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Byk-Rak
2 0 1 8www.byk-rak.com • 989.729.5884 • [email protected]
P. O. Box 40 • Owosso, Michigan 48867-0040
Byk-RakByk-RakByk-RakByk-Rak
Introduction..................................................................................................Benefits of the Byk-Rak...............................................................................Key Features...............................................................................................Specifications..............................................................................................Technical Features One Solo........................................................................................... 2 - Position ....................................................................................... 3 - Position .......................................................................................Quick Release Features..............................................................................Installation - General Information................................................................Bracket Mounting........................................................................................ Help Universal 96” and 102” Bumper Installation ............................ Help Slide In Bumper........................................................................ Slide In Bumper Stand Off................................................................ Nova C - Bracket .............................................................................. New Flyer Low Floor Bracket ...........................................................Height/Position Adjustment .........................................................................Mounting the Byk-Rak ................................................................................Byk-Rak Operation .....................................................................................Bus Washing................................................................................................Parts and Service Visual Inspection Checklist............................................................... 30 - Day Inspection .......................................................................... 30 - Day Service............................................................................... Quality Inspection Process Plan ......................................................Parts 640 Nova LFS Mounting Bracket ..................................................... 503 Bracket Assembly Flexible......................................................... 513D DART Bracket Assembly......................................................... 537 Bracket Assembly....................................................................... 557 Bracket Assembly ...................................................................... 811 Bracket Assembly Kit ................................................................ 560 Quick Release ........................................................................... 726 Bracket Surface Mount............................................................. 760 Explode ASM Kit Freightliner M2 .............................................. 770 Mounting Kit International ......................................................... 782 Bracket Mount Kit Thomas ........................................................ 785 Mnt Bracket Kit C3500 .............................................................. 785T Installation sheet for Chevy 3500 Standoff Bracket ................ 755 Chevy 3500 199-2010 ............................................................... 796 Mounting Kit C5500 .................................................................. 821 Z Bracket Assembly .................................................................. 800 F550 Mount Assembly Kit.......................................................... 802 Mounting Kit Inveros NF ............................................................. 805 Mounting Bracket Kit 3 Position NABI Bus LF ............................ 811 Bracket Assembly Kit ................................................................... 818 BRT Mounitng Kit ........................................................................ 794 BRT Mounting Kit ...................................................................... 597 Bracket Assembly-New Flyer 7.75”L .........................................
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Table of Contents
Byk-RakByk-RakByk-RakByk-Rak 713 bracket Kit Flexible .................................................................... Z900051 Template 713 Bracket ........................................................ Z900073 538 Bracket Template ......................................................... 773 E Receiver Bracket Exploded...................................................... 685-S Bracket Assembly Short .......................................................... 685 Bracket Assembly ....................................................................... 685-L Bracket Assembly Long ........................................................... 685-XL Bracket Assembly XLong ...................................................... 681 Bracket Assembly Rack MTG ..................................................... 681L Bracket Assembly 1L ................................................................ 797 Spacer Kit 3 Position Rack ......................................................... 766 Rack Kit Ford ............................................................................. 741 Blue Bird All American Bumper Bracket .................................... B1015 Ford Tansit Bracket -Gas......................................................... B660 Bracket .................................................................................... Z900043 Bolt Kit NABI BRT Mounting Bracket................................. 839 Kit Dodge Sprinter Bracket ........................................................ B0031A Rack Assembly - Single STN ............................................... B0873D Assembly Modular Rail.......................................................... B4032D Bike Rack Cplt. ..................................................................... B412-2D Assembly - Fr. Hardware ..................................................... B087-3D Assembly Modular Rail........................................................ B403-2G Bike Rack 2 Position BRT .................................................. B412-2G Assembly Fr. & Hardware BRT............................................ B0873D Assembly - Modular Rail ...................................................... B0033E Rack Assembly 3-Position Wide ........................................... B0123E Frame Assembly 3-Postiion Wide ........................................ B0873D Assembly Modular ............................................................... B403HD Bike Rack Cplt. .................................................................... B412HD Frame Assembly Cplt .......................................................... B471HD Assembly Modular Rail ....................................................... B472HD Assembly Modular Rail......................................................... B402HD Quick Disconnect Hinge Bracket ........................................ B002HD Hinge Bracket ...................................................................... B002CA Aluminum Pivot bracket Assembly ..................................... B002EDB Pivot Bracket .................................................................... Z900124 Kit Spring Assembly 3 Position .......................................... B0023D Bracket Hinge....................................................................... B0024CA Bracket Hinge.................................................................... B4032DS Bike Rack Cplt. w/Sensor.................................................. B0033ESN Bike Rack Cplt. w/Sensor ................................................ B901-3D Sensor Assembly ................................................................. B002HDS Bracket Hinge w/Sensor ................................................... B0024CASB Bracket Hinge w/Sensor ............................................. B9023DL Bike Rack Deployment Sensor ........................................... B002CASLB Bracket Assembly w/36” Sensor Leads ...................... B002HDSLB Hinge Bracket Assembly w/36” Lead ........................... Z900101 Harness 4 Sensor Extension ............................................. B056AC Damper Assembly ............................................................... 8161 Installation Exploded ............................................................... 8121 Installation Exploded ............................................................... W0121P Wall Mount Byk Rak ..........................................................
