neo-dyne AUN 100 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document provides assembly instructions for the Neo-Dyne AUN Ramps, which are designed to facilitate the loading and unloading of motorcycles and scooters. The ramp kits are delivered in a pre-assembled form, with most parts already put together and all bolts attached, simplifying the assembly process. The instructions cover the assembly of both the base ramp and the sliding ramp, along with the integration of the lift dolly and wheel chock.

Function Description:

The Neo-Dyne AUN Ramp system is a robust and versatile solution for safely loading motorcycles and scooters into vehicles. It consists of a base ramp and a sliding ramp, which work in conjunction with a lift dolly and wheel chock to provide a secure and efficient loading mechanism. The system is designed to be adaptable, allowing users to adjust component positions to suit different vehicle types and weights. The lift system, powered by a worm drive, assists in raising the motorcycle, while gas springs provide additional support and ease of operation. Straps and a wheel chock secure the motorcycle during the lifting process.

Important Technical Specifications:

Ramp Models: The instructions refer to AUN 200 and AUN 100 models, with differing lengths for the base and sliding ramps.
- Base Ramp (AUN 201 001):
  - Length: 2500mm (AUN 200) and 2100mm (AUN 100).
  - Width (overall): 557mm.
  - Width (inner, between beams): 456mm.
  - Joiner Spacing: Approximate 540mm and 560mm, adjustable.
  - Joiners required: 4 pcs for AUN 200, 3 pcs for AUN 100, plus an end roller plate.
- Sliding Ramp (AUN 202 002):
  - Length: 2345mm (AUN 200) and 1945mm (AUN 100).
  - Height: 411mm.
  - Wheel Support Frame (AUN 204 001) and Lift Dolly (AUN 203 001) are integrated.
  - Roller bracket position: 395mm from the front end of the beam.
  - Wheel support frame width: 190mm.
Materials: The ramps are constructed from aluminium beams with steel components for critical structural parts like joiners, roller plates, and support frames.
Fasteners: M10 Allen head bolts are used for attaching components to the rails. M8 bolts are used for pivot brackets.
Lift System: Features a worm drive mechanism for lifting, supported by gas springs.
- Gas Spring Attachment: Multiple holes are available for attaching gas spring pistons, allowing adjustment based on motorcycle weight.
  - Lighter motorcycles/scooters (around 250kg / 550lbs): Use the hole farthest away from the winch.
  - Heavier motorcycles (400-500kg / 1,100-1,250lbs): Use holes closer to the winch. If unsure, always use holes closer to the winch.
- Gap between worm drive and pulley bracket: 15mm.
Rollers: The system incorporates rollers for smooth sliding action of the ramp.
- Middle roller bracket: Sits in the middle of the two 30x30mm beams of the lift system.
- Rear stoppers: Placed 120mm from the rear, adjustable.
Security Features:
- Straps: Used to secure the wheel chock and align with pulleys.
- Snap locks: Attached to both gas springs.
- Safety brackets: Aligned with the nut in the lever brackets and tightened with bolts.
- Locking knob: Secures the safety brackets.

Usage Features:

Pre-assembled Components: The ramp kits arrive largely pre-assembled, with bolts already attached to parts, which significantly reduces initial setup time and complexity.
Adjustable Joiners: The joiners on the base ramp are not fixed at exact positions, allowing clients to slide them to suit their specific vehicles. Approximate spacing is sufficient during initial assembly, as fine-tuning can be done later.
Lift Dolly and Wheel Chock: These components are pre-assembled but require adjustments, such as attaching gas springs and straps, to function correctly.
Easy Sliding Mechanism: The sliding ramp components, including bolts and rollers, are pre-installed. Users need to loosen bolts slightly to slide parts through the beams and then tighten them.
Gas Spring Adjustment: The system offers multiple attachment points for gas springs, enabling users to optimize assistance based on the weight of the motorcycle or scooter being loaded. This ensures easier lifting for both lighter and heavier vehicles.
Strap Integration: Straps are threaded through the wheel chock front bar and secured with a round strap bar, which is then fastened by shaft collars. Proper alignment of straps with pulleys is crucial for smooth operation.
Worm Drive Operation: The worm drive is operated clockwise to tighten the straps and raise the lift system. The wheel chock automatically slides into position against the pulley bracket.
Adjustable Stoppers: Both front and rear stoppers are adjustable. The front stoppers are tightened against the wheel chock bars, while the rear stoppers can be positioned 120mm from the rear, allowing for customization.
Swing Lever Mounting: The swing lever is mounted with two flat washers on either side and a plastic washer in the middle, designed to rotate by hand with some friction to maintain its position.
Flipper Arms and Wheel Holder: These components are attached to complete the ramp structure, with a long bolt securing the flipper, which should be tightened hard.
Ramp Integration: The sliding ramp is placed with its rollers inside the beams of the base ramp and pushed horizontally. Users are advised to check the back to ensure the base ramp rollers track correctly into the groove of the sliding ramp.
Operational Check: After assembly, it is recommended to run the ramp a few times to ensure all mechanisms work properly.

Maintenance Features:

Washer Replacement: If the ramp was delivered with spring washers for M10 Allen head bolts, these should be replaced with flat washers during assembly for optimal performance.
Bolt Tightening: Instructions emphasize tightening bolts hard for joiners, roller plates, and pivot bracket bolts to ensure structural integrity and safe operation.
Spring Washer Handling: For Grower-type spring washers, it is suggested to squash them with pliers before sliding brackets through the beams, which can aid in assembly.
Gas Spring Caution: Gas springs are under high pressure and should not be opened or heated. This is an important safety and maintenance note.
Regular Checks: The final step of running the ramp a few times implies a functional check, which can be extended to regular operational checks to ensure continued proper functioning.
Roller Security: Ensuring the rear stoppers are tightened hard and that rollers cannot slide out is a critical maintenance point for safety and longevity.

neo-dyne AUN 100 Specifications

General

Brand	neo-dyne
Model	AUN 100
Category	Industrial Equipment
Language	English