door(s) fully and secure.

TO STOW PLATFORM:

1. Rotate the access cover to expose the override switches. See above photo.

2. Press the two override rocker switches to OVERRIDE.

3. To raise (fold) the outer barrier to vertical position, press the left toggle switch to STOW until barrier folds fully. Release switch.

4. Press the right toggle switch to UP until platform reaches oor level. Release switch.

5. Press the left toggle switch to STOW until platform reaches vertical position. Release switch.

6. Unlock (disengage) latch under middle platform section. See Figure A.

7. Manually close (rotate) the three platform sections to closed position (folded).

8. Engage latch under middle platform section to lock platform sections. See Figure A.

will not function).

Note: Following electrical override procedures, press the two override rocker switches to NORMAL. Close access cover and press the main control switch to STOW. Function lift through one full cycle to ensure proper operation.

Electrical Override Switches

Manual Reset Circuit Breaker

Braun Corporation FMVSS No. 403 Quick Reference Installation Sheet 31312 Rev. A

Maintenance and Lubrication

Proper maintenance is necessary to ensure safe, troublefree operation. Inspecting the lift for any wear, damage or other abnormal conditions should be a part of your daily routine. Simple inspections can detect potential problems.

The maintenance and lubrication procedures specied in this schedule must be performed by a Braun authorized service representative at the scheduled intervals according to the number of cycles. NHTSA NV05/NMV05 Series lifts are equipped with 2 cycle counters (1 display built into the control board and 1 located in the cover).

The NV05/NMV05 is equipped with hardened pins and self-lubricating bushings to decrease wear, provide smooth operation and extend the service life of the lift.

When servicing the lift at the recommended intervals, inspection and lubrication procedures specied in the previous sections should be repeated.

Clean the components and the surrounding area before applying lubricants. LPS2 General

Purpose Penetrating Oil is recommended where Light Oil is called out. Use of improper lubricants can attract dirt or other contaminants which could result in wear or damage to the components. Platform components exposed to contaminants when lowered to the ground may require extra attention.

Lift components requiring grease are lubricated

Main Drive Ballscrew

(in Frame Tube - hidden)

during assembly procedures. When these components are replaced, grease must be applied during installation procedures. Specied lubricants are available from The Braun Corporation (part numbers provided below).

All listed inspec-

tion, lubrication and maintenance procedures should be repeated at “750 cycle” intervals following the scheduled “4500 Cycles” maintenance. These intervals are a general guideline for scheduling maintenance procedures and will vary according to lift use and conditions. Lifts exposed to severe conditions (weather, environment, contamination, heavy usage, etc.) may require inspection and maintenance procedures to be performed more often than specied.

Discontinue lift use immediately if maintenance and lubrication procedures are not properly performed, or if there is any sign of wear, damage or improper operation. Contact your sales representative or call The Braun Corporation at 1-800-THE LIFT One of our national Product Support representatives will direct you to an authorized service technician who will inspect your lift.

RNING

Maintenance and lubrication procedures must be performed as specied by an authorized service technician. Failure to do so may result in serious bodily injury and/or property damage.

Lubricant Type Lubricant Amount Part No.

LO - Light Oil

DE - Door-Ease

LG - Light Grease

OS - Oil Stabilizer

Downstop pivot points (2)

Upper lift rod pin

Lower lift rod pin

750

Cycles

1500

Cycles

Kickout spring (located in switch arm)

Platform hinges (6)

Outboard barrier latch

Perform all procedures listed in previous section also

Inboard locator latch mechanism

Check mounting hardware

Check all fasteners (snap rings, nuts, hairpins, etc.)

Check all pivot points for excessive wear

Specied (recommended) Available Braun

Light Penetrating Oil LPS2, General Purpose 11 oz. (30 weight or equivalent) Penetrating Oil Aerosol Can

Stainless Stick Door-Ease 1.68 oz.

Light Grease Lubriplate 14 oz.

)ebut( kcitS )ebut( elytS

naC )esoprupitluM(

.tq 1 ytuD yvaeH sacuL liO

reniatnoC rezilibatS liO rezilibatS

Apply Light Grease - See Lubrication Diagram

Apply Light Oil - See Lubrication Diagram

Apply Light Grease - See Lubrication Diagram

Tighten, repair or replace if needed.

Tighten, resecure or replace if needed.

Resecure, replace damaged parts or otherwise correct as needed. Note: Apply lubricant during reassembly procedures.

15807

15806

15805

77000-000

Upper Lift

Rod Pin

Downstop Pivot Points

(hidden)

Lower Lift

Rod Pin

Kickout Spring

(hidden)

Inboard Locator

Latch Mechanism

Platform

Hinges (6)

Outer Barrier Latch

Platform Fold

Mechanism

(Under Cover)

Perform all procedures listed in previous sections also

4500

Cycles

Consecutive

750 Cycle

Intervals

Platform fold mechanism

Ballscrew / main drive

Clean ground cable at battery and frame

Check power cables

Repeat all previously listed inspection, lubrication and maintenance procedures at 750 cycle intervals.

Apply Light Grease - See Lubrication Diagram

Add Lucas Heavy Duty Oil Stabilizer

Braun FMVSS NO. 403 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual