Byk-Rak P. O. Box 40 Owosso, Michigan

Transcription

1 yk-rak ronc@byk-rak.com P. O. ox 0 Owosso, Michigan -000

2 Table of ontents yk-rak Introduction... enefits of the yk-rak... Key Features... - Specifications... Technical Features One Solo Position Position Quick Release Features... - Installation - General Information... racket Mounting... Help Universal 9 and 0 umper Installation... - Help Slide In umper Slide In umper Stand Off... 0 Nova - racket... - New Flyer Low Floor racket... Height/Position djustment... Mounting the yk-rak... yk-rak Operation... us Washing... Parts and Service Visual Inspection hecklist... Parts 0 - ay Inspection ay Service... Quality Inspection Process Plan... 0 Nova LFS Mounting racket racket ssembly Flexible... RT racket ssembly... racket ssembly... racket ssembly... racket ssembly Kit... 0 Quick Release... racket Surface Mount... 0 Explode SM Kit Freightliner M... 0 Mounting Kit International... 9 racket Mount Kit Thomas... 0 Mnt racket Kit T Installation sheet for hevy 00 Standoff racket... hevy Mounting Kit Z racket ssembly F0 Mount ssembly Kit... 0 Mounting Kit Inveros NF... 0 Mounting racket Kit Position NI us LF... racket ssembly Kit... 9 RT Mounitng Kit RT Mounting Kit... 9 racket ssembly-new Flyer. L... 9

3 Table of ontents (continued) Parts bracket Kit Flexible... Z9000 Template racket... Z9000 racket Template... yk-rak E Receiver racket Exploded... -S racket ssembly Short... racket ssembly... -L racket ssembly Long... -XL racket ssembly XLong... racket ssembly Rack MTG... L racket ssembly L... 9 Spacer Kit Position Rack... Rack Kit Ford... lue ird ll merican umper racket... 0 Ford Tansit racket -Gas... 0 racket... Z9000 olt Kit NI RT Mounting racket... 9 Kit odge Sprinter racket Rack ssembly - Single STN... 0 ssembly Modular Rail ike Rack plt ssembly - Fr. Hardware ssembly Modular Rail... 0-G ike Rack Position RT... -G ssembly Fr. & Hardware RT... 0 ssembly - Modular Rail... 00E Rack ssembly -Position Wide... 0E Frame ssembly -Postiion Wide... 0 ssembly Modular... 0H ike Rack plt.... H Frame ssembly plt... 9 H ssembly Modular Rail... 0 H ssembly Modular Rail... 0H Quick isconnect Hinge racket... 00H Hinge racket luminum Pivot bracket ssembly... 00E Pivot racket... Z900 Kit Spring ssembly Position racket Hinge racket Hinge... 0S ike Rack plt. w/sensor ESN ike Rack plt. w/sensor Sensor ssembly HS racket Hinge w/sensor S racket Hinge w/sensor L ike Rack eployment Sensor SL racket ssembly w/ Sensor Leads HSL Hinge racket ssembly w/ Lead... 9 Z9000 Harness Sensor Extension amper ssembly... 9 Installation Exploded Installation Exploded W0P Wall Mount yk Rak... 0

4 . Introduction Welcome to the yk-rak system. The yk-rak system is designed to allow flexibility in loading and unloading bikes regardless of style or size. Transit authorities were consulted on the design of the yk-rak system for ease of use on buses. Using that information, we incorporated four main elements to ensure compatibility.. Easy operation (for riders and maintenance employees). Economical choice. urable construction commercial grade. an go through bus wash and has little maintenance. enefits of the yk-rak The yk-rak system accepts all bicycles regardless of size or style, and can be operated by one person. Our efficient design coupled with the durable, commercial grade material makes it a cost effective choice that will last. ue to its quick use, the yk- Rak system will not slow down bus schedules. It is designed to go through a bus wash, and requires very little maintenance. Figure. yk-rak. Key Features Independent Loading/Unloading lthough the yk-rak has space for two bicycles, it is designed so the inside bike can be loaded and unloaded without removing the outside bike. Simply swing down the Wheel Lock, located near the sidewalk, and guide the bike down onto the curb. In this way, the rider need not lean uncomfortably over the other bike or access the bike from street-side to unload it. Safe use for bicycles The yk-rak system is designed to securely hold the bike by the wheels only, so there is no chance of scratched paint or other damage to the bicycle.

5 onvenient, secure Wheel Lock The yk-rak employs the use of a Wheel Lock that secures the bike after it is put in the yk-rak. The pedals do not have to be oriented to miss the frame. fter the bike is put in, the rider conveniently swings the Wheel Lock around to the top of the front wheel. This action is assisted with a spring-loaded lever that creates a positive locking system. This same lever holds the Wheel Lock in a stored position while not in use. Wheel Lock ike Wheel Handle Figure. Wheel Lock Figure. Stored Position Load/unload speed In order to ensure fast operation, a series of tests were administered to determine the average loading and unloading speed. These tests were completed by people who had no experience with the yk-rak system, using a variety of bikes, and included stowing and lowering the yk-rak from its stored position. mazingly, the average time of operation for either loading or unloading was 0 seconds or less! Operation with one hand The yk-rak is designed with a well-located locking pin release handle to allow riders to raise or lower the yk-rak with one hand while they hold their bikes with the other. No loose parts and simple construction The yk-rak has a simple construction with few parts, and no detachable parts such as pins, clips, or straps, that could be lost. icycle ompatibility The yk-rak is designed specifically to fit any type of bike and, more importantly, fit all in the same way. No modifications or additions are needed to load any type of bike, whether it s a mountain bike, road bike, or child s bike.

