Issue: May 2015 Art.-No.: 10019508 Instructions AMF-BRUNS BELT ANCHORAGE POINTS (tested in accordance with 2007/46/EG) Ford Tourneo Custom Ford Transit Custom The vehicle manufacturer's body fitting guidelines must be adhered to and AMF-Bruns original parts need to be used for the installation! www.amf-bruns.de
Foreword Foreword Dear reader, these Instructions serve to provide information for the correct installation of the AMF-BRUNS belt anchorage points. These Instructions only apply to the types of vehicle specified on the cover page. Keep these Instructions in a safe place so that they are readily available for a possible new installation or for installing additional components. If the vehicle fitted with AMF-Bruns special accessories changes ownership, the Instructions must be handed over to the new owner. The parts provided must never be converted or modified in any way, without seeking the prior, written permission of the manufacturer. The manufacturer will not be held responsible in any way whatsoever if conversions or modifications are carried out without authorisation. All details, figures and dimensions contained in these Instructions are non-binding. No claims in any form can be derived from these. This document must not be reproduced or duplicated, in full or in part, without the prior, written permission of the manufacturer. Contact our customer services department to order spare parts or accessories (see Chapter 4, page 30). AMF-Bruns Belt Anchorage Points Page 3 of 32
Foreword Explanation of symbols and signs To improve understanding, the following conventions should be met for these Operating Instructions. 1. The following types of special note are used to highlight text passages of an important nature. DANGER! warns of a situation of immediate danger, which will lead to serious or fatal injuries, if not avoided. WARNING! warns of a potentially dangerous situation, which will lead to serious or fatal injuries, if not avoided. CAUTION! warns of a potentially dangerous situation, which will lead to slight or minor injuries,or material damage if not avoided. CAUTION!...warns of a potentially dangerous situation, which can cause material damage, if not avoided....contains general notes and useful information....gives a reference to important information in other sections and documents. Page 4 of 32 AMF-Bruns Belt Anchorage Points
Foreword 2. Some texts serve a particular purpose. These are identified as follows: Lists Instructional text, e.g. a sequence of activities. 3. Meaning of directions: If directions are given in the text (in front of, front, behind, rear, right, left), these directions relate to the normal direction of travel of the vehicle. AMF-Bruns Belt Anchorage Points Page 5 of 32
Contents Contents Foreword... 3 Contents... 6 1 Safety... 7 2... 8 2.1 Safety Information for... 8 2.2 Suitable Positions... 10 2.3 Carrying Out Work... 11 2.4 Side Wall Belt Anchorage Points... 12 2.4.1 C-pillar... 12 2.4.2 Side wall... 14 2.4.3 D-pillar, area 1... 16 2.4.4 D-pillar, area 2... 18 2.5 Floor Belt Anchorage Points... 19 2.5.1 Floor Pockets, front anchorage point... 20 2.5.2 Floor Pockets, rear anchorage point... 21 2.5.3 Mono-Fittings, front anchorage point... 22 2.5.4 Mono-Fittings, rear anchorage point... 23 2.5.5 Floor Belt Reels... 24 2.5.6 Floor installation Airline rails... 25 3 Tightening torques... 29 3.1 Standard threaded steel screws... 29 3.2 Stainless-steel screws... 29 3.3 Belt screws... 29 3.4 Countersunk screws for Floor Pockets... 29 3.5 Countersunk screws for Mono-Fittings... 29 3.6 Airline rails... 29 4 Customer Service... 30 Page 6 of 32 AMF-Bruns Belt Anchorage Points
Safety 1 Safety The installation company itself is responsible for adherence to the safety regulations when installing the AMF-Bruns belt anchorage points. is insofar carried out at the sole risk installation company. The manufacturer will accept no liability whatsoever for damage caused during installation. Unless such damage is caused by grossly negligent or intentional breach of contract on the part of the manufacturer. In addition to the information given in these Instructions, standard ISO 10542 must also be adhered to when installing the belt anchorage points on the floor of the vehicle. In addition to this, local legislative regulations must be taken into consideration, in particular those regarding safety and accident prevention. Detailed information regarding safety when using the belt anchorage points can be found in the relevant Operating Instructions. Personnel Requirements The belt anchorage points must only be installed by specialist personnel, who have read and understood these Instructions, of whom it can be expected, that they will execute the job entrusted to them in a responsible and reliable manner and have been assigned to install the belt anchorage points by the owner of the vehicle. AMF-Bruns Belt Anchorage Points Page 7 of 32
