Installation manual
Automatic Ramp Opener
VW Caddy Short/Maxi
Version 2.1
Version 2.
2.1
Read the instructions carefully, before starting to mount the automatic ramp opener.
General guidelines:
• Never throw the dismounted parts away, unless mentioned
otherwise.
• Keep all the parts stored together.
• Be sure that you have enough working space in- and outside the
vehicle.
• Before you start, you need to disconnect the connections to the
battery.
Automatic Ramp Opener
Important: The Automatic Ramp Opener is only available for a C-Ramp.
Important: In this manual we assume the car has already been converted.
2
Version 2.1
Remove the rear wheel arch cover on the left site of the car (inside and outside the verhicle)
Drill two Ø 25 mm holes side by side in the floor on the indicated location to create an ellips shape hole.
3
Version 2.1
Drill a hole Ø 30 mm in the left wheelarch in the indicated location.
After drilling the holes, treat the steel against corrosion
4
Version 2.1
Make sure that al the parts are placed on the outer cable (two plastic plain bearings, two springs and four
M12 nuts). Attach the end of the cable onto the aluminium block. Screw all the bolts to each other, so there
is enough space to place the plain bearings. Push the plain bearings in position and tighten the nuts. These
nuts can be used to adjust the ramp in a later stage of the installation.
Attach the aluminium block at the end of the cable
onto the linear actuator, using the M6 grip screw and
the small aluminium block. Do not forget the plain
bearing.
In an emergency situation (empty battery or
problems with the electrical system) the grip screw
(in this case orange) could be removed so that the
ramp can be operated manually
5
Version 2.1
Attach the wire to the motor for easy installation. Connect the included wire as indicated.
Ground
Mount to body
of the car
15 amp fuse
Motor
Mount the switch next to othor switches for easy
connectability and easy acces for the costumer. Most switches
are places on the left panel in the back of the car.
6
12 V continous
Version 2.1
Test the function of the elektric motor with the connected switch. Make sure that the motor is fully
extended before proceeding with the installation.
Manouver the push and pull cable true the hole
you drilled previously and let the motor rest on the
floor. The motor can not be mounted yet, because
the cable needs to be adjusted in a later stage of the
installation.
7
Version 2.1
Remove the cover and the spring from the right hinge. Remove the magnet rampstop and replace it with
the rubber rampstop
Adjust the rubber rampstop on the hinge plate so the
ramp is in a vertical position and de rubber rampstop
is compressed 2-5 mm.
Tighten the rubber rampstop using the original bolts,
washers and plate. Also place the spring back on its
original location.
Remove the cover, spring, hinge and magnete from the left hinge plate. Mount the Cable Mounting on the
hinge plate with the bolts, washers and back-plate from the original hinge and the bolts and nuts included
in the set.
8
Version 2.1
Manouver the push-pull cable (yellow cable) between the components of the wheel suspension.
9
Version 2.1
Mount the Push-Pull Cable on the Cable mounting. Attach the end of the cable onto the slider, using the
M6 mut included with the cable and a M6 nut included in the set.
Place the modified hinge lever and attach the push-pull rod to the hinge lever. Align the push-pull rod.
Fit the spring back on the modified hinge lever and cable mounting.
10
Version 2.1
Adjust the nuts on the outer cable of the push-pull cable (see also page:5) for adjusting the ramp. The
spring on the push pull cable must be compressed a bit so the ramp is free of play in it’s closed position.
Brackets (one behind motor)
Remove the plastic material within the red square (picture above) and mount brackets included in the kit to
the body. Attach the strap included in the set to the bracket and tighten it to hold the motor frame in place.
Seal the holes where the push-pull cable goes through the floor sections.
11
Version 2.1
Before (re)installing the left and right hinge covers, check the operation of the automatic ramp opener.
When the ramp is working correctly, instal the hinge covers and secure them with the self drilling screws
(included in the set)
Assembling the automatic ramp opener is now completed, reinstal all the wheel arches (inside and outside
de verhicle) and other components to finish the verhicle.
Attention: Do not forget to place sticker on the bottom of the ramp!
12