6 . Specifications Figure. yk-rak Specifications omponents ) Release Handle ssembly ) Wheel Lock ssembly Outside Rail ) Wheel Lock ssembly Inside Rail ) amper ssembly ) Frame Weld ssembly ) Rail Weld ssembly ) ttachment Plate Figure. Hinge racket Specifications omponents ) racket ase Plate ) Locking am ) Hinge Plate (x)

7 . Technical Features ike Rack One (SOLO) Position Modular ike Rack ssembly yk-rak Technical Features and Safety The yk-rak is inches deep by 0 inches wide. The yk-rak weighs less than pounds. ll parts of the yk-rak are finished with powder coat paint. (Unless specified by customers request i.e. electro polish and/or bead blasted bike racks) ll moving parts on the yk-rak are made of stainless steel. (including the yk-rak itself) The yk-rak is mounted to the front of the bus. The yk-rak is always in the deployed position. The yk-rak has rounded outside corners, smooth welds, and few pinch points. ikes can be loaded and unloaded from the sidewalk-side or front of the yk-rak. enefits and dvantages The yk-rak is large enough to hold any adult-sized bikes (excluding tandem and recumbent) children s bikes down to a size of diameter wheels. The yk-rak meets OSH/NIOSH standards for lifting by a single individual. Powder coat painting provides corrosion resistance and will not flake off. It can chip, but that chip will not increase in size. This method of painting is also more environmentally safe than traditional methods. Stainless steel is corrosion resistant and will not chip like plated or coated steel. Front-mounting the carrier increases driver visibility, safety, and security. yk-rak protrudes minimally for increased maneuverability. Having these safety features lessen the likeliness of injury to the operator. ikes are always loaded and unloaded from the sidewalk-side so the user is not exposed to traffic. The main rail on the yk-rak are removable. The yk-rak is constructed to support over pounds static in the deployed position. ikes are secured by the front wheel lock, and supported on the back wheel. The yk-rak makes contact only with the tires of the bicycle. The yk-rak accepts bicycles without any orientation of the pedals. Removable rail allow commonality between yk-rak products and modular replacement of damaged parts for ease of repair and a lower cost. This allows the carrier to easily hold heavy bikes and provides for misuse. Loading/unloading times are under 0 seconds, so use of the yk-rak does not affect scheduling. ike frames or other parts will not be scratched or damaged. This speeds up loading times because the user need not adjust the pedals to miss any part of the yk-rak.

8 The yk-rak has no pins, clips, or straps. The yk-rak has minimal use of complex parts. The icycle Rack shall be clearly marked with easy to follow instructions for operation. The wheel lock folds away when stored The bumper mounting bracket is adjustable via multiple bolt-holes. ike Rack will have removable rail that can be replaced with a modular component. Headlight lockage and Turning Radius was main factors in development of our new design One Position ike Rack. There are no small parts to break down or lose. This also contributes to fast loading time. simple construction ensures high reliability and ease of use. Educated the user as to the correct orientation of the bike when loading, ensuring the shortest loading and unloading time possible. The wheel lock folds into the center of the yk- Rak automatically so it will not damage the front of the bus. The yk-rak s height can be adjusted for different buses or routes. Rack can be moved up or down away from Headlights With this design racks that have been damage to the rail component can be replaced without replacing the entire rack. With the small profile of the one position bike rack the drivers ability to turn and view what is in front of him have greatly been enhanced compared to and position bike racks

9 Technical Features and Specifications Position Modular ike Rack yk-rak Technical Features The yk-rak is 0 inches deep by inches wide. Lifting weight of the yk-rak is less than 0 pounds to stow. The yk-rak can be lowered or raised with one hand. ll parts of the yk-rak are finished with powder coat paint. Stainless Steel ike Racks are either bead blasted for a Non- Glare finish or Electro- Polished for a hrome like finish. ll moving parts on the yk-rak are made of stainless steel. The yk-rak is mounted to the front of the bus. The yk-rak has two locking positions, stowed and deployed. The yk-rak has rounded outside corners, smooth welds, and few pinch joints. The yk-rak does not block wipers or access panels in the stowed position. ikes can be unloaded from the sidewalkside or front of the yk-rak. ikes can be independently loaded or unloaded. dvantages The yk-rak is large enough to hold adult-sized bikes (excluding tandem and recumbent) and designed to hold smaller bikes down to a children s size of diameter wheels. The yk-rak meets OSH standards for lifting by a single individual, and anyone can raise or lower with one hand, ensuring convenient operation. This leaves the other hand free to stabilize the bike so the rider can operate the yk-rak independently. Powder coat painting provides corrosion resistance and will not flake off. It can chip, but that chip will not increase in size. This method of painting is also more environmentally safe than traditional methods. Very little Maintenance is needed on the Stainless Steel bike racks. Stainless steel is corrosion resistant and will not chip like plated or coated steel. Front-mounting the carrier increases driver visibility, safety, and security. In the stowed position the yk-rak protrudes minimally for increased maneuverability. Locking the carrier minimizes shaking. These safety features lessen the likeliness of an operator being injured. The carrier mounts to right to the bumper and bikes are held far enough away to not interfere with wipers or access panels. ikes never need to be unloaded from streetside so the user is not exposed to traffic. This allows either bike slot to be accessed at any time.

10 Technical Features on t The yk-rak is constructed to support over 0 pounds in the central portion. It will support bicycles up to lbs. per bike rail while the vehicle is moving. ikes wheels are secured by the front wheel lock and rail system. No contact is made to the frame of the bicycle. The yk-rak only makes contact with the tires of the bicycle. The yk-rak accepts bicycles without any orientation of the pedals. The yk-rak has no pins, clips, or straps or cords. The yk-rak has been designed to have a simple design with few parts. The wheel lock folds away when stowed automatically requiring no action from the bicycle rider for proper stowage. The bumper mounting bracket is adjustable via multiple bolt-holes. The Hinge racket is designed to attach to all mounting brackets similarly. ike Rack will have removable rails that can be replaced with a modular component. These rails are interchangeable for front or back dvantages This allows the carrier to easily hold heavy bikes and provides for misuse, such as someone climbing on to it to reach a mirror or window. This means loading and unloading times are under 0 seconds so use of the yk-rak will not affect scheduling. ike frames or other parts will not be scratched or damaged. This speeds up loading times because the user need not adjust the pedals to miss any part of the yk-rak. There are no loose parts to break down or become lost. This also contributes to the fast loading time. simple construction ensures ease of use and high reliability. The wheel lock folds into the center of the yk-rak automatically so it will not damage the front of the bus. The yk-rak s height can be adjusted for different buses or routes. The yk-rak can be installed on any bus through the use of different mounting brackets. With this design racks that have been damage to the rail component can be replaced without replacing the entire rack.