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Table of Contents (continued)Parts
3
1. Introduction
Welcome to the Byk-Rak system. The Byk-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 Byk-Rak system for ease of use on buses. Using that information, we incorporated four main elements to ensure compatibility. 1. Easy operation (for riders and maintenance employees) 2. Economical choice 3. Durable construction “commercial grade” 4. Can go through bus wash and has little maintenance
2. Benefits of the Byk-Rak
The Byk-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. Due to its quick use, the Byk-Rak system will not slow down bus schedules. It is designed to go through a bus wash, and requires very little maintenance.
3. Key Features
Independent Loading/Unloading Although the Byk-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 Byk-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.
Figure 2.1 Byk-Rak
1
4
Convenient, secure Wheel Lock The Byk-Rak employs the use of a Wheel Lock that secures the bike after it is put in the Byk-Rak. The pedals do not have to be oriented to miss the frame. After 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.
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 Byk-Rak system, using a variety of bikes, and included stowing and lowering the Byk-Rak from its stored position. Amazingly, the average time of operation for either loading or unloading was 10 seconds or less! Operation with one hand The Byk-Rak is designed with a well-located locking pin release handle to allow riders to raise or lower the Byk-Rak with one hand while they hold their bikes with the other.
No loose parts and simple construction The Byk-Rak has a simple construction with few parts, and no detachable parts such as pins, clips, or straps, that could be lost. Bicycle Compatibility The Byk-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.
Figure 3.2 Stored Position
Figure 3.1 Wheel Lock
Handle
Bike Wheel
Wheel Lock
2
5
Figure 4.2 Hinge Bracket Specifications
Figure 4.1 Byk-Rak Specifications
4. Specifications
2
1 3
4
5
6
6
Components 1) Release Handle Assembly 2) Wheel Lock Assembly Outside Rail 3) Wheel Lock Assembly Inside Rail 4) Damper Assembly 5) Frame Weld Assembly 6) Rail Weld Assembly 7) Attachment Plate
7 7
Components 1) Bracket Base Plate 2) Locking Cam 3) Hinge Plate (x2)
2
2
3
3
3 1
3
6
5. Technical Features Bike Rack
5.1. Position Modular Bike Rack Assembly
Byk-Rak Technical Features
Advantages
• The Byk-Rak is 30 inches deep by 60 inches wide.
• The Byk-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 16” diameter wheels.
• The Byk-Rak weighs less than 30 pounds.
• The Byk-Rak meets OSHA standards for
lifting by a single individual, and anyone can raise or lower with one hand, ensuring convenient operation.
• The Byk-Rak can be lowered or raised with
one hand.
• This leaves the other hand free to stabilize the bike so the rider can operate the Byk-Rak independently.
• All parts of the Byk-Rak are finished with
powder coat paint.
• 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.
• All moving parts on the Byk-Rak are made of
stainless steel.
• Stainless steel is corrosion resistant and will not chip like plated or coated steel.
• The Byk-Rak is mounted to the front of the
bus.
• Front-mounting the carrier increases driver visibility, safety, and security.
The Byk-Rak has two locking positions, stowed and deployed.
• In the stowed position the Byk-Rak protrudes minimally for increased maneuverability. Locking the carrier minimizes shaking.
• The Byk-Rak has rounded outside corners,
smooth welds, and few ‘pinch’ joints.
• These safety features lessen the likeliness of an operator being injured.
• The Byk-Rak does not block wipers or
access panels in the stowed position.
• The carrier mounts to right to the bumper and bikes are held far enough away to not interfere with wipers or access panels.
• Bikes can be unloaded from the sidewalk-
side or front of the Byk-Rak.
• Bikes never need to be unloaded from street-side so the user is not exposed to traffic.
• Bikes can be independently loaded or
unloaded.
• This allows either bike slot to be accessed at any time.
One (SOLO) Position Modular Bike Rack Assembly
Byk-Rak Technical Features and Safety
Benefits and Advantages
• The Byk-Rak is 7 inches deep by 50 inches wide.
• The Byk-Rak is large enough to hold any adult-sized bikes (excluding tandem and recumbent) children’s bikes—down to a size of 16” diameter wheels.
