Braun RA500 User Manual

Operator's/Installation/Service Manual

Braun

Commercial

RA500 Transit Ramp

for

Low-Floor Transit Vehicles

"Providing Access to the World"

International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA

1-800-THE LIFT® (574) 946-6153 FAX: (574) 946-4670

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ual

® ®

Read manual before operating, installing or servicing ramp. Failure to do so may result in serious bodily injury and/or property damage.

Braun RA500 Transit Ramp

32848 Rev. A

August 2006

Congratulations

We at The Braun Corporation wish to express our fullest appreciation on your new purchase. With you in mind, our skilled craftsmen have designed and assembled the ﬁnest ramp available. This manual includes operating instructions, installation instructions, servicing instructions and instructions for troubleshooting, if needed. Braun ramps are built for dependability and will provide years of service and mobility independence, as long as the ramp is installed and maintained as speciﬁed, and the ramp is operated by an instructed person.

THE BRAUN CORPORATION

Ralph W. Braun Chief Executive Ofﬁcer

Sincerely,

CONTENTS

Ramp Terminology

Ramp Terminology Illustration .................................... 2

Ramp Components Terminology Illustration ............. 3

Introduction .................................................................... 4

Ramp Components ........................................................ 5

Ramp Actions and Functions ....................................... 5

Ramp Operation

Ramp Operation Safety

Safety Symbols ......................................................... 6

Ramp Operation Safety Precautions ..................... 6, 7

Operation Notes and Details

Ramp Access Doors and Interlocks ........................... 8

Operation Procedure Review ..................................... 9

Preventive Maintenance............................................. 9

Maintenance and Lubrication

Lubrication Diagram ................................................... 30

Maintenance and Lubrication Schedule ............. 31, 32

Systems Descriptions

Electronic Controller Calibration .......................... 33-35

Electrical (Microswitches) .................................... 36, 37

Troubleshooting

Troubleshooting Diagnosis Chart ....................... 38, 39

Electrical Schematic .........................................41B, 42B

Wiring Diagram ........................................................... 43

Repair Parts

Ramp Power Operation ............................................... 10

Power Ramp Safety ......................................................11

Ramp Manual Operation ....................................... 12, 13

Ramp Passenger Safety........................................ 14, 15

Ramp Installation

Installation / Service Safety

Safety Symbols ....................................................... 16

Installation / Service Safety Precautions ........... 16, 17

Installation Requirements

Installation Requirements......................................... 18

Chassis Requirements ............................................. 18

Door Opening ........................................................... 18

Obstructions ............................................................. 18

Installation Illustrations ......................................... 19-27

Electrical Connections .......................................... 28, 29

Repair Parts List .......................................................... 40

Exploded View (Fold Out) ................................41A, 42A

Daily Preventive Maintenance Schedule ................ 44

Battery / Ground Connections ................................... 28

Page 1

RAMP TERMINOLOGY

Ramp Terminology Illustration

Refer to the Figure A below and Figure B on page 3

for identication of components and clarication of

direction terminology. Details regarding terminology, direction and components are provided on pages 4 and 5.

Sub oor

(Fixed)

Figure A

Pan Weldment

IN

Threshold Plate

Mounting Tab

(Qyt 10)

Ramp

Hand Hold

RIGHT

LEFT

As viewed from outside the vehicle

Page 2

OUT

Ramp Components Terminology Illustration

RAMP TERMINOLOGY

Electric Motor

Pan Weldment

Chain Drive

Figure B

Carrier Plate

Mounting Tab

(Qyt 10)

Ramp

IN

LEFT

As viewed from outside the vehicle

RIGHT

OUT

Hand Hold

Note: The sub oor and

transition threshold plate are removed from this illustration.

Page 3

RAMP TERMINOLOGY

Introduction

The Braun RA500 In-Floor Ramp (to be referred to as RA500 throughout this manual) is de-

signed for use in low-oor transit

vehicles. The RA500 provides vehicle access to people with disabilities (wheelchair passengers or standees using other type mobility aids).

The self-contained “drop-in” electric unit requires no pre-assembly. The electrical components are internal and easily accessible.

The RA500 features a 32” wide ramp in a 38” wide package. A

“oor pocket” built into the chassis/oor system allows for simple

installation (dimensional require-

ments specied in the Installation

section).

The RA500 is specically designed to be operated by an attendant. The ramp is controlled by either a “one-touch control” or a “press and hold control”.

The RA500 provides fully automatic operation of ramp functions. The electric system is controlled by a electronic controller board which activates an electric motor in opposite directions for deploy and stow functions (powering a chain drive system).

Obstruction sensing is a standard feature with the RA500 ramp. The RA500 also has an optional weight sensitive pad on the ramp platform. The ramp will not operate with 15 kilograms on the platform when equipped with the weight sensitive pad.

Instructions are provided for manual operation of the ramp in event of power or equipment failure. See Manual Override for further details.

Read and become familiar with all operation safety precautions, pre-operation notes and details, operating instructions and manual operating instructions before attempting operation.

Terminology: Become familiar with the terminology that will be used throughout this manual. Become familiar with the iden-

tication of RA500 components

and their functions. Contact your sales representative or call The Braun Corporation at 1-800-THE LIFT® if any of this information is not fully understood.

Direction: The terms “left”, “right”, “in” and “out” will be used throughout this manual to indicate direction (as viewed from the outside of the vehicle looking directly at the ramp). Refer to the Termi-

nology Illustrations for clarication

of direction terms.

Page 4

Ramp Components

RAMP TERMINOLOGY

Refer to the Terminology Illustrations on pages 2 and 3.

Control Box (Electronic Controller): The remote mounted

control box provides the logic to manage the inputs in order to produce the desired outputs in terms of ramp function and performance. In general terms the control box is commonly referred to as the “controller”.

Ramp Actions and Functions

Extend: Extend is the action of

the platform moving out of the pan weldment (housing).

Retract: Retract is the action of the platform moving in to the pan weldment (housing).

Deploy: Deploy is the action of the ramp assembly extending to ground level when the DEPLOY (OUT) switch is activated.

Stow: Stow is the action of the ramp assembly retracting inward to the stowed position when the STOW (IN) switch is activated.

Note: the one touch controller activates both the stow and deploy functions, dependant upon the state of the RA500.

Pan Weldment (Housing):

The pan is the aluminum (casing) mounted in the vehicle oor system which contains the electrical components that power the ramp

electrical systems. The xed sub-oor cover protects the com-

ponents from above. The cover is easily removed for access to

drive components. The sub-oor

provides an antiskid surface for entry and exit when the ramp is deployed. The RA500 ramp

stows into the sub oor

Stowed Position: Stowed position is achieved when the ramp platform assembly is fully retracted (resting fully in the pan weldment).

Manual Override: Manual operation is achieved through the use of a mechanical release. Simply pull the release and use the hand hold provided on the ramp platform to manually deploy or stow the ramp. Minimal physical effort is required to stow and deploy the ramp platform. Slow steady motion results in the least resistance and easy operation. See pages 12 and 13 for detailed manual release procedure.

providing an unobstructed antiskid surface for entry and exit when the ramp is not in use.

Ramp Platform: The ramp platform is the aluminum ramp section assembly featuring a full

antiskid surface.

Chain Drive Assembly: The electric motor driven chain drive deploys and stows the ramp platform assembly.

Obstruction Sensing: An obstruction sensing feature is standard with the RA500 ramp. The controller monitors the instantaneous movement of the electric motor, and calculates a “real time” running average of the current. It then compares the programmed peak (maximum vs. instantaneous) and delta (instantaneous minus running average) limits to determine if an obstruction has been encountered.

Weight Sensing Pad (optional): The platform can be equipped with a weight sensing pad. This optional feature will cause the ramp not to operate in the event that 15 kilograms or more is on the ramp platform.

Page 5

RAMP OPERATION

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CAUTION

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Safety Symbols

SAFETY FIRST! Know That....

All information contained

A

in this manual and supplements (if included), is provided for your safety. Familiarity with proper operation instructions as well as proper maintenance procedures are necessary to ensure safe, trouble free operation. Safety precautions are provided to identify potentially hazardous situations and provide instruction on how to avoid them.

Note: Additional information provided to help clarify or detail a specic subject.

D

These symbols will appear throughout this manual. Recognize the seriousness of this information.

Ramp Operation Safety Precautions

If the ramp operating instructions, manual operating instructions and/or ramp operation safety precautions are not fully understood, contact The Braun Corporation immediately. Failure to do so may result in serious bodily injury and/or property damage.

B

This symbol indicates important safety information regarding a potentially hazardous situation that could result in serious bodily injury and/or property damage.

Read manual and supplement(s) before operating ramp. Read and become familiar with all safety precautions, preoperation notes and details, operating instructions and manual operating instructions before operating the ramp. Note: All transit agency personnel (drivers and ramp attendants) must read and become familiar with the contents of this manual and supplement(s) before operation.