11 Position Wide Modular ike Rack ssembly yk-rak Technical Features and Safety The yk-rak is 9. inches deep by inches wide. The yk-rak weighs less than pounds. The yk-rak can be lowered or raised with one hand. spring assisted pivot bracket is recommended to reduce lifting weight. ll parts of the yk-rak are finished with powder coat paint. (Unless specified by customers request i.e. electro polish and/or bead blasted bike racks) ll moving parts on the yk-rak are made of stainless steel. (including the yk-rak itself) No surface lubrication is needed. The yk-rak is mounted to the front of the bus. The yk-rak has two locking positions, stowed and deployed. The yk-rak has rounded outside corners, smooth welds, and few pinch points. The yk-rak does not block wipers or access panels in the stowed position. ikes can be loaded and unloaded from the sidewalk-side or front of the yk-rak. ikes can be independently loaded or unloaded. The main rails on the yk-rak are removable. The yk-rak is constructed to support over 0 pounds static in the deployed position. pounds per bike rail. enefits and dvantages The yk-rak is large enough to hold any adult-sized bikes (excluding tandem and recumbent) children s bikes down to a size of diameter wheels. The yk-rak meets OSH/NIOSH standards for lifting by a single individual, and anyone can raise or lower with one hand, ensuring convenient operation. This leaves the other hand free to stabilize the bike so the rider can operate the yk-rak with ease. Powder coat painting provides corrosion resistance and will not flake off. It can chip, but that chip will not increase in size. This method of painting is also more environmentally safe than traditional methods. Stainless steel is corrosion resistant and will not chip like plated or coated steel. Non- Glare Stainless Steel Finish is available. Front-mounting the carrier increases driver visibility, safety, and security. In the stowed position the yk-rak protrudes minimally for increased maneuverability. Locking the carrier minimizes shaking. Having these safety features lessen the likeliness of injury to the operator. The carrier mounts right to the bumper, and bikes are held far enough away to not interfere with wipers or access panels. ikes are always loaded and unloaded from the sidewalk-side so the user is not exposed to traffic. This allows either bike slot to be accessed at any time. Removable rails allow commonality between yk-rak products and modular replacement of damaged parts for ease of repair and a lower cost. This allows the carrier to easily hold heavy bikes and provides for misuse.

12 ikes are secured by the front wheel lock, and supported on the back wheel. The yk-rak makes contact only with the tires of the bicycle. The yk-rak accepts bicycles without any orientation of the pedals. The yk-rak has no pins, clips, or straps. The yk-rak has minimal use of complex parts. The icycle Rack shall be clearly marked with easy to follow instructions for operation. The wheel lock folds away when stored The bumper mounting bracket is adjustable via multiple bolt-holes. The Hinge racket is designed to attach to all mounting brackets similarly. ike Rack will have removable rails that can be replaced with a modular component. These rails are interchangeable. Headlight lockage and Turning Radius was main factors in development of our new design Position ike Rack. Loading/unloading times are under 0 seconds, so use of the yk-rak does not affect scheduling. ike frames or other parts will not be scratched or damaged. This speeds up loading times because the user need not adjust the pedals to miss any part of the yk-rak. There are no small parts to break down or lose. This also contributes to fast loading time. simple construction ensures high reliability and ease of use. Educated the user as to the correct orientation of the bike when loading, ensuring the shortest loading and unloading time possible. The wheel lock folds into the center of the yk- Rak automatically so it will not damage the front of the bus. The yk-rak s height can be adjusted for different buses or routes. The yk-rak can easily be installed on any bus through the use of different mounting brackets. With this design racks that have been damage to the rail component can be replaced without replacing the entire rack. Testing has determined with bikes loaded there is no blockage increase from the Position bike rack loaded with bikes. Through Engineered off-set design and precise angles these goals were accomplished. 9

13 THE INFORMTION ONTINE IN THIS RWING IS THE SOLE PROPERTY OF YK-RK, LL. NY REPROUTION IN PRT OR WHOLE WITHOUT THE WRITTEN PERMISSION OF YK-RK, LL IS PROHIITE. REV. REVISIONS ESRIPTION SELINE RELESE REVISE TO UPTE SUSSEMLIES REVISE TO UPTE SUSSEMLIES Hardware updated TE 0//0 //00 //00 -- ITEM NO. PRT NUMER ESRIPTION REVISION QTY. INV0-0-E Frame Sy -Position Wide -00 INV0-0- sy-modular Rail G-00 INV0-9- olt - Hex Flg Hd -00 INV0-9- Hex Nut Nylon -00 INV0-9- olt - Hex Flg Hd -009 General Notes: Rail ssembly is universal; handle and damper are switched from side to side to change location Hardware Torque Specs are as follows: MM -. N-m (0 lbf-ft) 0MM N-m ( lbf-ft) Quick Release Mounting kit (#Z9000) is available Mass: 9 (g) Scale onfidential Printed: patents pending imensions are in mm unless otherwise specified Tolerances: Material: Treatment: no treatment required Status: Generated rawing, o Not Manually Update o Not Scale rawing Project: urrent production bike racks yk-rak, LL PO ox 0 Owosso, MI Phone: 00-- Notes Rack sy -Position Wide escription Name Rack sy -Position Wide Size wg. No. INV0-00-E : File INV0-00-E Monday, ecember 0, 0 Part Rev. Seq. Rev Ḍwg Seq. Sheet of 0

14 .. Quick Release yk-rak The Quick Release yk-rak is a special model that was designed to quickly and easily disassemble without sacrificing reliability. This model is useful for environments in which the yk-rak may be removed frequently or shared between buses. The Quick Release yk-rak is made up of three assembly features that may be used in concert, or separately as the situation demands. No tools are necessary to remove the quick release yk-rak... Quick Release Rails Each of the two rails may be removed for cleaning or maintenance. To install the rails onto the main frame, insert the two fixed pegs into the holes on one side of the frame and bolt down the other side. To remove the rail(s) simply remove the bolt and lift the rail off the frame... Quick Release Frame The Quick Release Frame uses a fixed pin and a removable cotter pin instead of bolts to attach the frame to the hinge plate. See Figure.. below. Figure.. Quick Release Frame To install, rotate the yk-rak frame to a angle and slide in the left side pin. Next, slide the right side pin in, put the washer on, and insert the cotter pin. To remove the yk-rak frame, reverse the process described above. The yk-rak may now be used to transport bicycles.