• The Byk-Rak weighs less than 35 pounds. • The Byk-Rak meets OSHA/NIOSH standards for lifting by a single individual.
•All parts of the Byk-Rak are finished with powder coat paint. (Unless specified by customers request i.e. electro polish and/or bead blasted bike racks)
•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.
•All moving parts on the Byk-Rak are made of stainless steel. (including the Byk-Rak itself)
•Stainless steel is corrosion resistant and will not chip like plated or coated steel.
• The Byk-Rak is mounted to the front of the bus.
• Front-mounting the carrier increases driver visibility, safety, and security.
• The Byk-Rak is always in the deployed position.
•Byk-Rak protrudes minimally for increased maneuverability.
• The Byk-Rak has rounded outside corners, smooth welds, and few ‘pinch’ points.
•Having these safety features lessen the likeliness of injury to the operator.
•Bikes can be loaded and unloaded from the sidewalk-side or front of the Byk-Rak.
•Bikes are always loaded and unloaded from the sidewalk-side so the user is not exposed to traffic.
• The main rail on the Byk-Rak are removable. •Removable rail allow commonality between Byk-Rak products and modular replacement of damaged parts for ease of repair and a lower cost.
• The Byk-Rak is constructed to support over 75 pounds static in the deployed position.
• This allows the carrier to easily hold heavy bikes and provides for misuse.
•Bikes are secured by the front wheel lock, and supported on the back wheel.
• Loading/unloading times are under 10 seconds, so use of the Byk-Rak does not affect scheduling.
• The Byk-Rak makes contact only with the tires of the bicycle.
•Bike frames or other parts will not be scratched or damaged.
• The Byk-Rak accepts bicycles without any orientation of the pedals.
• This speeds up loading times because the user need not adjust the pedals to miss any part of the Byk-Rak.
4
• The Byk-Rak has no pins, clips, or straps. The Byk-Rak has minimal use of complex parts.
• There are no small parts to break down or lose. This also contributes to fast loading time. A simple construction ensures high reliability and ease of use.
• The Bicycle Rack shall be clearly marked with easy to follow instructions for operation.
•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 away when stored The wheel lock folds into the center of the Byk-Rak automatically so it will not damage the front of the bus.
• The bumper mounting bracket is adjustable via multiple bolt-holes.
• The Byk-Rak’s height can be adjusted for different buses or routes. Rack can be moved up or down away from Headlights
•Bike Rack will have removable rail that can be replaced with a modular component.
•With this design racks that have been damage to the rail component can be replaced without replacing the entire rack.
•Headlight Blockage and Turning Radius was main factors in development of our new design One Position Bike 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 2 and 3 position bike racks
5
Technical Features and Specifications
2 Position Modular Bike Rack
Byk-Rak Technical Features Advantages
• The Byk-Rak is 30 inches deep by 55 inches wide.
• The Byk-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 16” diameter wheels.
• Lifting weight of the Byk-Rak is less than 30 pounds to stow.
• The Byk-Rak meets OSHA standards for lifting by a single individual, and anyone can raise or lower with one hand, ensuring convenient operation.
• The Byk-Rak can be lowered or raised with one hand.
• This leaves the other hand free to stabilize the bike so the rider can operate the Byk-Rak independently.
•All parts of the Byk-Rak are finished with powder coat paint. Stainless Steel Bike Racks are either bead blasted for a Non-Glare finish or Electro- Polished for a Chrome like finish.
•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.
•All moving parts on the Byk-Rak are made of stainless steel.
•Stainless steel is corrosion resistant and will not chip like plated or coated steel.
• The Byk-Rak is mounted to the front of the bus.
• Front-mounting the carrier increases driver visibility, safety, and security.
The Byk-Rak has two locking positions, stowed and deployed.
• In the stowed position the Byk-Rak protrudes minimally for increased maneuverability. Locking the carrier minimizes shaking.
• The Byk-Rak has rounded outside corners, smooth welds, and few ‘pinch’ joints.
• These safety features lessen the likeliness of an operator being injured.
• The Byk-Rak does not block wipers or access panels in the stowed position.
• The carrier mounts to right to the bumper and bikes are held far enough away to not interfere with wipers or access panels.
•Bikes can be unloaded from the sidewalk-side or front of the Byk-Rak.
•Bikes never need to be unloaded from street-side so the user is not exposed to traffic.
•Bikes can be independently loaded or unloaded.
• This allows either bike slot to be accessed at any time.
6
Technical Features Con’t Advantages
• The Byk-Rak is constructed to support over 250 pounds in the central portion. It will support bicycles up to 55 lbs. per bike rail while the vehicle is moving.
• 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.
•Bikes wheels are secured by the front wheel lock and rail system. No contact is made to the frame of the bicycle.
• This means loading and unloading times are under 10 seconds so use of the Byk-Rak will not affect scheduling.