2 2.1 Safety Information for DANGER! Risk of danger through incorrect installation. A number of risks of personal injury and material damage can be caused if the belt anchorage points are incorrectly installed in the vehicle. Such risks of danger can not only occur during installation but also as a result of installation not being carried out correctly. Therefore: The belt anchorage points must only be installed by trained, specialist personnel. DANGER! Danger through insufficiently stable or non-permanent connections. If the units are not force locked to the bodywork the screwed connection can become loose. As a result of this, the safety equipment that is fastened to the belt anchorage points can be rendered ineffective. Examples: Gaps between components and bodywork caused by corrugation, underbody sealant between components and bodywork. Therefore: The units must have force locked connection to the bodywork. This force locked connection must be made using compensating materials if necessary (e.g. spacers). DANGER! Dangers through use of unsuitable installation materials. Unsuitable installation materials will not withstand the loads imposed on them if an accident occurs. Multiple risks of injury for all of the vehicle's passengers can arise as a result of this. Material damage can be caused. Therefore: Only the original AMF-Bruns fastening parts listed in the test protocol must be used for the upper belt anchorage points, installation of the Airline Rails, Floor Pocket and Mono-Fittings. Page 8 of 32 AMF-Bruns Belt Anchorage Points
DANGER! Danger through screws becoming loose. If screws are not tightened to the specified torque, they can become loose during operation. As a result of this, the safety equipment that is fastened to the belt anchorage points can be rendered ineffective. Therefore: Tighten all fastening screws to the torque specified in Chapter 3, page 29. If any of the vehicle's original screws are loosened or removed for installation, they must be re-tightened to the torque specified by the vehicle manufacturer. NOTE The vehicle manufacturer's body fitting guidelines must be adhered to during installation. AMF-Bruns Belt Anchorage Points Page 9 of 32
2.2 Suitable Positions Figure 1 gives an overview of the areas of the vehicle in which the belt anchorage points can be installed. When selecting the installation position for the belt anchorage points on the floor of the vehicle, observe the information given on page 19. C-pillar Side wall D-pillar, area 2 D-pillar, area 1 Floor installation (shown here: Smartfloor) Figure 1: Positions for Belt Anchorage Points, Ford Tourneo Custom, Ford Transit Custom Page 10 of 32 AMF-Bruns Belt Anchorage Points
2.3 Carrying Out Work Remove the interior cladding from the area in which the belt anchorage points and Airline rails are to be installed. Fit the components for the foreseen belt anchorage points and Airline rails as shown in the figures in the sections that follow: Belt anchorage points on the C-pillar: see Section 2.4.1, page 12. Side wall belt anchorage points, see Section 2.4.2, page 14. Belt anchorage points on the D-pillar: see Section 2.4.3, page 16, and Section 2.4.4, page 18. Floor pockets, floor installation: see Section 2.5.1, page 20, and Section 2.5.2, page 21. Mono-Fittings, floor installation: see Section 2.5.3, page 22, and Section 2.5.4, page 23. Floor installation of belt retractor reels: see Section 2.5.5, page 24. Floor installation of Airline rails and relevant fittings: see Section 2.5.6, page 25. Tighten all fastening screws/bolts to the torque specified in Chapter 3, page 29. Make certain that all connections are force locked. Replace the interior cladding. When installing all components, observe Section 2.1, page 8. NOTE If you have any further questions regarding installation of the belt anchorage points, contact the customer service department. Contact information: see Chapter 4, page 30. AMF-Bruns Belt Anchorage Points Page 11 of 32