15 .. Quick Release S/S racket Kit This assembly was designed to allow an operator to quickly disconnect the hinge bracket from the bumper bracket. This is convenient if a yk-rak may be removed often or switched between different buses. The Quick Release racket is installed between the bumper bracket and the hinge bracket and is made up of two parts: one plate that is bolted to the bumper bracket and another that is bolted to the hinge bracket. No tools are necessary for operation. Figure.. Quick Release umper racket To install the Quick Release racket see the section on installing the bumper bracket specific to your bus or bumper type. The bracket is bolted to the bumper bracket in the same way as the hinge bracket usually would. Notice in Figure.. that there are three sets of holes for horizontal adjustment of the yk-rak. The other half of the Quick Release racket bolts to the hinge bracket in the same way. See Figure.. below. Figure.. Quick Release Pivot racket

16 . Installation- General Information Proper installation of the yk-rak is the most important factor in the safety and effectiveness of its use. Four main elements of the yk-rak s installation must be considered when setting up the carrier.. pproach ngle. Footprint. Loading Height. Protrusion Please read carefully before installing the yk-rak.. pproach ngle- The approach angle is the angle formed by the ground and a line from the front tire to the first obstruction ahead of it. This angle determines the steepness of incline that the bus can drive. The installer should be aware that mounting the yk-rak too low can decrease the approach angle of the bus.. Footprint- The footprint refers to the profile of the stowed yk-rak against the front of the bus. The carrier should be mounted so as to avoid blocking headlights and/or turn signals.. Loading Height- This height corresponds to the vertical distance that a bicycle must be lifted into the yk-rak. Mounting the carrier too high can make it difficult for users to load the bike.. Protrusion- Protrusion is the distance from the front bumper to the furthest edge of the yk-rak in the deployed position. This measurement is important because: ike rack protrusion is limited by many state epartments of Transportation (e.g. alifornia s limit is inches). pproach angle and turning radius are more affected as protrusion increases. Protrusion determines the distance between the stowed yk-rak and the front of the bus; the carrier should not interfere with windshield wipers or the driver s line-of-sight.

17 9. racket Mounting The yk-rak system is made up of two parts: the yk-rak and the bracket that fastens the carrier to the bus bumper. Proper installation of both is required to ensure the safe and effective operation of the yk-rak. The bracket usually connects to the bumper but may also attach to the front of the bus itself depending on the bus/bumper type. The installer must be sure to follow the directions for the correct bus type. fter determining the correct bumper bracket the installer should inspect the front of the bus for these conditions.. Is the bumper mounted correctly?. Is the bumper and bus frame in good repair? Make sure nothing is damaged, like a bent bumper from a collision.. Is there any other object installed on the bus that could compromise the installation or operation of the yk-rak?. Some installations require the installer to remove the bumper. It is then the installer s responsibility to determine whether the bumper-to-bus bolts should be reused. If the answer to any of these questions is NO, the bus must be repaired prior to installing the yk-rak mounting bracket. Mounting the yk-rak without making these repairs or modifying the yk-rak to fit on a damaged bus is unsafe, and voids all yk-rak warranties.

18 9. Help Universal 9 and 0 umper Installation The yk-rak system mounts to both the 9 wide and 0 wide Help Universal bumpers by the same method. The Help Universal bumper is identified by an array of exposed bolts on the top and bottom of the bumper. The yk-rak - racket attaches to four of these bolts. Generally, no modification is needed to install the -racket. However, make sure to check that there is enough space between the bumper and the bus body to fit the -racket. If there is not enough space to install the -racket, you have two options: a) modify the front body of the bus to make space for the -racket or b) re-mount the bumper low enough that the -racket will fit Follow these directions to install either a 9 or 0 -racket. The installation varies slightly between the two widths; the 9 -racket has welded ear tabs on the outside of the mounting arms while the 0 -racket does not. ) Set up the -rackets and Hinge racket in the orientation shown below and fasten the bolts loosely. Part Qty escription /-x-/ hex bolt / washer / lockwasher /- nut ) Figure 9.. -racket Installation

19 ) The next step is to find the four bolts, two on the top and two on the bottom of the bumper, that the -racket will attach too. The difference between the 9 and 0 Help Universal bumpers is that the 9 bumper has a bolt on the centerline. See Figure 9.. below. 0 umper 9 umper Use these bolts olt on centerline Figure 9.. Top View Use these bolts ) ttach the -racket to the Help Universal umper in places using /- x hex bolts, lockwashers, and spacers. See Figure 9.. below. hex bolt attaches to existing bumper clip (x) Figure 9.. -racket Installation Part Qty escription /-x hex bolt / lockwasher / washer spacer ) Next, tighten all of the fasteners and bolts, including those connecting the Hinge racket to the -rackets. ongratulations! You have successfully installed the mounting bracket and Hinge racket. ) Proceed to Section 0: Mounting the yk-rak.