Load and unload on level surface only.

Engage vehicle parking brake before operating ramp.

Provide adequate clearance outside the vehicle to accommodate the ramp before opening ramp door(s) or operating ramp.

C

This symbol indicates important information regarding how to avoid a hazardous situation that could result in minor personal injury or property damage.

Page 6

Inspect ramp before operation. Do not operate ramp if you suspect ramp damage, wear or any abnormal condition.

Keep operator and bystanders clear of area in which the ramp operates.

Load and unload clear of vehicular trafc.

Open ramp door(s) fully and secure before operating ramp.

Do not overload or abuse. The rated capacity is 300 kilograms (660 pounds).

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Ramp Operation Safety Precautions (continued)

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Do not activate control switch(es) when anyone is near the area in which ramp operates.

It is the responsibility of the attendant to oversee and assist ramp passengers.

Attendants must never operate the vehicle, the ramp or attend to passengers if intoxicated.

Intoxicated passengers should not be allowed to board the vehicle.

Wheelchair passengers must position and secure (buckle, engage, fasten, etc.) the wheelchair-equipped occupant seat belt before loading onto the ramp.

Be aware of the ramp slope (angle).

Wheelchair passengers should not raise front wheelchair wheels (pull wheelie) when on the ramp.

The wheelchair must be positioned in the center of the ramp when loading and unloading.

RAMP OPERATION

Keep ramp owner’s manual in ramp-mounted vehicle at all times.

Maintenance and lubrication procedures must be performed as specied in this manual by authorized (certied) service personnel.

Never modify (alter) a Braun Corporation ramp.

Do not use accessory devices not authorized by The Braun Corporation.

Do not remove any guards or covers.

If the information contained in this manual is not fully understood, contact The Braun Corporation immediately.

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

Page 7

RAMP OPERATION

Operation Notes and Details

The RA500 ramp provides vehicle access to people with disabilities (wheelchair passengers or standees using other type mobility aids). The commercial oriented RA500 ramp is operated by the transit vehicle driver/attendant. Unless your transit agency has a published policy stating that driver/attendants do not aid ramp passengers, safe entering and

Ramp Access Doors and Interlocks

Attendants must become familiar with the vehicle ramp access door system and interlock(s), as well as the proper operation of the ramp.

Vehicle ramp access door congurations and operation procedures vary. Ensure the ramp door is fully open before activating the ramp (an interlock typically prevents ramp operation unless the door is fully open). Attendants and passengers must keep clear of the area in which the power door operates. Ensure the path is clear before closing the door. Be sure the door is fully closed before attempting to drive the vehicle (interlocks typically ensure this).

exiting of ramp passengers is the responsibility of the driver/ attendant.

As stated in the Ramp Operation Safety section, all information in this manual is provided for the safety of passengers, attendants and bystanders. Recognize the seriousness of this information.

Interlocks are required by nearly all transit authorities. Vehicle interlocks typically prevent vehicle motion if the ramp is not stowed. In some cases, the ramp cannot be operated if interlock conditions are not met. Interlock requirements may include: the vehicle transmission must be engaged in Park, the parking brake must be engaged, the ramp access door must be fully open and/or others. Multiple interlocks may exist.

Instructions for operation of interlocks and door systems cannot be addressed in this manual due to the variety of procedures required for operating them.

Read and become familiar with all ramp operation safety precautions, pre-operation notes and details, operating instructions and manual operating instructions before attempting ramp operation procedures or assisting ramp passengers boarding and exiting the vehicle.

General instructions for safe operation of the ramp are provided. Ramp safety and ramp passenger safety information is included. It is the responsibil- ity of the attendant to properly open and close the ramp access door(s), to activate interlock(s), to properly activate the ramp power functions as well as assist ramp passengers.

Do not operate the ramp if you suspect ramp damage, wear or any abnormal condition. Discontinue use immediately and contact 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 the ramp.

Page 8

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Operation Procedure Review

RAMP OPERATION

The Braun Corporation recommends that transit agency supervisors and driver/attendants review the safety precautions and operation procedures appearing in this manual with the ramp sales representative (or vehicle converter) before attempting ramp operation.

Any questions or concerns can be answered at that time. Operate the ramp through all functions to ensure the proper use and operation is understood.

Transit agency supervisors should train and educate all driver/attendants on the proper use and operation of the vehicle, door system, interlock(s), ramp and ramp passenger safety.

The ramp owner’s/service manu-

al must be stored in the rampequipped vehicle at all times.

Read and become familiar with all ramp operation safety precautions, preoperation notes and details, operating instructions and manual operating instructions prior to operating the ramp. If this information is not fully understood, contact The Braun Corporation immediately. Failure to do so may result in serious bodily injury and/or property damage.

Preventive Maintenance:

Maintenance is necessary to ensure safe and trouble free operation. General preventive maintenance consisting of care- ful inspections and cleaning the ramp system should be a part of your transit agency’s daily service program. Simple inspections can detect potential operational problems.

Regular preventive maintenance will reduce potential operation downtime and increase the service life of the ramp, as well as possibly detecting potential hazards.

A generic Daily Preventive Maintenance Schedule is provided in this manual for your transit agency’s use. The form can be tailored to your particular application.

Exposure to harsh weather, environmental conditions, or heavy usage may require more frequent maintenance and lubrication procedures.

Preventive maintenance visual inspections do not take the place

of the procedures specied in

the Maintenance and Lubrication Schedule provided in this manual. Refer to the Maintenance and Lubrication section in this manual for further details.

Page 9

RAMP OPERATION

Ramp Power Operation

Ramp Operating Instructions address the required controller inputs and the corresponding ramp functions. Instructions for

customer specic display panels

and interlock options will not be addressed due to the boundless variations in application and installation of the ramp. Manual Operating Instructions are addressed in the event of power or equipment failure.

Before Operating Ramp: Always park the vehicle on a level

area, away from vehicle trafc.

Place the vehicle transmission in “Park” and engage the park or emergency brake.

Customer Interlock: The ramp controller requires either a ground (-) or (+) signal be supplied, one of these signals is required but not both. This signal interlocks the ramp functions. If this interlock signal is not present, the controller will not provide any outputs necessary to operate the ramp. If the interlock signal is lost during ramp operation, the platform assembly will stop, and the controller will not function any further until the interlock signal is present once again.

Operator Input Switches: The RA500 Ramp electronic controller provides fully automatic operation of all ramp functions. Ramp functions can be performed from any position the platform assembly happens to be in at the time the operator input switch is activated. The ramp is protected by a standard obstruction sensing feature.

One-Touch Operation: In onetouch mode, the ramp will deploy if fully stowed. If the ramp is in any other position the ramp will stow. The ramp function will continue until the switch is pressed again (indicating stop immediately), the unit reaches the end of travel, or a “halt condition” occurs (see Halt Conditions).

Two-Way Toggle Operation:

In two-way toggle mode, there are separate switches for deploy and stow functions. One of the switches must be pressed and held or locked into position (continuous input signal required) for the RA500 ramp to operate. The ramp will move in the selected direction until the switch is released (signal interrupted), the unit reaches the end of the travel, or a “halt condition” occurs (details follow).

Halt Conditions: Several conditions can cause a normal sequence to terminate (stop):

• Obstructions (details below)

• Customer Interlock signal lost (see Customer Interlock)

• Optional platform weight sensing pad senses a load equal to or greater than 15 kilograms (details below)

• End of travel reached

Obstructions: The controller performs obstruction sensing (see RA500 ramp Terminology: Obstruction Sensing) on all stow and deploy movements of the ramp. The selected obstruction

response mode congured in

the controller during installation, either immediately stops the present movement when obstructed, or stops and then reverses movement for 1 second. Once an obstruction has halted the ramp, the controller automatically resets and awaits operator input for further operation.

Weight Sensing Pad (optional): The platform can be equipped with a weight sensing pad. This optional feature will cause the ramp not to operate in the event that 15 kilograms or more is on the ramp platform.

Page 10

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Power Ramp Safety

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Keep clear of area in which ramp operates.

CAUTION

RAMP OPERATION

Be certain there is adequate clearance outside the vehicle before deploying the power ramp.

The ramp operator (attendant) and bystanders must keep clear of the area in which the ramp operates and clear of all moving parts. Attendants must ensure that passengers keep clear of the area in which the ramp operates. Do not attempt to grip or hold the ramp.

If you are an attendant operating the ramp, it is your responsibility to oversee and/or assist in

performing safe passenger loading and unloading procedures. Observe your passengers at all times when they are entering and exiting the vehicle. Attendants must be aware of any special needs and/or procedures required for safe transport of wheelchair passengers.