• The Byk-Rak only makes contact with the tires of the bicycle.
•Bike frames or other parts will not be scratched or damaged.
• The Byk-Rak accepts bicycles without any orientation of the pedals.
• This speeds up loading times because the user need not adjust the pedals to miss any part of the Byk-Rak.
The Byk-Rak has no pins, clips, or straps or cords.
• There are no loose parts to break down or become lost. This also contributes to the fast loading time.
• The Byk-Rak has been designed to have a simple design with few parts.
•A simple construction ensures ease of use and high reliability.
• The wheel lock folds away when stowed automatically requiring no action from the bicycle rider for proper stowage.
• The wheel lock folds into the center of the Byk-Rak automatically so it will not damage the front of the bus.
• The bumper mounting bracket is adjustable via multiple bolt-holes.
• The Byk-Rak’s height can be adjusted for different buses or routes.
• The Hinge Bracket is designed to attach to all mounting brackets similarly.
• The Byk-Rak can be installed on any bus through the use of different mounting brackets.
•Bike Rack will have removable rails that can be replaced with a modular component. These rails are interchangeable for front or back
•With this design racks that have been damage to the rail component can be replaced without replacing the entire rack.
7
3 Position Wide Modular Bike Rack Assembly
Byk-Rak Technical Features and Safety
Benefits and Advantages
• The Byk-Rak is 29.5 inches deep by 82 inches wide.
• The Byk-Rak is large enough to hold any adult-sized bikes (excluding tandem and recumbent) children’s bikes—down to a size of 16” diameter wheels.
• The Byk-Rak weighs less than 51 pounds. • The Byk-Rak meets OSHA/NIOSH standards for lifting by a single individual, and anyone can raise or lower with one hand, ensuring convenient operation.
• The Byk-Rak can be lowered or raised with one hand. A spring assisted pivot bracket is recommended to reduce lifting weight.
• This leaves the other hand free to stabilize the bike so the rider can operate the Byk-Rak with ease.
•All parts of the Byk-Rak are finished with powder coat paint. (Unless specified by customers request i.e. electro polish and/or bead blasted bike racks)
•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.
•All moving parts on the Byk-Rak are made of stainless steel. (including the Byk-Rak itself) No surface lubrication is needed.
•Stainless steel is corrosion resistant and will not chip like plated or coated steel. A Non-Glare Stainless Steel Finish is available.
• The Byk-Rak is mounted to the front of the bus.
• Front-mounting the carrier increases driver visibility, safety, and security.
• The Byk-Rak has two locking positions, stowed and deployed.
• In the stowed position the Byk-Rak protrudes minimally for increased maneuverability. Locking the carrier minimizes shaking.
• The Byk-Rak has rounded outside corners, smooth welds, and few ‘pinch’ points.
•Having these safety features lessen the likeliness of injury to the operator.
• The Byk-Rak does not block wipers or access panels in the stowed position.
• The carrier mounts right to the bumper, and bikes are held far enough away to not interfere with wipers or access panels.
•Bikes can be loaded and unloaded from the sidewalk-side or front of the Byk-Rak.
•Bikes are always loaded and unloaded from the sidewalk-side so the user is not exposed to traffic.
•Bikes can be independently loaded or unloaded.
• This allows either bike slot to be accessed at any time.
• The main rails on the Byk-Rak are removable.
•Removable rails allow commonality between Byk-Rak products and modular replacement of damaged parts for ease of repair and a lower cost.
• The Byk-Rak is constructed to support over 250 pounds static in the deployed position. 55 pounds per bike rail.
• This allows the carrier to easily hold heavy bikes and provides for misuse.
8
•Bikes are secured by the front wheel lock, and supported on the back wheel.
• Loading/unloading times are under 10 seconds, so use of the Byk-Rak does not affect scheduling.
• The Byk-Rak makes contact only with the tires of the bicycle.
•Bike frames or other parts will not be scratched or damaged.
• The Byk-Rak accepts bicycles without any orientation of the pedals.
• This speeds up loading times because the user need not adjust the pedals to miss any part of the Byk-Rak.
• The Byk-Rak has no pins, clips, or straps. The Byk-Rak has minimal use of complex parts.
• There are no small parts to break down or lose. This also contributes to fast loading time. A simple construction ensures high reliability and ease of use.
• The Bicycle Rack shall be clearly marked with easy to follow instructions for operation.
•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 away when stored The wheel lock folds into the center of the Byk-Rak automatically so it will not damage the front of the bus.
• The bumper mounting bracket is adjustable via multiple bolt-holes.
• The Byk-Rak’s height can be adjusted for different buses or routes.
• The Hinge Bracket is designed to attach to all mounting brackets similarly.