20 9. Help Slide-In umper Installation The Help Slide-In bumper is identified by its hollow aluminum bumper structure and its black urethane pieces that slide-in to the back structure and meet at the bumper centerline. One of two methods may be used to mount the yk-rak on the Help Slide-In bumper: the Stand-off bracket or the -racket. The Stand-off mounting bracket may be used if there is not enough space between the bumper and bus body for the -racket. 9. Slide-In umper -racket Installation The -racket for yk-rak mounts to the Slide-In bumper at four spots, two on top of the bumper and two on bottom of the bumper. Usually the -racket can be installed without changes to the existing bumper set-up. However, sometimes there is not enough space between the bumper and bus body for the -racket arm to fit. It is important that you check the clearance between the bumper and bus body before attempting to install the -racket. If there is not enough room for the -racket, you have three options: a) modify the front body of the bus to make space for the -racket, b) re-mount the bumper low enough that the -racket will fit, or c) use the Stand-off bracket method (see end of Section 9.) ) First, you must mark out the centerline of the front of the bus and the bumper. These lines will be used later to reattach the bumper. To make these lines, use the centerline of the aluminum back structure as a reference. ) Next, detach the Help Slide-In bumper from the bus frame by removing the bumper-to-frame bolts. ) Place and tightly hold the provided drill template on the top of the bumper, making sure to align the center lines. Make sure the top edge is flush with the edge of the aluminum back structure. Now drill two / pilot holes, on the right and left of the centerline. See Figure 9.. below. pilot holes align to centerline dowels Figure 9.. Template Set-up

21 ) Repeat step, now on the bottom of the bumper. ) Enlarge each of the holes made in steps and with a / drill bit. ) Set up the -rackets and Hinge racket in the orientation shown below and fasten the bolts loosely. Part Qty escription /-x-/ hex bolt / washer / lockwasher /- nut Figure racket Installation

22 ) ttach the -racket to the Help Slide-In umper in places using /-x- / bolts, lockwashers, and spacers. See Figure 9.. below. Tighten all fasteners and bolts. Part Qty escription /-x-/ hex bolt / lockwasher / washer /- locknut Figure 9.. -racket Installation ) Lastly, remount the bumper to the bus frame with the bumper-to-frame bolts, making sure to align the centerlines. Tighten all of the fasteners and bolts, including those connecting the Hinge racket to the -rackets. 9) ongratulations! You have successfully installed the mounting bracket and Hinge racket. Proceed to Section 0: Mounting the yk-rak. 9

23 9.. Slide-In umper Stand-Off Installation Using the Stand-Off installation method, four holes are drilled through the polyurethane structure and aluminum back structure. The Stand-Off bracket is then attached to the aluminum back structure via four bolts. This method is well suited for buses with insufficient space between the bumper and bus body to mount -rackets. Note before installation: If the bus has a wheelchair lift you may have to lower the lift and remove the lift pan to gain access to the bumper. lso, you may have to remove the bumper to gain access to some bolts. ) First, find the provided drill jig template and fit it to the front of the bumper. The semi-cylindrical pieces should help index the template. Make sure the center of the template is aligned with the center of the bus. drill holes (x) semicylinder Figure 9.. Stand-Off Template ) rill one / pilot hole through one of the top template drill holes. Insert a / dowel into the template and urethane to index the template. Now, drill the other top hole and put another / dowel into it. Lastly, drill the two bottom holes, making sure that the template does not move. ) With all the pilot holes drilled, remove the template. ut four holes using a - / hole saw with a / pilot drill. Make sure that each hole is drilled perpendicular to the bumper face and drill though any structural ribs that may be encountered. ) Now, insert the two Stand-Off brackets into the holes. The brackets should be pushed in until the tube contacts the aluminum back structure. 0

24 9. Nova -racket Installation The -racket for yk-rak mounts to the Nova bumper at four spots, two on top of the bumper and two on bottom of the bumper. Usually the -racket can be installed with no changes to the existing bumper set-up. Sometimes, however, there is not enough space between the bumper and bus body for the -racket arm to fit. It is important that you check the clearance between the bumper and bus body before attempting to install the -racket. If there is not enough room for the -racket, you have three options: a) modify the front body of the bus to make space for the -racket, b) re-mount the bumper low enough that the -racket will fit, or c) use the Threaded Insert bracket method (see Section 9.) ) First, you must mark out the centerline of the front of the bus and the bumper. These lines will be used later to reattach the bumper. To make these lines, use the centerline of the aluminum back structure as a reference. ) Now, detach the Nova bumper from the bus frame by removing the bumperto-frame bolts. ) Place and tightly hold the provided drill template on the top of the bumper, making sure to align the center lines. lso, make sure the top edge is flush with the edge of the aluminum back structure. Now drill two / pilot holes, on the right and left of the centerline. See Figure 9.. below. Figure 9.. Nova Template ) Repeat step, now on the bottom of the bumper. ) Enlarge each of the holes made in steps and with a / drill bit. ) Set up the -rackets and Hinge racket in the orientation shown below and fasten the bolts loosely.

25 Part Qty escription /-x-/ hex bolt / washer / lockwasher /- nut Figure 9.. ) ttach the -racket to the Nova umper in places using /-x-/ bolts, lockwashers, and spacers. See Figure 9.. below. Tighten all fasteners and bolts. Figure 9.. Nova -racket Installation Part Qty escription /-x-/ hex bolt / lockwasher / washer /- locknut ) Lastly, remount the bumper to the bus frame with the bumper-to-frame bolts, making sure to align the centerlines. Tighten all of the fasteners and bolts, including those connecting the Hinge racket to the -rackets. 9) ongratulations! You have successfully installed the mounting bracket and Hinge racket. Proceed to Section 0: Mounting the yk-rak.

26 9.9 New Flyer low floor racket Installation The New Flyer low floor bracket is a tube-style stand-off bracket that is very similar to the Help Slide-In and RTS stand-off brackets (Sections.,.). The only difference is this bracket has inline tubes instead of offset. For step-by-step installation instructions, refer to Sections 9. or 9.. Figure 9.9. New Flyer low floor racket

27 . Height/Position djustment To change the height or left/right positioning of the yk-rak, first detach the carrier from the hinge bracket, if installed already. Next, uninstall the hinge bracket and position it up, down, left, or right as desired and reinstall the fasteners/bolts in another set of adjustment holes. Figure 0. djustment Holes (e.g - racket) epending on the bus type, some brackets do not have multiple height adjustment holes. If so, the hinge bracket will be positioned optimally and no adjustment is required.