Do not attempt to load or unload a passenger in a wheelchair or

other apparatus that does not t

on the ramp. Do not exceed the 300 kilograms (660 pound) load capacity of the ramp. Passengers should enter and exit one at

a time. The attendant should not board the ramp with the passenger except when assistance is required and the load capacity is not exceeded. Always return the ramp to the stowed position when not in use.

Provide adequate clearance outside of vehicle to accommodate ramp. Failure to do so may result in serious bodily injury and/or property damage.

Allow ramp to deploy fully before boarding. Failure to do so may result in damage.

Page 11

RAMP OPERATION

TO

LOCK

TURN

TO

LOCK

TURN

TO LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

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Push T-handle in fully and manually move platform in and out to engage platform lock before driving vehicle. Failure to lock platform may result in unintended platform deployment. Unintended platform deployment may result in serious bodily injury and/or property damage.

Ramp Manual Operation

If you experience power or equipment failure, the ramp can be manually stowed and deployed. The RA500 must be manually operated by an attendant.

The RA500 is equipped with a cable-activated manual release system and a oval-shaped hand hold slot in the platform for manual operation (see Figure C and E).

The safety precautions addressed in the Ramp Power Operation section apply to manual operation of the ramp also. Read and

become familiar with all ramp safety precautions.

Cable-Activated Manual Release System: A cable activated

manual release system disengag-

es (unlocks) the ramp platform assembly drive chain to allow the platform to be manually extended or retracted as required. A Thandle is provided on the release cable for activation of the manual release system (details follow).

After manually extending or retracting the platform assembly, it is extremely important that the cable-activated manual release is positively re-engaged to secure (lock) the platform assembly before loading a passenger or continuing vehicle use (details provided). Failure to re-engage

and secure the platform may result in unintended ramp movement, which may result in serious bodily injury and/or property damage.

To Manually Extend or Retract Ramp:

1. Turn (loosen) the manual release “T” handle 90°.

2. Pull the “T” handle fully outward (3" to 4").

3. Turn (tighten) the “T” handle 90° to secure handle in the disengaged (unlocked) position.

Page 12

Step 1 Step 2 Step 3

4. Verify mechanism is disengaged (unlocked).

5. Carefully move the platform in or out to desired location using the platform Hand Hold (see Figure E).

Note: Minimal physical effort is required to manually operate the ramp. Slow steady motion results in the least resistance and easy operation. The faster you attempt to manually operate the ramp, the greater the resistance.

Figure C

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

TO

LOCK

TURN

Ramp Manual Operation (continued)

To Reengage Carriage Assembly to Drive Chain:

RAMP OPERATION

1. Position the ramp platform manually so that only 15 cm is extended out of the cassette.

2. Turn (loosen) the manual release “T” handle 90°.

3. Push the “T” handle fully inward until handle contacts shaft shoulder (3" to 4").

4. Grasp the platform Hand Hold and move the platform slightly outward until platform locks into position (secured by reengaging the carriage assembly with the drive chain).

5. Turn (tighten) the “T” handle 90° to secure handle in the engaged (locked) position.

6. Verify mechanism is reengaged (locked). Pull on the Hand Hold to ensure no movement occurs.

7. Stow the remaining portion of the platform by using the electrical system.

Figure D

Step 2 Step 3 Step 5

Figure E

Hand Hold

Page 13

RAMP OPERATION

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Keep clear of area in which ramp operates.

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Be aware of ramp slope.

52217

Ramp Passenger Safety

Unless your transit agency has a published policy stating that driver/attendants do not aid ramp (disabled) passengers, it is the

responsibility of the driver/attendant to ensure that ramp passengers enter and exit the vehicle on the ramp in the safest manner.

ADA requirements state that transit drivers/attendants must assist with attaching and removing wheelchair and occupant restraint belts.

Ramp passengers (wheelchair passengers and standees), and attendants must use common sense and good judgment regarding ramp safety. Each wheelchair passenger (or standee) has a unique set of physical abilities combined with the physical characteristics of his or her wheelchair (or other mobility aid) that dictate the method in which he or she will enter and exit the vehicle.

Wheelchair attendants should be instructed on any special needs and/or procedures required for safe transport of wheelchair passengers. Follow all safety instructions regarding torso restraints,

Position and fasten the wheelchairequipped occupant seat belt before loading onto the wheelchair ramp. Failure to do so may result in serious bodily injury and/or property damage.

stability, balance, weight distribution and use of attendants as

specied in the owner’s manual

supplied with the passenger’s wheelchair (or other mobility aid). Wheelchair passengers must determine, establish and practice ramp boarding and exiting procedures under the direction of the their personal health care professional and wheelchair representative. Those procedures should be conveyed to the ramp attendant. Know your passengers abilities and needs for optimum safety.

Attendants must never operate the vehicle, the ramp or assist passengers if intoxicated. Intoxicated passengers should not be allowed to board or exit the vehicle.

Passengers should be positioned in the center of the ramp at all times. Attendants and ramp passengers must be able to clearly view the ramp whenever boarding and exiting the vehicle. Observe your passengers at all times when they are entering and exiting the vehicle.

Wheelchair-Equipped Occupant Seat Belts: Wheelchair passen-

gers should position and buckle their wheelchair-equipped seat

belt (torso restraint), as specied

by the manufacturer, before loading onto a wheelchair ramp.

Different types of disabilities require different types of wheelchairs and different types of wheelchair-equipped occupant restraint belt systems (torso restraint). It is the responsibility of the wheelchair passenger to have his or her wheelchair equipped with an occupant restraint (seat belt) under the direction of their health care professional.

Stabilizing Wheelchairs: Powered and manual wheelchairs are designed to remain upright and stable during normal operation. All activities which involve movement in a wheelchair have an effect on the combined center of gravity of the occupant and wheelchair. Be aware of the ramp slope (angle). The slope of the ramp has a direct effect on the center of gravity. The wheelchair passenger’s center of gravity and their ability to maintain stability and balance must be kept in mind by the wheelchair passenger and the attendant.

The aid of an attendant stabilizing the wheelchair is recommended for optimum safety. Wheelchair passengers who are unable to maintain stability and balance should not board a ramp without assistance. Counterbalance devices (anti-tippers) may be available from the wheelchair representative to enhance stability and balance.

Page 14

Ramp Passenger Safety

RAMP OPERATION

Wheelchairs should be operated at a slow and constant speed when on the ramp. Wheelchairs should not accelerate suddenly when on the ramp. Wheelchair passengers should not raise the front wheelchair wheels (pull wheelie) when on the ramp.

Wheelchair passengers who intend to enter and exit the vehicle without the assistance of an attendant must determine the safest and most practical method and orientation of entering and exiting based on the physical characteristics of their personal wheelchair and his or her physical capabilities to maintain stability while the wheelchair is in motion on the ramp.

Wheelchair Attendants: When assisting a wheelchair occupant, remember to use good body mechanics. When the wheelchair is on the ramp, the attendant must grasp the push handles (or other) securely. Detachable wheelchair parts such as arms or leg rests must never be used for hand holds or lifting supports. Doing so could result in the parts being inadvertently detached from the wheelchair resulting in possible

injury to the wheelchair occupant and/or the attendant.

Page 15

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CAUTION

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RAMP INSTALLATION

CAUTION

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Safety Symbols

SAFETY FIRST! Know That....

All information contained

A

in this manual and supplements (if included), is provided for your safety. Familiarity with proper operation instructions as well as proper maintenance procedures are necessary to ensure safe, trouble free operation. Safety precautions are provided to identify potentially hazardous situations and provide instruction on how to avoid them.

Note: Additional information provided to help clarify or detail a specic subject.

D

These symbols will appear throughout this manual. Recognize the seriousness of this information.

Installation / Service Safety Precautions

B

This symbol indicates important safety information regarding a potentially hazardous situation that could result in serious bodily injury and/or property damage.

Read this manual and supplement(s) before performing installation, operation or service procedures.

C

This symbol indicates important information regarding how to avoid a hazardous situation that could result in minor personal injury or property damage.

If installation, maintenance or repair procedures cannot be completed exactly as provided in this manual or if the instructions are not fully understood, contact The Braun Corporation immediately. Failure to do so may result in serious bodily injury and/or property damage.

Installation specications and dimensions must be met.

Remove any obstructions within the ramp mounting/operating area prior to beginning installation procedures.

Do not operate ramp prior to positive securement of the pan.

Check for obstructions such as gas lines, wires, exhaust, etc. before drilling or cutting during installation procedures.

Route all cables clear of exhaust system, other hot areas, moving parts, wet areas, etc.

Risk of electrical shock or re! Use extra care when making

electrical connections. Connect and secure as outlined in Installation Instructions and Wiring Diagrams.

Maintenance and repairs must be performed only by authorized service personnel.