• The Byk-Rak can easily be installed on any bus through the use of different mounting brackets.
•Bike Rack will have removable rails that can be replaced with a modular component. These rails are interchangeable.
•With this design racks that have been damage to the rail component can be replaced without replacing the entire rack.
•Headlight Blockage and Turning Radius was main factors in development of our new design 3 Position Bike Rack.
• Testing has determined with 3 bikes loaded there is no blockage increase from the 2 Position bike rack loaded with bikes. Through Engineered off-set design and precise angles these goals were accomplished.
9
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6.3. Quick Release Byk-Rak
The Quick Release Byk-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 Byk-Rak may be removed frequently or shared between buses. The Quick Release Byk-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 Byk-Rak.
6.4. 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.
6.5. 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 6.5.1 below.
To install, rotate the Byk-Rak frame to a 45° 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 Byk-Rak frame, reverse the process described above. The Byk-Rak may now be used to transport bicycles.
Figure 6.5.1 Quick Release Frame
11
15
7.2. Quick Release Bracket
This assembly was designed to allow an operator to quickly disconnect the hinge bracket from the bumper bracket. This is convenient if a Byk-Rak may be removed often or switched between different buses. The Quick Release Bracket 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.
To install the Quick Release Bracket 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 7.2.1 that there are three sets of holes for horizontal adjustment of the Byk-Rak. The other half of the Quick Release Bracket bolts to the hinge bracket in the same way. See Figure 7.2.2 below.
Figure 7.2.1 Quick Release Bumper Bracket
Figure 7.2.2 Quick Release Pivot Bracket
7.2 Quick Release S/S Bracket Kit
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17
8. Installation- General Information
Proper installation of the Byk-Rak is the most important factor in the safety and effectiveness of its use. Four main elements of the Byk-Rak’s installation must be considered when setting up the carrier.
1. Approach Angle 2. Footprint 3. Loading Height 4. Protrusion
Please read carefully before installing the Byk-Rak.
1. Approach Angle- 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 Byk-Rak too low can decrease the approach angle of the bus.
2. Footprint- The footprint refers to the profile of the stowed Byk-Rak against the front of the bus. The carrier should be mounted so as to avoid blocking headlights and/or turn signals.
3. Loading Height- This height corresponds to the vertical distance that a bicycle must be lifted into the Byk-Rak. Mounting the carrier too high can make it difficult for users to load the bike.
4. Protrusion- Protrusion is the distance from the front bumper to the furthest edge of the Byk-Rak in the deployed position. This measurement is important because:
• Bike rack protrusion is limited by many state Departments of Transportation (e.g. California’s limit is 36 inches).
• Approach angle and turning radius are more affected as protrusion increases.
• Protrusion determines the distance between the stowed Byk-Rak and the front of the bus; the carrier should not interfere with windshield wipers or the driver’s line-of-sight.
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9. Bracket Mounting
The Byk-Rak system is made up of two parts: the Byk-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 Byk-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. After determining the correct bumper bracket the installer should inspect the front of the bus for these conditions.
1. Is the bumper mounted correctly? 2. Is the bumper and bus frame in good repair? Make sure nothing is
damaged, like a bent bumper from a collision. 3. Is there any other object installed on the bus that could compromise the
installation or operation of the Byk-Rak? 4. 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 Byk-Rak mounting bracket. Mounting the Byk-Rak without making these repairs or modifying the Byk-Rak to fit on a damaged bus is unsafe, and voids all Byk-Rak warranties.
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9.1 Help Universal 96” and 102” Bumper Installation
The Byk-Rak system mounts to both the 96” wide and 102” 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 Byk-Rak C-Bracket attaches to four of these bolts. Generally, no modification is needed to install the C-Bracket. However, make sure to check that there is enough space between the bumper and the bus body to fit the C-Bracket. If there is not enough space to install the C-Bracket, you have two options:
a) modify the front body of the bus to make space for the C-Bracket or b) re-mount the bumper low enough that the C-Bracket will fit
Follow these directions to install either a 96” or 102” C-Bracket. The installation varies slightly between the two widths; the 96” C-Bracket has welded ‘ear’ tabs on the outside of the mounting arms while the 102” C-Bracket does not. 1) Set up the C-Brackets and Hinge Bracket in the orientation shown below and
fasten the bolts loosely. 2)
Figure 9.1.1 C-Bracket Installation
Part Qty Description A 4 3/8-16x1-1/4” hex bolt B 8 3/8” washer C 4 3/8” lockwasher D 4 3/8-16 nut
A B
B C
D
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20
102” Bumper 96” Bumper
Figure 9.1.2 Top View
A
A
B
C
B
C
D
D hex bolt attaches to existing bumper clip (x4)
Part Qty Description A 4 1/2-13x3” hex bolt B 4 1/2” lockwasher C 4 1/2” washer D 4 spacer
2) The next step is to find the four bolts, two on the top and two on the bottom of the bumper, that the C-Bracket will attach too. The difference between the 96” and 102” Help Universal bumpers is that the 96” bumper has a bolt on the centerline. See Figure 9.1.2 below.