28 . Mounting the yk-rak Now that the bracket has been mounted to the bus per the instructions, the yk- Rak can be installed to the hinge bracket. This installation is extremely quick and simple, because only two bolts must be fastened. See Figure. below. Figure. yk-rak Mounting Instructions omponents ) Zinc-Plated Grade Medium Strength Hex Head ap Screw / - Thread, -/ Length (x) ) Zinc-Plated Steel SE High Strength Flat Washer / Screw Size, -/ O, / I,.09 Min Thk (x) ) NSI Type 0 Tube Spacer 9mm MX O,.mm MIN I, Wall Thickness.mm±0.mm ) Zinc-Plated Grade Steel Hex Nylon-Insert Locknut, / - Screw Size, / W, 9/ HT (x) Once the yk-rak has been secured by the two machine screws, make sure the carrier can swing freely and lock into the stowed and deployed positions.

29 . yk-rak Operation The yk-rak is very fast and easy to use, eliminating any deviation from typical bus schedules. The yk-rak can be quickly loaded or unloaded by an individual rider, although young children should be assisted by an adult. When loading or unloading a bicycle, follow these steps: UTION: Loading or unloading your bike from street side may cause death or serious injury.. Loading a icycle ) Make ready your bike for loading by removing any loose items that may fall off, such as water bottles or tire pumps. ) Make sure that the bus driver is aware that you are loading your bike. Load from the curb or in front of the bus; never step into oncoming traffic to load your bike. ) To lower the yk-rak from the stowed position, pull the handle with one hand and lower the carrier until you feel it lock. Use your other hand to steady your bicycle. ) Next, lift your bike and set it into yk-rak. Tire slot is clearly labeled FRONT WHEEL. The bike can be loaded and secured backwards, but the label is attached to make it easier to unload the inside bike. ) Swing the wheel lock around (from under the yk-rak) and on top of the front wheel. ) You may now board the bus.. Unloading a icycle ) s the bus approaches your stop, notify the bus driver that you will be unloading your bike. Unload from the curb or in front of the bus; never step into oncoming traffic to unload your bike. ) Swing the wheel lock around to under the front tire. ) You may now lift your bike out of the yk-rak. ) If the yk-rak is empty and no one is waiting to load their bike, lift the yk- Rak up until it locks into the stowed position. UTION: Loading or unloading your bike from street side may cause death or serious injury. yk-rak does not condone use of motorized vehicles on their ike Racks. Use of Motorized vehicles will void the warranty of the yk-rak equipment.

30 . us Washing One of the major features of the yk-rak is it s compatibility with bus washes. s long as the yk-rak is empty and in the stowed position, it can be safely taken through a bus wash facility. The yk-rak system was designed with round tubing and edges so the wash brushes will not become entangled or stuck in the carrier. lthough the yk-rak is fully compatible with bus wash facilities, the following conditions can damage the carrier and should be avoided. ) Slow brush rotation- If the wash brushes are spinning too slowly they may catch onto any protruding object such as a mirror. lso, if the axle pushes too deeply onto the yk-rak it may get caught on any vertical ridges. ) High bus speed- If the bus is moving too quickly through the bus wash system, the same problems explained above may occur. ) Low brush density- If there are too few brushes on the brush arm, the axle may be pushed too deeply onto the yk-rak and may catch on any vertical ridges. ) rushes blocking bus path- The brushes should spin away from the front of the bus in order to climb across any protrusions. If the brush is on the driver s side, it should spin counter-clockwise when viewed from above. ny brush on the opposite side should spin clockwise. See Figure. for a visual representation. brushes spinning away from bus Figure. us Wash s long as these conditions are not present and the yk-rak is in the stowed position, there should be no damage above regular wear and tear. If excess damage is observed, examine the yk-rak setup and the bus wash facility. If any further problems are encountered, please contact yk-rak at (00) -.

31 . Parts and Service Figure. Visual Inspection yk-rak Visual Inspection hecklist yk-rak recommends a quick visual inspection before utilizing the carrier. Use this as a checklist and inspection sheet for bus drivers. If any of the following statements are false, repair the yk-rak before putting into service. ) yk-rak swings from stowed to deployed position freely and locks in each position automatically. ) Release handle easily unlocks yk-rak to change positions without sticking. ) Wheel lock swings all the way around and spring keeps tension. ) End caps are present and not damaged. 0 ay Inspection heck every 0 days to ensure that: ) The yk-rak swings easily between the stowed and deployed positions. ) The release handle unlocks the yk-rak and does not stick. ) The locking pin automatically locks in the deployed and stowed positions. ) ll bolts/fasteners are present and tight. ) The two end caps on the front of the yk-rak are present and not damaged. ) ll instruction labels are present and intact (not shredded, marred, or scratched off). When replacing, first clean the surface with isopropyl alcohol. ) The main frame and bike rails are unbent and structurally sound. 0 ay Service If 0 day inspection shows damage, follow this service list: ) If the yk-rak does not swing easily, check the hinge plate assembly, attachment plate, and hinge bolts for incorrect installation or damage. If they are damaged, replace immediately. If the hinge or attachment plates are bent, remove and straighten or replace. ) Make sure the main frame and bike rails are undamaged and unbent. If they are damaged, replace immediately.

32 Process ontrol Plan Prototype Pre Launch Production ontrol Plan Number: ccessory Part for Transit uses Key ontact/ Phone: 99-- ate (Orig.): -Jun-0 pproved Part Number 00-HE / ore Team: GL, GM, KG ustomer Engineering pproval/ ate: N/ Latest hange Level: Rev. pproval ate: -Jun-0 ustomer Quality pproval/ ate: N/ Part Name ike Rack/ Pivot racket ssembly Other pproval ate (if req.): N/ pproved y: ob Reichert Part/ Process Number Inspection Team: Midwest us Supervisor: Greg Limbaugh Process Name/ Operation escription Machine, evise, Jig, Tools, for Mfg. haracteristics Number Product Process Special haracteristic lass Product/ Process Spec. Tolerance Evaluation/ Measurement Technique Methods Sample Size Frequency ontrol Method 0 heck all hardware is secure Roll Pins, olt & Nuts 0- Zero efects Visual, Wrench 00% Each Part Per Q Process 0 heck Red Stoppers on Rack heck both nuts are tight 0- Zero efects Visual, Wrench 00% Each Part Per Q Process 0 Operate Release Handle Ensure that the release handle freely engages and disengages the pin 0- Zero efects Mechanical 00% Each Part Per rawing 0 heck all labels that they are correct heck position and straightness 0- Zero efects Visual 00% Each Part Per Q Process 0 Inspect Powder oated Parts No hips, Scratches, or missing paint 0- Touch up Paint Zero efects Visual 00% Each Part Per Q Process 0 Package Rack into box over Rack with plastic bag and support material 0- N/ Labor 00% Each Part Per Q Process -Jun-0 Reaction Plan Tighten loose parts Modify Stopper to Spec isassemble Pin assembly and replace ad Parts hange out Labels Touched up parts must blend in with powder coating person job to ensure quality 9