Perform maintenance and lubrication procedures exactly as outlined in the Maintenance and Lubrication Schedule contained in this manual. Disconnect the power cable at the battery prior to servicing.

Keep hands, arms and all other body parts clear of moving parts.

Page 16

Installation / Service Safety Precautions

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Never modify (alter) a Braun Corporation ramp.

Replacement parts must be Braun authorized replacements.

Never install screws or fasteners (other than factory equipped).

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

RAMP INSTALLATION

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RAMP INSTALLATION

Installation Requirements

Braun RA500 Ramp must be installed and serviced by a Braun authorized service representative who has attended and been certied by The Braun Corporation Sales and Service School for Braun Mobility Products.

Chassis Requirements

The Braun RA500 Ramp is

designed for use in low-oor transit vehicles. A “oor pocket”

(mounting hole) built into the

chassis/oor system allows for

simple installation (accepts “dropin” unit). The Floor Pocket Clear Opening Dimensions on the following pages.

An optional RA500 model without

the xed sub oor is available.

When installing this model the

vehicle oor is installed above

the ramp assembly. This model is designed to be installed above the frame, but below the vehicle

oor. This model does not have the xed sub oor on top of the

assembly.

The ramp installer must provide an appropriate framework in the applicable location in the vehicle (aligned center with passenger door opening). Ramp assembly mounting hardware and/or bracketry are directly dependant upon

the vehicle chassis and “oor pocket” conguration (not sup-

plied).

Read and become familiar with the operating instructions and the installation instructions contained in this manual before beginning installation, operation or service procedures.

Outboard Support Tube: An outboard support tube must be positioned under the outboard edge of the opening (minimum 40mm x 50mm steel tube). See Figure F. The recommended maximum height of the support tube is 210mm above ground level.

Kneeling Vehicles: 210mm is the maximum dimension measured with suspension lowered.

EU: Installations with the support tube positioned higher than 210mm above ground level may not comply with EU ramp slope requirements.

Some OEM chassis meet these

specications. The RA500 ramp

was designed to conform to these

specications.

The ramp pan horizontal bor-

der (lip) sets on the oor pocket perimeter (framework, sub oor, etc.). The nished ooring can be

cut to conform to the border of the

pan for a ush transition surface from ramp-to-oor. The nished ooring can also go over the top

of the ramp if the optional ramp

model with out the xed sub oor

is installed.

Read this manual before performing installation, operation or service procedures. Failure to do so may result in serious bodily injury and/or property damage.

Door Opening: Open the door(s) fully and check the clear door opening width dimension. Specied minimum clear door opening width must be provided

(850mm for 825mm ramp).

Door(s) must open outward. When closed, the door(s) should align with and conform to the outboard edge of the ramp pan (rubber seal on bottom of door).

Minimum Clear Door Opening Dimensions are dened as nished door opening, including any

intrusive door jambs, headers,

sills or hinges.

Obstructions: Any intrusive obstructions within the door opening or the ramp mounting/operating area (such as seats, molding, lights, brackets, etc.) must be removed. Trim or molding that creates an uneven mounting surface should be removed.

Page 18

Ramp Support Structure

Chassis

SUPPORT TUBE

Floor Pocket

Frame Work

RAMP INSTALLATION

Outboard Support Tube: Recommended Maximum Height: 210mm above ground level. Kneel-

ing Vehicles (measured with suspension lowered).

EU: Installations with support tube positioned higher than 210mm above ground level may not comply with EU ramp slope requirements.

Figure F

Structure: Minimum 40mm x 50mm steel tubing (or equivalent).

In

Left

As viewed from outside the vehicle

Right

Out

Page 19

Chassis

SUPPORT TUBE

1455mm

1005mm

Floor Pocket

Frame Work

RAMP INSTALLATION

"Floor Pocket" Clear Opening Dimensions

Figure G

The ramp must be supported by a minimum of three chasis members.

Page 20

In

Left

As viewed from outside the vehicle

Right

Out

Chassis

C

L

Minimum Door Opening Width:

850

mm opening

for 825mm Ramp

C

L

MINIMUM

DOOR OPENING

WIDTH

1455mm

1005mm

Clear Door Opening Width Dimension

RAMP INSTALLATION

Figure H

The ramp platform

must be aligned

with the center of the door opening.

Door(s) must open outward.

Page 21

Chassis

C

L

Minimum Door Opening Width:

850

mm opening

for 825mm Ramp

C

L

MINIMUM

DOOR OPENING

WIDTH

RAMP INSTALLATION

Installed Ramp - Stowed

Figure J

Ramp positioned in

Stowed RA500

the “oor pocket.”

Page 22

In

Left

As viewed from outside the vehicle

Right

Out

Ramp Support Structure for RA500 w/o Fixed Sub oor

Chassis

SUPPORT TUBE

RAMP INSTALLATION

Outboard Support Tube: Recommended Maximum Height: 210mm above ground level. Kneel-

ing Vehicles (measured with suspension lowered).

EU: Installations with support tube positioned higher than 210mm above ground level may not comply with EU ramp slope requirements.

Figure K

Structure: Minimum 40mm x 50mm steel tubing (or equivalent).

Page 23

RAMP INSTALLATION

Chassis

1455mm

1005mm

SUPPORT TUBE

"Floor Pocket" Clear Opening Dimensions for RA500 w/o Fixed Sub oor

Figure L

Page 24

In

Left

As viewed from outside the vehicle

Right

Out

Clear Door Opening Width Dimension for RA500 w/o Fixed Sub oor

Chassis

C

L

Minimum Door Opening Width:

850mm opening

for 825mm Ramp

C

L

MINIMUM

DOOR OPENING

WIDTH

Chassis

SUPPORT TUBE

1455mm

1005mm

SUPPORT TUBE

RAMP INSTALLATION

Figure M

The movable ramp platform must be

aligned with the center of the door

opening.

In

Left

As viewed from outside the vehicle

Right

Out

Page 25

RAMP INSTALLATION

Chassis

C

L

Minimum Door Opening Width:

850mm opening

for 825mm Ramp

C

L

MINIMUM

DOOR OPENING

WIDTH

Installed Ramp - Stowed RA500 w/o Fixed Sub oor

Figure N

The movable ramp platform must be

aligned with the center of the door

opening.

Page 26

Door(s) must

open outward.

Installed Ramp - Stowed with Vehicle Floor Installed over Ramp

Chassis

Figure P

RAMP INSTALLATION

Floor should support upper surface of the ramp.

In

Left

As viewed from outside the vehicle

Right

Out

Page 27

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RAMP INSTALLATION

Electrical Connections

The ramp installer provides an appropriate control switch for the end user. One-touch operation using a single "operate" button (switch) or two-way toggle operation with dedicated switches for the stow and deploy command are options.

Battery / Ground Connections

The Positive (+) “battery” lead wire must be protected by an in-line 25 ampere fuse or circuit breaker (installer pro-

vided).

Do not connect the power “battery” lead wire to the battery until all other connections are made.

Installer connections are listed in the table on the following page. Strip wires, crimp and install con-

tacts as specied in instructions

supplied with the power connector (Molex 2-pin) and the data connector (Amp 14-pin).

Figure Q

Cable

Clip

Route cables clear of exhaust system, other hot areas and moving parts. Failure to do so may result in serious bodily injury and/or property damage.

Secure all cables using cable ties and/or cable clips (mount clips with self-tap screws).

Cable

(typical)

Connect the 14-pin data harness plug to the mating connector on the controller. Connect the 2-pin Power harness plug to the mating connector on the controller.

Risk of electrical shock! Use extra care when making electrical connections.

Risk of electrical re!

Use extra care when making electrical connections.

Vehicle

Floor

Cable Tie

Vehicle

Floor Framing Member

Self-Tap Screw

Carefully connect the power “battery” lead wire to the Positive (+) battery post.

Chassis Ground Corrosion: When mounting chassis ground cables, remove undercoating, dirt, rust, etc. from the framing member around the mounting holes. Apply a protective coating to mounting holes to prevent corrosion. Apply grease to ground cable terminals and mounting hardware. Failure to do so will void war- ranty of certain electrical components.

Page 28

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Electrical Connections

RAMP INSTALLATION

The 2 pin power harness connector and the 14-pin data harness connector are supplied with the ramp.

Note: Connectors are supplied only, harnesses are supplied by ramp installer. The ramp installer is responsible for vehicle connections.

Terminate the power supply, ground and ramp data signals as

specied in the legends below.

The Positive (+) “battery” lead wire must be protected by an

in-line 25 ampere fuse or circuit breaker (installer provided).

Positive (+) battery lead wire must be protected by installer-provided 25 ampere fuse or circuit breaker. Failure to do so may result in serious

The ramp installer provides an appropriate momentary contact

bodily injury and/or property damage.

control switch.