3) Attach the C-Bracket to the Help Universal Bumper in 4 places using 1/2-
13x3” hex bolts, lockwashers, and spacers. See Figure 9.1.3 below. 4) Next, tighten all of the fasteners and bolts, including those connecting the
Hinge Bracket to the C-Brackets. Congratulations! You have successfully installed the mounting bracket and Hinge Bracket.
5) Proceed to Section 10: Mounting the Byk-Rak.
Bolt on centerline
Use these bolts
Use these bolts
Figure 9.1.3 C-Bracket Installation
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Figure 9.2.1 Template Set-up
dowels
align to centerline
pilot holes
9.2 Help Slide-In Bumper Installation
The Help Slide-In bumper is identified by its hollow aluminum bumper structure and its 2 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 Byk-Rak on the Help Slide-In bumper: the Stand-off bracket or the C-Bracket. The Stand-off mounting bracket may be used if there is not enough space between the bumper and bus body for the C-Bracket.
9.3 Slide-In Bumper C-Bracket Installation
The C-Bracket for Byk-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 C-Bracket 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 C-Bracket arm to fit. It is important that you check the clearance between the bumper and bus body before attempting to install the C-Bracket. If there is not enough room for the C-Bracket, you have three options:
a) modify the front body of the bus to make space for the C-Bracket, b) re-mount the bumper low enough that the C-Bracket will fit, or c) use the Stand-off bracket method (see end of Section 9.2)
1) 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.
2) Next, detach the Help Slide-In bumper from the bus frame by removing the bumper-to-frame bolts.
3) 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 1/4” pilot holes, on the right and left of the centerline. See Figure 9.2.1 below.
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22
Figure 9.2.2 C- Bracket Installation
4) Repeat step 3, now on the bottom of the bumper. 5) Enlarge each of the 4 holes made in steps 3 and 4 with a 17/32” drill bit. 6) Set up the C-Brackets and Hinge Bracket in the orientation shown below and
fasten the bolts loosely.
A B
B C
D
Part Qty Description A 4 3/8-16x1-1/4” hex bolt B 8 3/8” washer C 4 3/8” lockwasher D 4 3/8-16 nut
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23
7) Attach the C-Bracket to the Help Slide-In Bumper in 4 places using 1/2-13x1-1/2” bolts, lockwashers, and spacers. See Figure 9.2.3 below. Tighten all fasteners and bolts.
Part Qty Description A 4 1/2-13x1-1/2” hex bolt B 4 1/2” lockwasher C 4 1/2” washer D 4 1/2-13 locknut
8) 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 Bracket to the C-Brackets.
9) Congratulations! You have successfully installed the mounting bracket and Hinge Bracket. Proceed to Section 10: Mounting the Byk-Rak.
A
A
B
C
B
C
D
D
Figure 9.2.3 C-Bracket Installation
19
24
semi-cylinder
drill holes (x2)
9.4. Slide-In Bumper 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 C-Brackets. 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. Also, you may have to remove the bumper to gain access to some bolts. 1) 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.
2) Drill one 1/4” pilot hole through one of the top template drill holes. Insert a
1/4” dowel into the template and urethane to index the template. Now, drill the other top hole and put another 1/4” dowel into it. Lastly, drill the two bottom holes, making sure that the template does not move.
3) With all the pilot holes drilled, remove the template. Cut four holes using a 1-1/2” hole saw with a 1/4” pilot drill. Make sure that each hole is drilled perpendicular to the bumper face and drill though any structural ribs that may be encountered.
4) Now, insert the two Stand-Off brackets into the holes. The brackets should be pushed in until the tube contacts the aluminum back structure.
Figure 9.4.1 Stand-Off Template
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26
9.5 Nova C-Bracket Installation
The C-Bracket for Byk-Rak mounts to the Nova bumper at four spots, two on top of the bumper and two on bottom of the bumper. Usually the C-Bracket 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 C-Bracket arm to fit. It is important that you check the clearance between the bumper and bus body before attempting to install the C-Bracket. If there is not enough room for the C-Bracket, you have three options:
a) modify the front body of the bus to make space for the C-Bracket, b) re-mount the bumper low enough that the C-Bracket will fit, or c) use the Threaded Insert bracket method (see Section 9.4)
1) 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.
2) Now, detach the Nova bumper from the bus frame by removing the bumper-to-frame bolts.