2.4 Side Wall Belt Anchorage Points 2.4.1 C-pillar Car Body Thread cutting during assembly Retaining Waher Washer d = 11,5 / D = 20 Shoulder Bolt 7/16 20 UNF 1 3/16 Optional for OEM trim: Bushing component part of 10019582 Webbing Chromed Pillar Loop Cover Figure 2: C-Pillar, Top Belt Anchorage Point Page 12 of 32 AMF-Bruns Belt Anchorage Points
Car Body Thread cutting during assembly Retractor Shoulder Bolt 7/16 20-UNF 1 component part of 10019362 Figure 3: C-Pillar, Bottom Belt Anchorage Point AMF-Bruns Belt Anchorage Points Page 13 of 32
2.4.2 Side wall plate component part of 10019550 Car Body Rivet 4 12 / K 8,0 component part of 10019550 Retaining Washer Washer d = 11,5 / D = 20 Chromed Pillar Loop Shoulder Bolt 7/16 20 UNF 1 3/16 Optional for OEM trim: Bushing component part of 10019582 Cover Webbing Figure 4: Side wall, top belt anchorage point Page 14 of 32 AMF-Bruns Belt Anchorage Points
Locknut 7/16 20-UNF component part of 10019362 Washer d = 11.5 component part of 10019362 Retractor Car Body Hexagonal Screw 7/16 20-UNF 1 component part of 10019362 Figure 5: Side wall, bottom belt anchorage point AMF-Bruns Belt Anchorage Points Page 15 of 32
2.4.3 D-pillar, area 1 Car Body Plate component part of 10019550 Rivet 4 12 / K 8.0 component part of 10019550 Retaining Washer Washer d = 11,5 / D = 20 Chromed Pillar Loop Shoulder Bolt 7/16 20 UNF 1 3/16 Optional for OEM trim: Bushing component part of 10019582 Webbing Cover Figure 6:D-Pillar, Area 1, Top Belt Anchorage Point Page 16 of 32 AMF-Bruns Belt Anchorage Points
Retractor Rivet 4 12 / K 8,0 component part of 10019550 Hexagonal Screw 200046511 7/16 20 UNF 1 Car Body Plate component part of 10019550 Figure 7: D-Pillar, Area 1, Bottom Belt Anchorage Point AMF-Bruns Belt Anchorage Points Page 17 of 32
2.4.4 D-pillar, area 2 Technical design: see Figure 6, page 16. Figure 8: D-Pillar, Area 2, Top Belt Anchorage Point The belt reel can be installed at two different heights in area 2 of the D-pillar (see Figure 9). For a view of the technical design, see Figure 7, page 17. Figure 9: D-Pillar, Area 2, Bottom Belt Anchorage Point Page 18 of 32 AMF-Bruns Belt Anchorage Points
2.5 Floor Belt Anchorage Points All areas of the vehicle's floor can be used to install the belt anchorage points. Selecting the installation position for the belt anchorage points on the floor of the vehicle will determine the future position of the wheelchair in the vehicle. For the safety and comfort of the passenger in the wheelchair, it is necessary to provide sufficient space to the front, rear and above. NOTE Adhere to standard ISO 10542 when selecting the belt anchorage points. DANGER! Dangers through use of unsuitable installation materials. Unsuitable installation materials will not withstand the loads imposed on them if an accident occurs. Multiple risks of injury for all of the vehicle's passengers can arise as a result of this. Material damage can be caused. Therefore: Only the original AMF-Bruns fastening parts listed in the test protocol must be used for the installation of the Airline Rails, Floor Pocket and Mono-Fittings. DANGER! Danger through belt anchorage points behind the wheelchair that are not strong enough. If an accident occurs, the belt anchorage points behind the wheelchair are subjected to more severe strain than the belt anchorage points in front of the wheelchair. The floor of the vehicle alone can not withstand such strain. The belt anchorage points could be torn out. Multiple risks of injury for all of the vehicle's passengers can arise as a result of this. Material damage can be caused. Therefore: When installing the floor belt anchorage points behind the wheelchair, reinforce these using the U-profile provided (see Figure 11, page 21, and Figure 13, page 23). Position the U-profile such that it rests perpendicularly against a vehicle cross member. AMF-Bruns Belt Anchorage Points Page 19 of 32
2.5.1 Floor Pockets, front anchorage point Countersunk Screw M 10 700 component part of 200269390 Driving Direction Pocket component part of 200269390 Bushingg component part of 200269390 Washer component part of 200269390 Locknut M 10 component part of 200269390 Figure 10: Floor Pocket, Floor Ahead of the Wheelchair Page 20 of 32 Adapt the length of the t spacer bushings to match the struc- ture of the floor AMF-Bruns s Belt Anchorage Points