Power Harness with Molex 42816-0212 Connector (installer provided)

Function Pin No. Description Wire Size

Input 1 Battery - 24 Volt with 25 Amp. Protection Device 10 Gauge Input 2 Ground - Battery 10 Gauge

Wire Maximum Length: 10 Meters

Data Harness with AMP 206044-1 Connector (installer provided)

Function Pin No. Description Wire Size

Output 1 Indicator - Move Out - Normally Open (N.O.) 14 to 18 Gauge Output 2 Indicator - Alarm - Normally Open (N.O.) 14 to 18 Gauge Input 3 Switch - Ramp Deploy 14 to 18 Gauge Input 4 Switch - One Touch 14 to 18 Gauge Input 5 Indicator - Power Common Fused 14 to 18 Gauge Output 6 Indicator - Manual Release - Normally Open (N.O.) 14 to 18 Gauge Input 7 Ramp Enable 14 to 18 Gauge Output 8 Switch - Common 14 to 18 Gauge Output 9 Indicator - Full In - Normally Open (N.O.) 14 to 18 Gauge Input 10 Switch - Ramp Stow 14 to 18 Gauge Input 11 Switch - Park Brake (LOW) to Operate 14 to 18 Gauge Output 12 Indicator - Move In - Normally Open (N.O.) 14 to 18 Gauge Output 13 Indicator - Full Out - Normally Open (N.O.) 14 to 18 Gauge Input 14 Switch - Park Brake (HIGH) to Operate 14 to 18 Gauge

Notes: Either the One touch switch or both the Deploy and Stow switch connections should be utilized but not both.

The Park Brake switch (either high or low) and Ramp Enable are required for ramp to operate. Ramp Enable requires + Vehicle

See metric to US wire size conversion chart on page 43.

power to operate.

Page 29

MAINTENANCE and LUBRICATION

Lubrication Diagram

See the Maintenance/Lubrication Schedule for recommended applications per number of cycles or elapsed time.

Motor Guide

Rails

LO

Manual

Release CAM

LO

Drive Gear

LG

Drive Chain

LO

Drive Chain / Pulley

LO

Carrier Plate

Wear Strips

DE

Ramp Hinge

LO

Specied (recommended) Available Braun

Lubricant Type Lubricant Amount Part No.

LO - Light Oil

DE - Door-Ease

LG - Light Grease

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

Stainless Stick Door-Ease 1.68 oz. Style (tube) Stick (tube)

Light Grease Lubricate 14 oz. (Multipurpose) Can

15807

15806

15805

Page 30

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Maintenance and Lubrication Introduction

MAINTENANCE and LUBRICATION

Proper maintenance is necessary to ensure safe, trouble-free operation. Inspecting the ramp for any wear, damage or other abnormal conditions should be a part of all transit agencies daily service program (preventive maintenance). Simple inspections can detect potential problems.

A generic Daily Preventive Maintenance Sched- ule is provided in this manual for transit agency use. The form can be tailored to your particular application. Preventive maintenance visual inspections do not take the place of the procedures speci-

ed in this schedule.

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 or

elapsed time, whichever comes rst.

RA500 ramps are equipped with hardened pins and self-lubricating bearings to decrease wear, provide smooth operation and extend the service life of the ramp.

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

pose 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. Ramp components exposed to contaminants when lowered to

the ground may require extra attention. Specied

lubricants are available from The Braun Corporation (part numbers provided on page 30).

Recommended Intervals: These intervals are a general guideline for scheduling maintenance pro-

cedures and will vary according to ramp use and conditions. Transit agencies operating vehicles equipped with ramps that are not monitored by cycles may choose to have the ramp system maintained on the same schedule as the vehicle (routine maintenance). Doing so ensures the ramp is being maintained regularly.

When servicing the ramp at the consecutive recommended intervals, inspection and lubrication proce-

dures specied in the previous sections should be

performed (repeated). All listed inspection, lubrication and maintenance procedures should be repeated at “8 Weeks or 200 Cycles” intervals following the scheduled “1 Year or 1250 Cycles” maintenance.

Lifts exposed to severe conditions (weather, environment, contamination, heavy usage, etc.) may require inspection and maintenance procedures to be per-

formed more often than specied.

Discontinue ramp 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 ramp.

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.

Maintenance and Lubrication Schedule

Inboard ramp hinge

8 Weeks

Threshold plate hinge

or 200

Cycles

continued

Drive chain (chain, pulleys and guides)

Manual release (cable and mechanism)

Clean and lubricate. Apply Light Oil - See Lubrication Diagram

Apply Light Oil - See Lubrication Diagram

Page 31

MAINTENANCE and LUBRICATION

Maintenance and Lubrication Schedule (continued)

continued

Carrier plate wear strips

Clean and lubricate. Apply Door-Ease

8 Weeks

or 200

Cycles

1 Year

or

1250

Cycles

Clean ramp and ramp mounting area (ensure no debris in area to obstruct stowing )

Inspect ramp for wear, damage or any abnormal condition.

Perform all procedures listed in previous section also

Remove motor cover and clean dirt and other foreign debris

Remove motor cover and inspect:

• Harness cables, wires, terminals and connections for securement or damage

Drive gear

Motor guide rails

Manual release CAM

Drive chain

Clean and remove debris or obstructions

Correct as needed

Blow out with air compressor

Re secure, replace defective parts or otherwise correct as needed.

Apply Grease - See Lubrication Diagram

Apply Light Oil - See Lubrication Diagram

Consecutive

8 Week or

200 Cycle

Intervals

Page 32

Adjust chain tension

Inspect vehicle-to-ramp wiring harness

Mounting

Antiskid

Repeat all previously listed inspection, lubrication and maintenance procedures at 8 week or 200 cycle intervals (or per vehicle maintenance schedule).

Adjust as needed

Re secure, repair or replace or otherwise correct as needed

Check to see that the ramp is securely anchored to the vehicle and there are no loose bolts, broken welds, or stress fractures.

Replace decals if worn, missing or illegible. Replace antiskid if worn or missing.

Electronic Controller

SYSTEMS DESCRIPTIONS

Introduction: The following procedure is for calibration of the RA500 Series Controller. Calibrate the controller only if ramp does not function

properly.

Electronic Controller can be calibrated using a computer (recommended) or manually using the onboard Calibrate button and potentiometers.

Computer Calibration Instructions for Controller

Connect the Computer to the Controller:

1. Remove the controller cover. Press the “Calibrate” button and then the “Calibrate Reset” button to restore factory defaults (see Figure S).

2. Locate J9 (9-pin Port) and connect a serial cable from J9 to an available COM slot on the computer.

Establish a connection between the computer and the controller:

Note: This is done from the computer after the

physical connection has been made.

1. In the start menu, go to “Programs” and select “Accessories.”

Computer Calibration procedures are provided for Microsoft Windows XP. Other Operating Systems may vary. Consult the operating system search menu or users guide for alternate routes and procedures to access port settings.

Figure R

Port Settings

Bits per second:

Data bits:

Parity:

Stop bits:

Flow control:

19200

8

None

1

None

2. Under “Accessories”, choose “Communications”, and then “Hyperterminal.” Once selected, a “Connection Description” window will pop up.

3 Under name: Enter “RA500” and hit OK. A

“Connect To” window will then pop up.

4. Under the “Connect Using” line, select the com port that the serial cable is connected to (typically COM1) and hit OK.

5. A window similar to the one in Figure R will pop up. Ensure the settings match the settings listed in Figure R. Press OK.

Restore Defaults

OK Cancel

Apply

Page 33

SYSTEMS DESCRIPTIONS

Computer Calibration Instructions for Controller (continued)

Calibrate the Controller:

Press the “Calibrate” button on the controller (see Figure S). Ensure that the Calibrate LED is red. If connected properly, a text window will pop up. The numerical values will be different, but the general format of the text window will read similar to the following:

Deploy Limit: 50 Stow Limit: 975

Adjust limits as follows:

Note: Use Limit Adjustment Chart to calculate the

Deploy and Stow limit values. Three charts are provided on the right for calculation.

1. Ensure that the Calibrate LED is red.

2. Function the ramp through 4 complete deploy and stow cycles.

3. Record the Deploy Minimum and Stow Maximum values.

4. Average the Deploy Minimum and Stow Maximum values.

Limit Adjustment Chart:

Operation Deploy MIN. Stow MAX.

Cycle 1 (C1)

Cycle 2 (C2)

Cycle 3 (C3)

Cycle 4 (C4)

Total (C1+C2+C3+C4)

Average (Total / 4)

Deploy Limit (Avg. - 10) N/A

Stow Limit (Avg. + 10) N/A

Operation Deploy MIN. Stow MAX.