3) Place and tightly hold the provided drill template on the top of the bumper, making sure to align the center lines. Also, make sure the top edge is flush with the edge of the aluminum back structure. Now drill two 1/4” pilot holes, on the right and left of the centerline. See Figure 9.5.1 below.
4) Repeat step 3, now on the bottom of the bumper. 5) Enlarge each of the 4 holes made in steps 3 and 4 with a 17/32” drill bit. 6) Set up the C-Brackets and Hinge Bracket in the orientation shown below and
fasten the bolts loosely.
Figure 9.5.1 Nova Template
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27
Figure 9.5.3 Nova C-Bracket Installation
A
B
C
A
B
C
D
D
7) Attach the C-Bracket to the Nova Bumper in 4 places using 1/2-13x1-1/2”
bolts, lockwashers, and spacers. See Figure 9.5.3 below. Tighten all fasteners and bolts.
Part Qty Description A 4 1/2-13x1-1/2” hex bolt B 4 1/2” lockwasher C 4 1/2” washer D 4 1/2-13 locknut
A B
B C
D
Part Qty Description A 4 3/8-16x1-1/4” hex bolt B 8 3/8” washer C 4 3/8” lockwasher D 4 3/8-16 nut
Figure 9.5.2
28
8) 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 Bracket to the C-Brackets.
9) Congratulations! You have successfully installed the mounting bracket and Hinge Bracket. Proceed to Section 10: Mounting the Byk-Rak.
9.6. Nova (Threaded Insert) Bracket Installation
This installation method for the Nova bumper utilizes the threaded inserts on the front of the bus usually used for towing. The bracket consists of two C-shaped brackets that each bolt to a threaded insert via 1/2” bolts and underneath to the bus frame behind the bumper. An attachment plate is then bolted to the C-brackets with 3/8” bolts. The hinge plate is then bolted to this attachment plate similarly to other brackets.
ITEM NO.
PART NUMBER Revision DESCRIPTION QTY.
1 650 AD-004 attachment plate 1
2 655 AA-007 bracket assy 2
3 669 AA-005 insert 1 3/4" 2
4 670 AA-001 bolt 1/2" - 13x 1.5" Grade 5 2
5 526 AA-005 washer 1/2" USS Flat 2
6 671 AA-002 bolt M16 x 15. DIN 933, fully
threaded 4
7 672 AA-001 washer M16 DIN125 8
8 673 AA-002 lock nut M16 x 2 DIN125 4
9 514 AA-004 washer 3/8" split lock 18-8 8
10 521 AA-004 bolt 3/8" - 16 x 1.5" Grade 5 8
11 520 AA-004 washer 3/8" SAE Flat 16
12 515 AA-004 nut 3/8" - 16 Grade 5 8
Figure 9.6.1 Nova (Threaded Insert)
22
33
9.9 New Flyer low floor Bracket 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 8.2, 8.6). The only difference is this bracket has inline tubes instead of offset. For step-by-step installation instructions, refer to Sections 9.2 or 9.6.
Figure 9.9.1 New Flyer low floor Bracket
23
36
12. 703 Mounting Bracket
Part Number Description Qty. Price
B703-Kit Kit – BRKT PKG ASSY 1 $225.00 B681 BKRT ASSY RACK MTG 1 $175.00 B700 PIN HITCH 1 $8.95 B702 PIN HAIRPIN COTTER 1 $5.95
Z900009 37C150HCS8Y BOLT 3/8 - 16 X 1 1/2" 4 $12.75 Z900010 NUT - 3/8" - 16 4 $6.75 Z900011 WASHER - 3/8" LOCK 4 $5.95 Z900012 37NWUS8Y WASHER - 3/8" FLAT 4 $5.95
13. Height/Position Adjustment
To change the height or left/right positioning of the Byk-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. Depending 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.
Figure 12.1
Figure 10.1 Adjustment Holes (e.g C- Bracket)
24
37
14. Mounting the Byk-Rak
Now that the bracket has been mounted to the bus per the instructions, the Byk-Rak can be installed to the hinge bracket. This installation is extremely quick and simple, because only two bolts must be fastened. See Figure 14.1 below.
Once the Byk-Rak has been secured by the two machine screws, make sure the carrier can swing freely and lock into the stowed and deployed positions.
1 1
2 2
4 2 2 4
3 3
Components 1) Zinc-Plated Grade 5 Medium Strength Hex Head Cap Screw
1/2”-13 Thread, 2-1/4” Length (x2) 2) Zinc-Plated Steel SAE High Strength Flat Washer 1/2” Screw
Size, 1-1/16” OD, 17/32” ID, .097 Min Thk (x4) 3) ANSI Type 304 Tube Spacer 19mm MAX OD, 12.7mm MIN
ID, Wall Thickness 2.5mm±0.5mm 4) Zinc-Plated Grade 5 Steel Hex Nylon-Insert Locknut, 1/2”-13
Screw Size, 3/4” WD, 19/32” HT (x2)
Figure 14.1 Byk-Rak Mounting Instructions
25
38
15. Byk-Rak Operation
The Byk-Rak is very fast and easy to use, eliminating any deviation from typical bus schedules. The Byk-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: CAUTION: Loading or unloading your bike from street side may cause death or serious injury.