33 . Nova LFS Mounting racket. LFS Mounting racket 0 Label # Part Number escription Qty. Price N/ 0 Kit - LFS Mounting racket $.00 0 attachment plate all bracket assembly all 9 insert / all 0 bolt / x. Grade all washer / USS Flat all bolt M x, IN 9, fully all threaded washer M IN all lock nut Mx IN 9 all 9 washer / split lock - all 0 bolt / x. Grade all 0 washer / SE Flat all nut / Grade all

34 9 THE INFORMTION ONTINE IN THIS RWING IS LTIR ENGINEERING. NY REPROUTION IN PRT THE WRITTEN PERMISSION OF LTIR ENGINEERING THE SOLE PROPERTY OR WHOLE WITHOUT IS PROHIITE. tighten with ft-lbs (x) OF tighten with 0ft-lbs (x) ITEM NO. PRT NUME R Revisio n ESRIPTIO N INV INV QTY. F lexible bracket ass y " bolt /" - x." Grade INV s pacer / " INV bolt /" - x." Grade INV washer /" SE Fla t INV w asher /" Split lock - INV w asher /" split lock - INV n ut /" - grade 9 INV washe r /" /" / " " imensions are in inch unless otherwise specified Tolerances: Material: Treatment: Status: Generated rawing, o Not Manually Update o Not Project: ttachment Standard: Scale racket yk-rak rawing Systems Notes for Flxible escription brckt ass'y FLXILE Name brckt ass'y FLXILE Size wg. No. Rev. Seq. INV Scale File Sheet : I NV-0-0 of Printed: Tuesday, October, 00 onfidential patent pending

35 .000 Tolerances Project Material Treatment ZONE REV REVISIONS ESRIPTION TE PPROVE //0 yk-rak Name SIZE RT racket ssm. WG NO. INV-0- Scale Sheet Status TE rawn y //0 JW

36 THE INFORMTION ONTINE IN THIS RWING IS THE SOLE PROPERTY OF ITEM NO. PRT NUME R Revisio n ESRIPTIO N QTY. LTIR ENGINEERING. NY REPROUTION IN PRT OR WHOLE WITHOUT THE WRITTEN PERMISSION OF LTIR ENGINEERING IS PROHIITE. INV attachment bracket ass y INV bolt /" - x." Grade INV washer /" USS Fla t INV SE /" flat washe r INV bolt /" - x." Grade INV washer /" SE Fla t INV washer /" split lock - INV nut /" - grade 9 INV lock nut /" - grade tighten with 0 ft-lbs. (x) tighten with ft-lbs. (x) " 9 imensions are in inch unless otherwise specified Tolerances: Material: Treatment: Status: Generated rawing, o Not Manually Update o Not Project: ttachment Standard: Scale rawing racket yk-rak Systems Notes for escription bracket bracket Name Size ass'y INV-0- Scale :0 Printed: New Flyer ass'y for low floor wg. No. Rev. File Thursday, New Flyer May, onfidential patents pending -0 I NV-0- of 00 Sheet Seq.

37 T H E I N F O R M T I O N LTIR ENGINEERING. N Y T H E W R I T T E N P E R M I S S I O N O N T I N E I N T H I S R W I N G I S T H E S O L E P R O P E R T Y O F R E V I S I O N S R E P R O U T I O N I N P R T O F L T I R E N G I N E E R I N G O R I S W H O L E W I T H O U T P R O H I I T E. Z O N E R E V. E S R I P T I O N T E I n i t i a l r e l e a s e, based on INV / / 0 0 s pacing dimensioned d i f f e r e n t / 0 / 0 0 I T E M N O. P RT NUME R R e v i s i o n E S R I P T I O N Q T Y. a t t a c h m e n t b r a c k e t a s s y, I N V c u r b s i d e I N V a t t a c h m e n t b r a c k e t a s s y, d r i v e r s i d e I N V b o l t / " - x. " G r a d e I N V w a s h e r / " USS Fla t I N V l o c k n u t / " - g r a d e I N V S E / " f l a t w a s h e r I N V b o l t / " - x. " G r a d e I N V w a s h e r / " SE Fla t 9 I N V w a s h e r / " s p l i t l o c k - 0 I N V n u t / " - g r a d e 0 9 " tighten with 0 ft- lbs. ( x ) tighten with ft - lbs. ( x ) i m e n s i o n s a r e u n l e s s o t h e r w i s e T o l e r a n c e s : M a t e r i a l : T r e a t m e n t : i n i n c h s p e c i f i e d S t a t u s : Generated o N o t M a n u a l l y o N o t P r o j e c t : t t a c h m e n t S t a n d a r d : S c a l e r a w i n g, U p d a t e r a w i n g r a c k e t yk-rak S y s t e m s N o t e s f o r e s c r i p t i o n b r a c k e t b r a c k e t a s s ' y w g. N o. I N V N a m e S i z e S c a l e : 0 P r i n t e d : New Flyer a s s ' y low floor f o r R e v. File T h u r s d a y, New Flyer M a y S h e e t I N V o f, o n f i d e n t i a l p a t e n t s p e n d i n g 0 0 S e q.