2.5.2 Floor Pockets, rear anchorage point Countersunk Screw M 10 70 component part of 200269390 Driving Direction Pocket 200263620 component part of 200269390 Bushing component part of 200269390 Washer component part of 200269390 U-profile 200279572 Vehicle Cross Member Locknut M 10 component part of 200269390 Adapt the length of the spacer bushings to match the structure of the floor Perpendicular Alignment between U-Profile and Vehicle Cross Member Figure 11: Floor Pocket, Floor Behind the Wheelchair AMF-Bruns Belt Anchorage Points Page 21 of 32
2.5.3 Mono-Fittings, front anchorage point Countersunk Screw M 12 component part of H150917 / H150919 Pocket component part of H150917 / H150919 Safety Plate component part of H150917 / H150919 Mono-Fitting Bushing component part of H150917 / H150919 Belt (optional) Retractor (optional) Washer component part of H150917 / H150919 Locknut M12 component part of H150917 / H150919 Driving Direction Adapt the length of the spacer bushings to match the structure of the floor Safety Plate Figure 12: Retractor with Mono-Fitting, Floor Ahead of the Wheelchair Page 22 of 32 AMF-Bruns Belt Anchorage Points
2.5.4 Mono-Fittings, rear anchorage point Countersunk Screw M 12 70 component part of H150919 Pocket component part of H150919 Mono-Fitting Safety Plate component part of H150919 Bushing 200301282 Belt (optional) Retractor (optional) Vehicle Cross Member U-Profile 200279572 Washer component part of H150919 Driving Direction Locknut M12 component part of H150919 Adapt the length of the spacer bushings to match the structure of the floor Safety Plate Perpendicular Alignment between U-Profile and Vehicle Cross Member Figure 13: Retractor with Mono-Fitting, Floor Behind the Wheelchair AMF-Bruns Belt Anchorage Points Page 23 of 32
2.5.5 Floor Belt Reels Locknut 7/16 20-UNF component part of 10019362 Hexagonal Screw 7/16 20-UNF 2 3/16 component part of 10019361 90 angle Bracket 10013014 Washer d = 11.5 component part of 10019362 Retractor Bushing Ø = 20 / Ø = 11.2 10 component part of 10019361 Hexagonal Screw 7/16 20-UNF 1 component part of 10019362 Plate H150237 component part of 10019361 Figure 14: Floor Belt Reels Page 24 of 32 AMF-Bruns Belt Anchorage Points
2.5.6 Floor installation Airline rails Countersunk Screw M 8 Airline Rail Washer Locknut M 8 max. 8 inches Adapt the length of the spacer bushing 200301282 to match the structure of the floor Figure 15: Floor, Airline Rail Recessed AMF-Bruns Belt Anchorage Points Page 25 of 32
Countersunk Screw M 8 Airline Rail Washer Locknut M 8 max. 8 inches Adapt the length of the spacer s bushing 200301282 to match the structure of the floor Figure 16: Floor, Airline Rail Surface Mounted Page 26 of 32 AMF-Bruns s Belt Anchorage Points
optional: Belt optional: Retractor Hexagonal Screw M 8 Fitting Airline Rail Vehicle Floor optional: Washer Locknut M 8 (optional) Adapt the length of the spacer bushing 200301282 to match the structure of the floor Figure 17: Retractor with Quadruple Fitting for Floor-Mounted Airline Rail AMF-Bruns Belt Anchorage Points Page 27 of 32
Countersunk Screw M 8 optional: Retractor Fitting Airline Rail Vehicle Floor optional: Washer optional: Locknut M 8 Adapt the length of the spacer bushing 200301282 to match the structure of the floor Figure 18: Belt Reel with Quadruple Fitting for Floor-Mounted Airline Rail Page 28 of 32 AMF-Bruns Belt Anchorage Points
Tightening torques 3 Tightening torques 3.1 Standard threaded steel screws Property Class 8.8 10.9 M 8 25 Nm 36 Nm M 10 50 Nm 72 Nm M 12 85 Nm 125 Nm 3.2 Stainless-steel screws Property Class M 5 M 6 M 8 M 10 M 12 M 16 A2/A4-70 3.5 Nm 10 Nm 20 Nm 35 Nm 60 Nm 135 Nm 3.3 Belt screws 7/16 40 Nm 3.4 Countersunk screws for Floor Pockets M 10 47 Nm 3.5 Countersunk screws for Mono- Fittings M 12 50 Nm 3.6 Airline rails Smartfloor-profile installation, M10, A2-70 Floor installation, M10, A2-70 Side wall installation, M8 / M10, A2-70 18 Nm 35 Nm 20 / 35 Nm AMF-Bruns Belt Anchorage Points Page 29 of 32
Customer Service 4 Customer Service The AMF-Bruns customer service department will be more than pleased to assist in ordering spare parts, maintenance and repair work and help with general problems or queries. The address is: AMF-Bruns GmbH & Co. KG Hauptstraße 101 D 26689 Apen Tel.: +49 (0) 44 89 / 72 72-22 Fax: +49 (0) 44 89 / 62 45 hubmatik@amf-bruns.de www.amf-bruns.de Page 30 of 32 AMF-Bruns Belt Anchorage Points
AMF-Bruns GmbH & Co. KG Hauptstraße 101 26689 Apen Telefon +49 (0) 4489 / 72 71 01 Fax +49 (0) 4489 / 62 45 hubmatik@amf-bruns.de www.amf-bruns.de Reg.-Nr. Q1 0105027