15.1 Loading a Bicycle
1) Make ready your bike for loading by removing any loose items that may fall off, such as water bottles or tire pumps.
2) 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.
3) To lower the Byk-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.
4) Next, lift your bike and set it into Byk-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.
5) Swing the wheel lock around (from under the Byk-Rak) and on top of the front wheel.
6) You may now board the bus.
15.2 Unloading a Bicycle
1) As 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.
2) Swing the wheel lock around to under the front tire. 3) You may now lift your bike out of the Byk-Rak. 4) If the Byk-Rak is empty and no one is waiting to load their bike, lift the Byk-
Rak up until it locks into the stowed position. CAUTION: Loading or unloading your bike from street side may cause death or serious injury.
Byk-Rak does not condone use of motorized vehicles on their Bike Racks. Use of Motorized vehicles will void the warranty of the Byk-Rak equipment.
26
39
16. Bus Washing
One of the major features of the Byk-Rak is it’s compatibility with bus washes. As long as the Byk-Rak is empty and in the stowed position, it can be safely taken through a bus wash facility. The Byk-Rak system was designed with round tubing and edges so the wash brushes will not become entangled or stuck in the carrier. Although the Byk-Rak is fully compatible with bus wash facilities, the following conditions can damage the carrier and should be avoided.
1) Slow brush rotation- If the wash brushes are spinning too slowly they may catch onto any protruding object such as a mirror. Also, if the axle pushes too deeply onto the Byk-Rak it may get caught on any vertical ridges.
2) High bus speed- If the bus is moving too quickly through the bus wash system, the same problems explained above may occur.
3) Low brush density- If there are too few brushes on the brush arm, the axle may be pushed too deeply onto the Byk-Rak and may catch on any vertical ridges.
4) Brushes 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. Any brush on the opposite side should spin clockwise. See Figure 16.1 for a visual representation.
As long as these conditions are not present and the Byk-Rak is in the stowed position, there should be no damage above regular wear and tear. If excess damage is observed, examine the Byk-Rak setup and the bus wash facility. If any further problems are encountered, please contact Byk-Rak at 1(800) 627-6627.
brushes spinning away from bus
Figure 16.1 Bus Wash
27
40
Figure 17.1 Visual Inspection
17. Parts and Service
Byk-Rak Visual Inspection Checklist Byk-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 Byk-Rak before putting into service. 1) ____ Byk-Rak swings from stowed to deployed position freely and locks in each
position automatically. 2) ____ Release handle easily unlocks Byk-Rak to change positions without sticking. 3) ____ Wheel lock swings all the way around and spring keeps tension. 4) ____ End caps are present and not damaged.
30 Day Inspection
Check every 30 days to ensure that: 1) The Byk-Rak swings easily between the stowed and deployed positions. 2) The release handle unlocks the Byk-Rak and does not stick. 3) The locking pin automatically locks in the deployed and stowed positions. 4) All bolts/fasteners are present and tight. 5) The two end caps on the front of the Byk-Rak are present and not damaged. 6) All instruction labels are present and intact (not shredded, marred, or scratched off).
When replacing, first clean the surface with isopropyl alcohol. 7) The main frame and bike rails are unbent and structurally sound.
30 Day Service
If 30 day inspection shows damage, follow this service list: 1) If the Byk-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.
2) Make sure the main frame and bike rails are undamaged and unbent. If they are damaged, replace immediately.
1
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29
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23.1 LFS Mounting Bracket
23. Nova LFS Mounting Bracket
Label # Part Number Description Qty. Price
N/A 640 Kit - LFS Mounting Bracket 1 $425.00 1 650 attachment plate 1 Call 2 655 bracket assembly 2 Call 3 669 insert 1 3/4” 2 Call 4 670 bolt 1/2” – 13 x 1.5” Grade 5 2 Call 5 526 washer 1/2” USS Flat 2 Call 6 671 bolt M16 x 55, DIN 933, fully
threaded 4 Call
7 672 washer M16 DIN 125 8 Call 8 673 lock nut M16x2 DIN 934 4 Call 9 514 washer 3/8” split lock 18-8 8 Call
10 521 bolt 3/8” – 16 x 1.5” Grade 5 8 Call 11 520 washer 3/8” SAE Flat 16 Call 12 515 nut 3/8” – 16 Grade 5 8 Call
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87
65
43
21 1
23
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101