Cycle 1 (C1)

Cycle 2 (C2)

Cycle 3 (C3)

Cycle 4 (C4)

Total (C1+C2+C3+C4)

Average (Total / 4)

Deploy Limit (Avg. - 10) N/A

Stow Limit (Avg. + 10) N/A

5. Subtract 10 from the Average Delpoy Minimum value.

6. Add 10 to the Average Stow Maximum value.

7. Adjust the stow limit and the deploy limit potentiometers to show values caluclated above. Values will display on computer screen as the potentiometers are adjusted.

Note: Clockwise rotation of potentiometers decreases values.

Once the limits are set, return the ramp to normal operation by pressing the “Calibrate” button a second time. Make sure that the Calibrate LED is changed to green.

Note: To reinstall factory default values, press the “Calibrate” button, followed by pressing the “Calibrate Reset” button (see Figure S).

Operation Deploy MIN. Stow MAX.

Cycle 1 (C1)

Cycle 2 (C2)

Cycle 3 (C3)

Cycle 4 (C4)

Total (C1+C2+C3+C4)

Average (Total / 4)

Deploy Limit (Avg. - 10) N/A

Stow Limit (Avg. + 10) N/A

Page 34

HAZARD

CAUTION!

ESD

K1

K2

U1

D12

51

U9

76

26

1

R10

R11

U13

U14

U15

1413

214 7

6

5

11 12

J7

3

109

8

J4

J5

100218-

REVISION

U2

U8

U11

U12

J10

1 9

2 1010

9

2

1

F1

J1

U7

U5

Y1

U6

U3

61

41

21

1

U4

J9

5 3J84 12

AZ987-2C

D13

C20

D15

D16

D14

C19

D7

D2

AZ987-2C

F3

J6

12

6

7

1

J3

D17

D18

+ +

C24

Q5

S1

S2

1

J14

2 3

Manual Calibration Instructions for Controller

SYSTEMS DESCRIPTIONS

Press the “Calibrate” button. Once pressed, the calibrate LED should turn on.

Adjust the Deploy Limit potentiometer to the obstruction sensing level desired (see Figure S). Rotating the potentiometer counterclockwise increases the force that the ramp will exert when it is deploying.

Caution: Ensure that the force exerted is not excessive. It is recommended to adjust the potentiometer in small amounts and check operation after each adjustment.

Power

Harness

Port

Ramp

Harness

Port

Calibrate

Button

Adjust the Stow Limit potentiometer to the obstruction sensing level desired. Rotating the potentiometer counterclockwise increases the force that the ramp will exert when it is stowing.

Caution: Ensure that the force exerted is not excessive. It is recommended to adjust the potentiometer in small amounts and check operation after each adjustment.

Once the desired force levels are reached, press the “Calibrate” button a second time to store the settings. Ensure the calibrate LED is off before returning the ramp to service.

Figure S

Calibrate

Reset Button

Data

J9 Port

Potentiometer

Deploy Limit

Potentiometer

Harness

Port

Stow Limit

Page 35

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SYSTEMS DESCRIPTIONS

Electrical

Improper microswitch adjustment may result in serious bodily injury and/or property damage.

Microswitch Sequence

Stowed Position: When the

ramp is in the stowed position, the IN-Limit microswitch is activated (common and normally open terminals have continuity). In contrast, the OUT-LImit microswitch is deactivated.

Deploy Sequence: When the ramp is in the stowed position, the OUT-Limit microswitch is deactivated, and thus allows current to pass from the vehicle’s Deploy switch circuit and energize the ramp’s Bidirectional motor in the deploy direction (motor drives chains to deploy ramp).

Microswitches: Three microswitches (limit switches) are incorporated in the RA500 electrical system (IN-Limit, OUT-Limit and Manual Release signal). Details and illustrations of the micro-

switches are provided. Adjust

microswitch (es) as detailed.

Deployed Position: When the ramp is in the deployed position, the OUT-Limit microswitch is activated. In contrast, the IN-Limit microswitch is deactivated.

Stow Sequence: When the ramp is in the deployed position, the INLimit microswitch is deactivated , allowing current to pass from the vehicle’s Stow switch circuit and energize the ramp’s Bidirectional motor in the stow direction (motor drives chains to stow ramp).

Note: Under normal circumstances the RA500 microswitches

should not need adjustment. If adjustment or replacement is

required, follow the procedures provide on the next page.

Manual Release State: When the ramp’s manual release is engaged the manual release microswitch signals the controller that the manual release state of the ramp has been engaged. This signals the controller to disable the power functions of the RA500.

OUT-Limit Microswitch

The OUT-Limit microswitch is located in the outboard mounting position of the platform carrier plate.

To adjust:

1. Power or manually move the ramp to the full out position.

2. With the ramp in the deployed position loosen the OUT-Limit microswitch mounting screws.

3. Slide the switch body outward until resistance is felt from the switch being fully depressed.

4. Tighten the mounting screws in this position.

Page 36

OUT-Limit

Microswitch

Figure L

Ramp in Full-Out Position

(As viewed from under the carrier plate)

IN-Limit Microswitch

The IN-Limit microswitch is located in the inboard mounting position of the platform carrier plate.

To adjust:

1. Power or manually move the ramp to the fully stowed position.

2. Remove the ramp top plate (cover).

3. With the ramp in the stowed position loosen the IN-Limit microswitch mounting screws.

SYSTEMS DESCRIPTIONS

IN-Limit

Microswitch

Figure M

4. Slide the switch body outward until resistance is felt from the switch being fully depressed.

5. Tighten the mounting screws in this position.

6. Replace the ramp top plate (cover), before operating the ramp.

Manual Release Signal Microswitch

The MR-Signal microswitch is located behind the electric motor mounting plate.

To adjust:

1. Power or manually move the ramp to the fully stowed position.

2. Remove the ramp top plate (cover).

3. Disengage the manual release T-handle to so the ramp is in the manual release state.

Ramp in Fully-Stowed Position

(As viewed from under the carrier plate)

MR-Signal

Microswitch

Figure N

4. Loosen the MR-Signal microswitch mounting screws.

5. Slide the switch body toward the motor mounting plate until resistance is felt from the switch being fully depressed.

6. Tighten the mounting screws in this position.

7. Re-engage the manual release T-handle.

8 . Replace the ramps top plate (cover), before

operating the ramp.

Ramp in Fully-Stowed Position

Page 37

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TROUBLESHOOTING

Troubleshooting Diagnosis Chart

Troubleshooting and repair procedures must be performed

as specied by an

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

If a problem occurs with your ramp, discontinue operation immediately! 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 ramp.

The cause of the problem can be determined by locating the lift function and related symptom in

Chart. The specic cause and

remedy can then be determined by process of elimination. A Wiring Diagram and Electrical Schematic are provided to aid in troubleshooting.

A Repair Parts section with an exploded view and corresponding parts list is also provided. Correct the problem if possible. If the problem continues, contact The Braun Corporation.

the Troubleshooting Diagnosis

FUNCTION SYMPTOM POSSIBLE CAUSE REMEDY

Clean and tighten Clean and tighten. See Chassis Ground Corrosion on page 28.

Replace Charge battery Replace controller fuse or vehicle fuse Check for loose terminals or broken wire Correct or replace Disconnect harness from controller. Using volt meter test for proper voltage:

1.10

No Power

To Controller

1.11 Battery terminals dirty

1.12 Bad chassis ground

1.13 Battery defective

1.14 Battery discharged

1.15 25 ampere in-line fuse faulty

1.16 Power cable

1.17 Vehicle Interlock(s) circuit incomplete

1.18 Vehicle-to-controller power harness

1.00 NO

OPERATION

1.20

Power to

Controller But

No Function

1.21 Ramp to controller wiring harness

1.22 Vehicle to controller data harness

1.23 Faulty Controller

1.24 Ramp enable circuit incomplete

1.25 Parking brake interlock inactive

1.26 Manual release disengaged

Pin 1 = + 12/24 V Pin 2 = - Ground

Check harness for loose or broken connections. Check harness for loose or broken connections. See Controller Diagnostic Guide Correct or replace Correct or replace Check that manual release is re-engaged

Page 38

TROUBLESHOOTING

FUNCTION SYMPTOM POSSIBLE CAUSE REMEDY

2.00

DEPLOY

OPERATION

2.10

Ramp Starts

to Deploy

then Stops

2.20

Ratcheting

Noise at End

or during

Ramp

Deployment

2.30

Excessive

Noise during

Ramp

Deployment

3.10

Ramp Starts

to Stow

then Stops

2.11 Pressure mat activated

2.12 Obstruction sensing activated

2.21 Ramp OUT-Limit microswitch is out

of adjustment or defective

2.31 Loose chain

2.32 Debris inside ramp cassette

3.11 Pressure mat activated

3.12 Obstruction sensing activated

Remove object from mat.

See controller diagnostic guide Check ramp for obstructions. Check ramp for excessive debris contamination inside cassette

Check adjustment or replace

Adjust chain

Clean debris from cassette

Remove object from mat.

