Issue: May 2015 Art.-No.: 10019662 Instructions AMF-BRUNS BELT ANCHORAGE POINTS (tested in accordance with 2007/46/EG) Mercedes-Benz Sprinter Volkswagen Crafter 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 29). AMF-Bruns-Gurtbefestigungspunkte Seite 3 von 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. Seite 4 von 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 Seite 5 von 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 Side wall... 12 2.4.2 Side wall top rail... 16 2.5 Floor Belt Anchorage Points... 18 2.5.1 Floor Pockets, front anchorage point... 19 2.5.2 Floor Pockets, rear anchorage point... 20 2.5.3 Mono-Fittings, front anchorage point... 21 2.5.4 Mono-Fittings, rear anchorage point... 22 2.5.5 Floor Belt Reels... 23 2.5.6 Floor installation Airline rails... 24 3 Tightening torques... 28 3.1 Standard threaded steel screws... 28 3.2 Stainless-steel screws... 28 3.3 Belt screws... 28 3.4 Countersunk screws for Floor Pockets... 28 3.5 Countersunk screws for Mono-Fittings... 28 3.6 Airline rails... 28 4 Customer Service... 29 Seite 6 von 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 Seite 7 von 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. Seite 8 von 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 28. 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 Seite 9 von 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 18. Side wall Side wall top rail Floor Figure 1: Positions for Belt Anchorage Points, Mercedes-Benz Sprinter, Volkswagen Crafter Seite 10 von 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: Side wall belt anchorage points, see Section 2.4.1, page 12. Installing the side wall Airline rails and relevant fittings: see Section 2.4.2, page 16. Floor pockets, floor installation: see Section 2.5.1, page 19, and Section 2.5.2, page 20. Mono-Fittings, floor installation: see Section 2.5.3, page 21, and Section 2.5.4, page 22. Floor installation of belt retractor reels: see Section 2.5.5, page 23. Floor installation of Airline rails and relevant fittings: see Section 2.5.6, page 24. Tighten all fastening screws/bolts to the torque specified in Chapter 3, page 28. 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 29. AMF-Bruns Belt Anchorage Points Seite 11 von 32
2.4 Side Wall Belt Anchorage Points 2.4.1 Side wall 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 Cover Webbing Figure 2: Side wall, top belt anchorage point, Version 1 Seite 12 von 32 AMF-Bruns Belt Anchorage Points
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 3: Side wall, top belt anchorage point, Version 2 AMF-Bruns Belt Anchorage Points Seite 13 von 32
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 4: Side wall, top belt anchorage point, Version 3 Seite 14 von 32 AMF-Bruns Belt Anchorage Points
Retractor Washer d = 10,5 10000083 Plate 200116470 Hexagonal Screw M 10 25 10000165 Locknut M 10 10008495 Car Body Countersunk Screw M 10 30 10003875 Washer d = 10, 5 10000083 Figure 5: Side Wall, Bottom Belt Anchorage Point AMF-Bruns Belt Anchorage Points Seite 15 von 32
2.4.2 Side wall top rail The Airline rails can be installed between B- and C-pillars, between C- and D-pillars and end to end from the B- to the D-pillar. The Airline rails are available in differing lengths to enable this. Car Body Plate 200159031 Rivet 4 16 / K 8,0 10003585 Bushing 200160102 Countersunk Screw M 8 60 10002021 Airline Rail Figure 6: Side Wall Top Rail Seite 16 von 32 AMF-Bruns Belt Anchorage Points
Fitting Retaining Washer Shoulder Bolt 7/16 20-UNF 1 3/16 Washer d = 11,5 / D = 20 Chromed Pillar Loop Webbing Cover Figure 7: Automatic diagonal shoulder belt, quadruple fitting, side wall rail AMF-Bruns Belt Anchorage Points Seite 17 von 32
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 9, page 20, and Figure 11, page 22). Position the U-profile such that it rests perpendicularly against a vehicle cross member. Seite 18 von 32 AMF-Bruns Belt Anchorage Points
Adapt the length of the t spacer bushings to match the struc- ture of the floor 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 8: Floor Pocket, Floor Ahead of the Wheelchair AMF-Bruns Belt Anchorage Points Seite 19 von 32
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 9: Floor Pocket, Floor Behind the Wheelchair Seite 20 von 32 AMF-Bruns Belt Anchorage Points
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 10: Retractor with Mono-Fitting, Floor Ahead of the Wheelchair AMF-Bruns Belt Anchorage Points Seite 21 von 32
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 11: Retractor with Mono-Fitting, Floor Behind the Wheelchair Seite 22 von 32 AMF-Bruns Belt Anchorage Points
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 12: Floor Belt Reels AMF-Bruns Belt Anchorage Points Seite 23 von 32
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 13: Floor, Airline Rail Recessed Seite 24 von 32 AMF-Bruns s Belt Anchorage Points
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 14: Floor, Airline Rail Surface Mounted AMF-Bruns Belt Anchorage Points Seitee 25 von 32
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 15: Retractor with Quadruple Fitting for Floor-Mounted Airline Rail Seite 26 von 32 AMF-Bruns Belt Anchorage Points
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 16: Belt Reel with Quadruple Fitting for Floor-Mounted Airline Rail AMF-Bruns Belt Anchorage Points Seite 27 von 32
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 Seite 28 von 32 AMF-Bruns Belt Anchorage Points
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 AMF-Bruns Belt Anchorage Points Seite 29 von 32
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