38 9 0 Tighten / bolts - ft-lbs (x) Tighten /" bolts - ft-lbs () ZONE REVISIONS REV ESRIPTION TE PPROVE Initial Release 9//0 KP " Item # Qty Part NumberPart Name 0 Z90000 Hex nut /"- grade 0 Z9000 Washer /" SE flat 00- SE /" flat Z90000 Washer /" USS flat 0 Z9000 Washer /" Lock 09 rkt ttachment sy 9 Z90000 olt. - x. 0 0 Z olt /"-x." Grade 0- Lock Nut /"- grade SIZE racket rkt ssembly ssy. Kit Kit Scale Sheet WG NO. TE rawn y 9// KP

39 THE INFORMTION ONTINE IN THIS RWING IS THE SOLE PROPERTY OF REVISIONS LTIR ENGINEERING. NY REPROUTION IN PRT OR WHOLE WITHOUT ZONE REV. ESRIPTION TE THE WRITTEN PERMISSION OF LTIR ENGINEERING IS PROHIITE. initial release /0/00 rackets Updated & dded Mtg Fasteners 0//0 /" bolt." wqs.". Hardware part numbers changed -- ITEM NO. PRT NUMER Revision ESRIPTION QTY. INV quick release mechanism INV jam nut /" - grade zinc plate INV Pin - Quick Release Z9000 washer /" SE Flat Z9000 washer /" split lock - Z9000 bolt /" - x." Grade Z90000 nut /" - grade onfidential patents pending imensions are in inches unless otherwise specified Tolerances: Material: Treatment: Status: Generated rawing, o Not Manually Update o Not Scale rawing Project: ttachment racket Systems Mass: $PRP:. yk-rak Notes escription quick release complete Quick release Name Size wg. No. INV-0-0 Scale File : INV-0-0 Printed: Thursday, May 0, 0 Rev. Part Seq. Rev Ḍwg Seq. Sheet of

40 ZONE REV.00 Tolerances Project +/-.0" +/- deg. Material Treatment Mild Steel Pwdr t lk.000 Name SIZE REVISIONS ESRIPTION TE PPROVE // yk-rak racket WG NO. Scale Sheet Status TE rawn y : //09 JW

41 PROPRIETRY N ONFIENTIL THE INFORMTION ONTINE IN THIS RWING IS THE SOLE PROPERTY OF YK RK. NY REPROUTION IN PRT OR S WHOLE WITHOUT THE WRITTEN NEXT SSY PERMISSION OF YK RK IS PROHIITE. USE ON PPLITION IMENSIONS RE IN INHES TOLERNES: FRTIONL NGULR: MH EN TWO PLE EIML THREE PLE EIML MTERIL -- FINISH -- O NOT SLE RWING 0 RWN HEKE ENG PPR. MFG PPR. Q.. ITEM # PRT # ESRIPTION QTY. rkt enter rkt Mounting Rt rkt Mounting Lt 0 Z90000 Washer- /" USS Flat 0- Nut - Lock OMMENTS: Z90009 NME TE KP -- SHSREW 0.-x.-HX-N SS Z9000 Holt.-x. Z HOLT 0.0-x.x.-N Z90000 HHNUT N Z9000 Heavy LW 0. Z9000 Regular FW 0. EXPLOE SM KIT FREIGHTLINER M SIZE WG. NO. SLE::0 WEIGHT: 0 SHEET OF REV.

42 0 REVISIONS ZONE REV ESRIPTION TE PPROVE Initial Release 9-- KP Item # Qty Part # Part Name 9 00-H PIVOT RKT SM Z90009 olt M-.X0MM Z9000 FlatWSHR _~N rkt Lower Mounting Spacer-Mnt rkt 9 Z90000 HEX NUT_~- 0 Z HEX H_~- Z90000 WSHER Z9000 LK WSHR~ r rkt Upper Mounting Mounting Kit International SIZE WG NO. 0 I Scale Sheet TE rawn y 9-- KP 9

43 ZONE REVISIONS REV ESRIPTION Initial release TE PPROVE 9--0 KP Item Part # escription Qty Z9000 olt."- x. Z9000 Washer Flat." Z9000 Washer Lock." Z90000 Hex Nut."- rkt Mount sm rkt Mount Kit Thomas SIZE Scale Sheet WG NO. TE 9--0 rawn y KP 0

44 REVISIONS ZONE REV ESRIPTION TE Initial Release 0--0 PPROVE KP 9 0 Item Part # escription Qty Z Outside acking Plate 00 Inside acking Plate 00 Mounting rkt 00 Standoff Mnt 00 olt /"- x." Grade Flat Washer /" Lock nut /"- Grade Z olt /- x /" 9 0 Z9000 Washer - /" Flat Z9000 Washer /" Lock Z90000 Nut - /- Z9000 Z9000 olt /"- x /" Grd Hex Hd olt /"- x /" Grd Hex Hd yk-rak WG NO. Mnt rkt Kit 00 Sheet 00 - Present SIZE Scale TE 0--0 rawn y KP

45 HEVY 00 RKET INSTLLTION )Remove bumper from Vehicle )Locate drill template as shown on inside of bumper, -clamp to bumper when positioned ) rill /" pilot hole places ) Remove drill template and cut -/" diameter holes in bumper with hole saw places ) Install tovehicle frame ) Reinstall bumper to vehicle and mount standoffs thru bumper to ) Torque all fasteners to specified torque REVISIONS ZONE REV. ESRIPTION TE INITIL RELESE 0//0 RILL / PILOT HOLE THRU UMPER PLES LOTE TO TOP OF INSIE UMPER. LIGN WITH UMPER L PROPRIETRY N ONFIENTIL THE INFORMTION ONTINE IN THIS RWING IS THE SOLE PROPERTY OF YK RK. NY REPROUTION IN PRT OR S WHOLE WITHOUT THE WRITTEN PERMISSION OF YK RK IS PROHIITE. NEXT SSY PPLITION USE ON IMENSIONS RE IN INHES TOLERNES UNLESS NOTE: FRTIONL ± NGULR: MH ±.0º EN ±.0º TWO PLE EIML ±0.0 THREE PLE EIML ±0.0 TRIMLINE ±0.0 HOLE SIZE ±0.0 MTERIL 0-O (SS) FINISH no treatment required O NOT SLE RWING RWN HEKE ENG PPR. MFG PPR. Q.. OMMENTS: NME TE LTIR SLE:: INSTLLTION SHEET FOR HEVY 00 STNOFF RKET SIZE WG. NO. WEIGHT: SHEET OF REV. T -00.