See controller diagnostic guide Check ramp for obstructions. Check ramp for excessive debris contamination inside cassette

3.00

STOW

OPERATION

3.20

Ratcheting

Noise at End

or during

Ramp Stowing

3.30

Excessive

Noise while

Ramp

Stowing

3.21 Ramp full in limit switch defective

3.31 Lose chain

3.32 Debris inside ramp cassette

Check adjustment or replace

Adjust chain

Clean debris from cassette

Page 39

REPAIR PARTS

Item Qty. Description RA500-3236

1 1 Weldment, Ramp Frame - RA500 RA0111W 2 1 Linear Guide System - Rail MOD RA0020M 3 3 Linear Guide System - Carriage RA0021 4 1 Switch, Rear Stop - RA500 RA0022 5 1 Sprocket, Fixed Guide - Manual Release - ER01 27491 6 1 Bearing, Plain Plastic - ID 8MM / OD 10MM - ER 27497 7 1 Weldment, Traveling Cross Arm - RA500 RA0112W 8 1 Weldment, Chain End - RA500 RA0024W 9 17 Nut, M5 Nylock ZP 83038 10 3 Skid Pad, RA500 RA0026 11 1 Roller, Carriage - RA500 RA0028 12 3 Microswitch, Sealed 30205 13 1 Top Plate, Alum w/ or w/o Laminate RA0123 14 1 Hinge, SS 2" x 1/4" x 30" or 40" 18619R030 15 1 Threshold, RA500 RA0122Y 16 1 Track Cover, Left - RA500 RA0031Y 17 1 Track Cover, Right - RA500 RA0032Y 18 1 Bottom Panel - RA500 RA0124 19 1 Access Panel - RA500 RA0034 20 41 Screw, M5 x 10 Flat Socket Head Cap - SS 27448 21 23 Screw, M5 x 23 Flat Socket Head Cap - SS 27453 22 1 Motor, GR63 x 55 w/PLG52 28:1RDU - 24V RA0080A 23 1 Miter Gear Set, 1.5M 16/32 Tooth - Bev Gear RA0081M 24 1 Motor Support - RA500 RA0083 25 1 Pivot Pin - RA500 RA0084 26 2 Stainless Rod, 3/8" Dia. #303 x 12.5" or 13" 80379R012.5 27 1 Release Cam - RA500 RA0090 28 1 Steel Bar - 3/16" Sq. x 7/8" 21118R000.875 29 2 Bearing, Flange - 8MM x 7.7MM 32400 30 20 Screw, M4 x 6 - FHSCS/SS 32399 31 2 E Clip, 5/16" Shaft - 1/4" Groove 84086 32 22 Screw, M4 x 10 - BHSCS/SS 30153 33 - - 34 9 Screw, M5 x 10 Button Head Socket Cap - SS 28786 35 1 Motor Mount - RA500 RA0089 36 1 Washer, .328" x .562" x .042" - SS 83583 37 2 Spring, 0.72" OD / .096" WD / 1.5L / Compr - SS RA0014 38 3 Screw, M5 x 5MM Set 18321 39 18 Rivet, M4 x 10 Countersunk Blind 27441 40 6 Screw, M6 x 16 Flat Head Socket Cap - SS 27758 41 18 Screw, M4 x 10 Flat Head Socket Cap - SS 27440 42 4 Screw, M3 x 10 Flat Head Socket Cap - SS 27438 43 2 Plate, Tapped #4-40 Microswitch 24998 44 6 Screw, Mach. #4-40 x 5/8" Rd Hd - Auto BK 14810 45 23 Nut, Weld - M5 Plain Slab Base 32402 46 1 Screw, M5 x 20 Hex Head Cap - SS 27452 47 1 Chain, Roller 8MM Pitch - Procoat x 99" 28532R099 48 4 Bearing, Plastic - Flange 3/8" ID x 1/4" 24028 49 1 Cable, Manual Release - M8 x 1450 x79-ER0 27526 50 1 Assembly, Platform - Weight Sensing - RA323 RA0110A 51 4 Tape, Adhesive - UHMW Film - .020" x 3" - Blk 28475R 52 1 Weldment, Hinge 2" x 1/4" x 32" or 41" - SS 18619W032Y 53 1 Weldment, Sprocket - Drive Position - Carriage RA0126W 54 1 Top Cover, Mat RA0131 55 2 Link, Chain Master - 8mm Pitch - SS 27428 56 1 Harness, Ramp RA0060A 57 1 Assembly, RA500 Interface Board 100218-001 58 2 Grip Tape, Traction Adhesive 3" x 12" - Yellow or Black 24173-YL 59 1 Harness, Ramp Controller RA0128A 60 2 Tag, Serial # / Series # - Plastic 18548P 61 1 Assembly, Platform - Weight Sensitive RA0110A 62 1 Assembly, Controller RA500 Interface Board 100218-001

*

* *

*

* * *

* * * *

*Item not Shown

Page 40

DETAIL A

Rotated 90˚

A

32

1

2

20

38

42

4

41

31

26

35

3

45

19

18

9

14

6

5

36

50

7

13

17

30

16

11

10

40

54

52

21

15

58

12

34

48

35

23

34

48

24

22

31

25

12

29

23

28

31

1

27

53

37

26

EXPLODED VIEW

Page 41A Page 42A

TO PARK BRAKE to OPERATE (HIGH)

TO FULL OUT INDICATOR (N.O.)

TO MOVE IN INDICATOR (N.O.)

TO PARK BRAKE to OPERATE (LOW)

TO RAMP STOW SWITCH

TO FULL IN INDICATOR (N.O.)

TO SWITCH (COM.)

TO RAMP ENABLE

TO MANUAL RELEASE INDICATOR (N.O.)

TO FUSED POWER INDICATOR (COM.)

TO ONE TOUCH SWITCH

TO RAMP DEPLOY SWITCH

TO ALARM INDICATOR (N.O.)

TO MOVE OUT INDICATOR (N.O.)

NOTES:

1) DRAWING SHOWN WITH RAMP IN STOWED POSITION.

2) CROSSING INTERSECTIONS ARE NOT CONNECTIONS (JUNCTION), UNLESS MARKED AS JUNCTION.

3) * RECOMMENDED WIRE GAUGE.

1234567

8

J5

9

1011121314

1234567

8

P5

9

1011121314

1 2 3 4 5 6

J2

1 2 3

J3

1 2

J4

7 8

1 2 3 4 5 6

P2

1 2 3

P3

1 2

P4

10 GA.*

14 GA. WH

10 GA.*

10 GA.* 10 GA.*

14 GA. BK

20 GA. PK

20 GA. GY

20 GA. YL

20 GA. GN

20 GA. BR

20 GA. WH

1 2 3 4 5 6

J1 1 2 3 4 5 6

P1

18 GA. RD18 GA. RD

18 GA. BK

MOTOR RD MOTOR BK

18 GA.

LT GN/YL

18 GA.

5 CON. (#4)

18 GA.

LT GN/GN

18 GA. WH

18 GA.

5 CON. (#3)

18 GA. WH

18 GA.

5 CON. (#2)

18 GA. WH

18 GA. LT GN/YL

18 GA. - 5 CON. (#4)

18 GA. - 5 CON. (#3)

18 GA. - 5 CON. (#2)

18 GA. WH18 GA. WH

14 to 18 GA.*

18 GA. BK

18 GA. RD

14 to 18 GA.*

M

CONTROLLER

CIRCUIT

PROTECTION

DEVICE

(25 AMP.)

GROUND

BATTERY

(24V)

NC

NO

C

NC

NO

C

NO

C

NC

NO

C

"MANUAL

RELEASE"

MICROSWITCH

"WEIGHT SENSING

PLATFORM"

PRESSURE SWITCH

"IN-LIMIT"

MICROSWITCH

"OUT-LIMIT"

MICROSWITCH

CONTROLLER ASSEMBLY

POWER AND DATA CONNECTIONS (PROVIDED BY INSTALLER)

RA500 RAMP ASSEMBLY

HARNESS RA0128A

RA500 RAMP ASSEMBLY

M

BATTERY

CHASSIS GROUND

CIRCUIT PROTECTION DEVICE

JUNCTION

MOTOR

MICROSWITCH

SYMBOLDESCRIPTION

NC

NO

C

SYMBOL KEY

Unfold for:

RA500 Ramp

Exploded View

WIRING SCHEMATIC

Page 41B Page 42B

Wiring Diagram

CONNECTOR - J1

(B.C.# 86206)

4

3

2

1

COLOR

HARNESS

(B.C.# RA0128A)

8-COND WIRE CODE

8

7

6

5

YELLOW - 20 GA.

GREEN - 20 GA.

BROWN - 20 GA.

WHITE - 20 GA.

BLACK - 14 GA.

WHITE - 14 GA.

PINK - 20 GA.

GRAY - 20 GA.

METRIC - mm

WIRE SIZE CONVERSION

Note: See page 29 of this manual

for detailed information on installer

provided wiring connections.

2.0 mm

1.0 mm

0.8 mm

0.5 mm

2

22222

2

5.0 mm

3.0 mm

US - Gauge

14 GA.

16 GA.

18 GA.

20 GA.

10 GA.

12 GA.

CONNECTOR - P1

(B.C.# 25496)

4

3

2

1

COLOR

HARNESS

(B.C.# RA0060A)

8-COND WIRE CODE

8

7

6

5

5 CONDUCTOR (#4) - 18 GA.

5 CONDUCTOR (#3) - 18 GA.

5 CONDUCTOR (#2) - 18 GA.

WHITE - 18 GA.

BLACK - 18 GA.

RED - 18 GA.

PLUG - NOT USED

LT GREEN / YELLOW - 18 GA.

CONNECTOR - P2

(B.C.# 95170-000)

4

3

2

1

COLOR

WIRING PROVIDED

BY INSTALLER

6-COND WIRE CODE

5

YELLOW - 20 GA.

GRAY - 20 GA.

6

PINK - 20 GA.

GREEN - 20 GA.

WHITE - 20 GA.

BROWN - 20 GA.

COM.

N.O.

N.C.

COLORPIN

MICROSWITCH CONN.

N.C.

N.O.

COM.

WHITE - 18 GA.

5 CONDUCTOR (#2) - 18 GA.

NOT USED

"OUT-LIMIT"

MICROSWITCH

COM.

N.O.

N.C.

COLORPIN

MICROSWITCH CONN.

N.C.

N.O.

COM.

WHITE - 18 GA.

5 CONDUCTOR (#3) - 18 GA.

NOT USED

"IN-LIMIT"

MICROSWITCH

COM.

N.O.

N.C.

COLORPIN

MICROSWITCH CONN.

N.C.

N.O.

COM.

LT GREEN / GREEN - 18 GA.

LT GREEN / YELLOW - 18 GA.

NOT USED

MANUAL RELEASE

MICROSWITCH

-

COLORPLAT.

PLATFORM CONN.

5 CONDUCTOR (#4) - 18 GA.

WHITE - 18 GA.

WEIGHT SENSING

PLATFORM (OPTIONAL)

BK

RD

COLORMOT.

MOTOR CONNECTIONS

BLACK - 18 GA.

RED - 18 GA.

ELECTRIC MOTOR

123

4

876

5

567

8

123

4

1 2 3

4 5 6

3

2

1

COLORPIN

WHITE - 14 GA.

NOT USED

BLACK - 14 GA.

21 3

3-COND WIRE CODE

WIRING PROVIDED

BY INSTALLER

WIRING PROVIDED

BY INSTALLER

2

1

FUNCTIONPIN

GROUND - 10 GA. *

BATTERY (24V) - 10 GA. *

1 2

* RECOMMENDED WIRE GAUGE

3-COND WIRE CODE

1 2 3

4 5 7

8 9 11

6

10

1213 14

4

3

2

1

FUNCTIONPIN

14-COND WIRE CODE

5

ONE TOUCH - 14 to 18 GA.*

POWER COM. - 14 to 18 GA.*

MANUAL REL. - 14 to 18 GA.*

DEPLOY RAMP - 14 to 18 GA.*

ALARM - 14 to 18 GA.*

MOVE OUT - 14 to 18 GA.*

8

7

6

9

SWITCH COM. - 14 to 18 GA.*

FULL IN - 14 to 18 GA.*

RAMP STOW - 14 to 18 GA.*

RAMP ENABLE - 14 to 18 GA.*

12

11

10

13

MOVE IN - 14 to 18 GA.*

FULL OUT - 14 to 18 GA.*

PARK BK HIGH - 14 to 18 GA.*

PARK BK LOW - 14 to 18 GA.*

14

CONNECTOR - P3

(B.C.# 32778)

DATA HARNESS

CONNECTOR - P5

(B.C.# 27517)

SHEILD (B.C.# 27742)

PIN (B.C.# 27482)

POWER HARNESS

CONNECTOR - P4

(B.C.# 29877)

CONTACT (B.C.# 29221)

RA0128A

RA0060A

TROUBLESHOOTING

Page 43

Page 41

DAILY PREVENTIVE MAINTENANCE SCHEDULE

Vehicle Number:

Inspector:

Date:

Pre-Trip Inspection:

Before each scheduled day of lift service, operate ramp minimum one complete cycle and

inspect each of the following :

✓

Do the vehicle interlock(s) function as intended?

Does the ramp deploy when the ramp interlock is activated as intended?

Does the control switch(es) function properly?

Does the ramp cargo door light (if equipped) function as intended?

Do the lift cargo door securement devices function as intended (if equipped)?

Does the ramp safely clear the cargo door as the ramp is deployed and stowed?

Does the ramp operate smoothly (no jerking or abnormal movement)?

Does the ramp operate at normal speed?

Is the power source adequate?

Is ramp operation quiet (no rattles, abnormal sounds, etc.)?

Is the ramp antiskid in place, worn or damaged?

Can you visually detect any ramp wear, damage, misalignment, loose bolts, broken welds or any abnormal conditions?

Post-Trip Inspection:

Operate ramp minimum one complete cycle and check each of the above daily pre-trip inspections if applicable for your daily inspection routine (outlined by your transit agency).

Clean ramp surfaces where wheelchairs travel

Clean and lubricate key locations based on ramp usage frequency and climate conditions (outlined by your transit agency). Lubrication procedures should be performed by a Braun authorized service representative as detailed in this manual.

Page 44

Page 42

Over 300 Braun

Dealers Worldwide

"Providing Access to the World"

®

"Providing Access to the World"

International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA

1-800-THE LIFT® (574) 946-6153 FAX: (574) 946-4670

®

Braun RA500 Transit Ramp

Commercial

Braun “Worry-Free” Limited Warranty

The Braun Corporation (“Braun”) warrants it’s ramp against defects in material and workmanship for three years, provided the ramp is installed, operated and maintained in conformity with this manual. Warrantied replacement parts are covered until the expiration of the Braun warranty or 90 days, whichever is longer. The Braun warranty covers the cost of labor for any repair or replacement covered under the warranty during the first year of the warranty period, if an approved Braun dealer completes the warranty work. The warranty registration card accompanying this ramp is to be completed and returned to The Braun Corporation within 20 days of purchase. If Braun receives the warranty card, the warranty period begins on the day the ramp is put into service. If Braun does not receive the warranty card, the parts warranty will expire in three years, and the labor warranty will expire in one year from the manufacture date of the ramp. The Braun warranty does not cover any defects in the motor vehicle on which the ramp is installed, or defects in the ramp caused by any defect in the motor vehicle. The warranty does not cover work deemed by Braun to be normal maintenance, service, or periodic adjustments necessitated by use or wear. The Braun warranty is null and void if any repair or maintenance work is completed during the warranty period using parts not authorized by Braun or if, as determined solely by Braun, the ramp is damaged through accident, misuse or abuse, or altered in any way.

THIS WARRANTY IS IN LIEU OF ALL IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, PERFORMANCE, OR OTHERWISE, WHICH ARE HEREBY EXCLUDED. IN NO EVENT SHALL BRAUN BE LIABLE FOR ANY DAMAGES, WHETHER DIRECT, IMMEDIATE, INCIDENTAL, FORESEEABLE, CONSEQUENTIAL, OR SPECIAL, ARISING OUT OF OR IN CONNECTION WITH ITS PRODUCT.

Braun RA500 Transit Ramp

32848 Rev. A

August 2006

To contact Braun or to obtain a list of Braun authorized dealers, call 1-800-THE-LIFT or visit our web site at www.braunlift.com. The Braun Corporation Winamac, Indiana

Return Authorization Procedure

When processing any warranty claims (parts, repairs, etc.), all requests must be processed through The

Braun Corporation Product Support Department. Call 1-800-THE LIFT during normal working hours.

Product Support will issue a Return Material Authorization (RMA) number and detail the procedures

required for processing returns and/or authorizing credit.

The lift identification information is provided on the Braun Serial No./Series No. identification tag and

the two warranty cards (shown on inside front cover). The lift identification information must be

provided when filing a warranty claim or ordering parts.

"Providing Access to the World"

International Corporate Hdqrs: P.O. Box 310 Winamac, IN 46996 USA

1-800-THE LIFT® (574) 946-6153 FAX: (574) 946-4670

® ®

All illustrations, descriptions and specifications in this manual are based on the latest product information available at the

time of publication. The Braun Corporation reserves the right to make changes at any time without notice.

Braun RA500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual