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Wabtec Ricon Faiveley FoldOver FR2E Series Service Manual

Electric low-floor vehicle access ramp for transit buses
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FoldOver
Electric FR2E-Series
Low-Floor Vehicle Access Ramp
for Transit Buses
Service Manual
32DFRE02.C
2020 RICON CORPORATION
05/20/20
All Rights Reserved
U.S and Foreign Patents Pending
Printed in the United States of America

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Summary of Contents for Wabtec Ricon Faiveley FoldOver FR2E Series

  • Page 1 ® FoldOver Electric FR2E-Series Low-Floor Vehicle Access Ramp for Transit Buses Service Manual 32DFRE02.C 2020 RICON CORPORATION 05/20/20 All Rights Reserved U.S and Foreign Patents Pending Printed in the United States of America...
  • Page 2 For the location of a Ricon dealer or qualified service technician in your area, call Ricon Product Support at 1-800-322-2884 or visit our website at http://ricondealer.wabtec.com. Customer Name: Installing Dealer: Date Installed: Serial Number: 32DFRE02.C...
  • Page 3 FR2E-SERIES SERVICE MANUAL TABLE OF CONTENTS MAY 2020 REVISION RECORD PAGES DESCRIPTION OF CHANGE Update to company logo Revised all title bars/footers Update to company logo Text update 32DFRE02. Update to Figure 4-2.4 9239 4-9, 4-10 Update to Figure 4-2 Parts List 4-15 Update to Figure 4-4 Parts List 4-16...

  • Page 4: Table Of Contents

    FR2E-SERIES SERVICE MANUAL MAY 2020 TABLE OF CONTENTS Chapter Page I. FOLDOVER ELECTRIC FR2E-SERIES RAMP INTRODUCTION ......... 1-1 A. RAMP FEATURES .......................... 1-1 1. INTERLOCK SUPPORT ..........................1-1 2. AUDIBLE ALERT ............................1-1 3. RAMP CONTROL PANEL ......................... 1-1 B. RICON PRODUCT SUPPORT ......................1-2 C.
  • Page 5 FR2E-SERIES SERVICE MANUAL TABLE OF CONTENTS MAY 2020 This page intentionally left blank. 32DFRE02.C...

  • Page 6: Foldover Electric Fr2E-Series Ramp Introduction

    FR2E-SERIES SERVICE MANUAL MAY 2020 INTRODUCTION ® FOLDOVER ELECTRIC FR2E-SERIES RAMP INTRODUCTION his manual applies to the Ricon FoldOver ® Electric FR2E-Series Low-Floor Vehicle Access Ramp when installed in transit vehicles. The chapters in this service manual contain product description, maintenance instructions, and a spare parts list.

  • Page 7: Ricon Product Support

    RICON PRODUCT SUPPORT If you have questions about this manual, or you need additional copies, please contact Ricon Product Support at the locations listed. Also, refer to the Ricon website at: http://ricondealer.wabtec.com Ricon Corporation 1135 Aviation Place San Fernando, CA 91340 Telephone: ........
  • Page 8 FR2E-SERIES SERVICE MANUAL MAY 2020 INTRODUCTION ® RICON FOLDOVER ELECTRIC FR2E-SERIES LOW FLOOR VEHICLE ACCESS RAMP FOR TRANSIT BUSES TWO-YEAR LIMITED WARRANTY Ricon Corporation (Ricon) warrants to the original purchaser of this product that Ricon will repair or replace, at its option, any parts that fail because of defective material or workmanship as follows: ...

  • Page 9: Shipping Information

    FR2E-SERIES SERVICE MANUAL INTRODUCTION MAY 2020 SHIPPING INFORMATION • When the product is received, unpack the product and check for freight damage. Claims for any damage should be made to the carrier immediately. • Be sure the ramp assembly contains all items listed on the included bill of material. Please report any missing items immediately to Ricon Product Support.

  • Page 10: Customer Orientation

    FR2E-SERIES SERVICE MANUAL MAY 2020 INTRODUCTION CUSTOMER ORIENTATION Figure 1-3 shows major components of the Ricon FoldOver ® Electric FR2E-Series ramp. A description of each component is provided in Table 1-1. Refer to Chapter IV “Parts Diagrams and Lists” for more details. RSM0067200 FIGURE 1-3: ELECTRIC FR2E-SERIES RAMP MAJOR COMPONENTS 1 - 5...
  • Page 11 FR2E-SERIES SERVICE MANUAL INTRODUCTION MAY 2020 TABLE 1-1: FOLDOVER ® ELECTRIC FR2E-SERIES RAMP MAJOR COMPONENTS ITEM DESCRIPTION Item Description Front, Rear, Left Reference point from outside the vehicle looking inward. and Right Adjustable Coupler - Use for adjustment and alignment of chain sprocket. Chain –...

  • Page 12: Foldover Electric Fr2E-Series Ramp Installation

    FR2E-SERIES SERVICE MANUAL MAY 2020 INSTALLATION ® FOLDOVER ELECTRIC FR2E-SERIES RAMP INSTALLATION A. INSTALLATION GUIDELINES Careful installation of the Ricon FoldOver ® Electric FR2E-Series Low-Floor Vehicle Access Ramp contributes to proper and safe operation. Use the electrical wiring diagram in Chapter III, Figure 3-4 to supplement this sec- tion.
  • Page 13 FR2E-SERIES SERVICE MANUAL INSTALLATION MAY 2020 c. Use lifting device to place ramp into bus. d. Refer to Figure 2-2. Lower ramp onto bus floor. Ensure that rear ramp flange rests on bus floor. REAR FLANGE BUS FLOOR REAR FRONT RSM0068400 FIGURE 2-2: RAMP INSTALLATION (SHORT RAMP SHOWN) NOTE: Ramp should sit securely and level on bus structure.

  • Page 14: Installing Vehicle Wiring Harness

    FR2E-SERIES SERVICE MANUAL MAY 2020 INSTALLATION INSTALLING VEHICLE WIRING HARNESS Route wiring harness from vehicle ramp controls to rear of ramp. Use the supplied electrical installation kit to connect vehicle control wiring to the ramp interface connector (Ricon P/N 51034). See Table 2-1 for 12- pin Deutsch connector pin and signal descriptions.

  • Page 15: Final Inpsection

    FR2E-SERIES SERVICE MANUAL INSTALLATION MAY 2020 MASTER CHAIN LINK TRAY POSITION ASSY SWITCHES CHAIN ADJUSTMENT SCREWS SPIDER COUPLING RSM0068500 FIGURE 2-4: CHAIN REMOVAL e. Refer to Figure 2-4. Remove and retain master chain link. Replace and install new chain then install master chain link. g.

  • Page 16: Foldover Electric Fr2E-Series Ramp Maintenance

    FR2E-SERIES SERVICE MANUAL MAY 2020 MAINTENANCE ® III. FOLDOVER ELECTRIC FR2E-SERIES RAMP MAINTENANCE he maintenance information in this chapter applies to the Ricon FoldOver ® Electric FR2E-Series Low-Floor Vehicle Access Ramp when installed in transit vehicles. The information consists of safety precautions, a maintenance schedule, component information, and diagrams for the electrical system.

  • Page 17: Daily Inspection

    FR2E-SERIES SERVICE MANUAL MAINTENANCE MAY 2020 DAILY INSPECTION Check ramp daily, following the Daily Inspection outlined in Table 3-1. Meet all inspection criteria before allowing pas- sengers on ramp. TABLE 3-1: DAILY INSPECTION INSPECTION POINT CHECK  Power ON/OFF switch operates correctly. Ramp controller ...

  • Page 18: Ramp Component Information

    FR2E-SERIES SERVICE MANUAL MAY 2020 MAINTENANCE TABLE 3-2: MAINTENANCE SCHEDULE INSPECTION POINT ACTION – 12,000 MILE INSPECTION – Wiring harnesses Check wiring insulation for heavy abrasions, and connectors for looseness. Replace as necessary. Fasteners Check all threaded fasteners for tightness and retighten as necessary. Non-slip Check non-slip surface for excessive wear or damage (rips, tears, peeling, etc.), and re- surfaces...

  • Page 19: Interlock Output Status

    FR2E-SERIES SERVICE MANUAL MAINTENANCE MAY 2020 CONTROLLER 55-PIN CONNECTOR RSM0030600 FIGURE 3-1: CONTROLLER NOTE: Voltage levels are 24 to 28 VDC in this application. INTERLOCK OUTPUT STATUS The FoldOver Electric ramps has two ramp positions that are monitored by the controller. This position is fully stowed to deployed position.
  • Page 20 FR2E-SERIES SERVICE MANUAL MAY 2020 MAINTENANCE FUSE 55-PIN AMP DUETSCH 12-PIN DUETSCH (AMPERAGE CONNECTOR CONNECTOR CONNECTOR INDICATED) CONNECTED CONNECTED DIODE WIRE CROSSINGS BATTERY COMMON (POWER SOURCE) RSM0068900 FIGURE 3-2: SCHEMATIC SYMBOLS TABLE 3-4: HARNESS FUSES FUSE RATING CIRCUIT 5 AMP Lift Enable (Ramp Switch) 15 AMP 12V/24V High Voltage (Motor Power)
  • Page 21 FR2E-SERIES SERVICE MANUAL MAINTENANCE MAY 2020 Refer to Figure 3-3 for an overall wiring diagram of the ramp system. The wiring diagram is located at the end of this chapter. MICROSWITCH (6 PL) COUNTER 15 AMP FUSE WITH FUSE HOLDER 5 AMP FUSE WITH FUSE HOLDER 55-PIN AMP...
  • Page 22 FR2E-SERIES SERVICE MANUAL MAY 2020 MAINTENANCE WIRING DIAGRAM FR2E RAMP ASSY RAMP DEPLOY STOW RAMP DEPLOY STOW DIRECTION SHUNT SHUNT STOWED CUTOFF CUTOFF Y B R Y B R Y B R Y B R Y B R Y B R N/C N/C N/C 9 10 11 12 COUNTER CONN...
  • Page 23 FR2E-SERIES SERVICE MANUAL MAINTENANCE MAY 2020 FR2E RAMP ASSY 5-PIN WHITE WHITE PROVIDED BY BUS BUILDER RAMP CONTROL DEPLOY STOW DOOR SWITCH RED (#12) RED (#10) INTERLOCK CONFIG CONN 12-PIN INT (GND) INT (GND) WHITE WHITE RAMP POWER INT (+) INT (+) 12V/24V BLACK (#12)
  • Page 24 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS ® FOLDOVER ELECTRIC FR2E-SERIES SHORT AND LONG RAMP SPARE PARTS ® he parts layouts and lists in this chapter apply to the Ricon FoldOver Electric FR2E-Series Low-Floor Vehicle Access Short and Long Ramp when installed in a transit vehicle. Replaceable ramp parts are illustrated in ex- ploded views of major ramp assemblies, which show smaller assemblies and components with reference num- bers.
  • Page 25 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 RSM0067300 FIGURE 4-1: FR2E DECAL LOCATIONS 4 - 2 32DFRE02.C...
  • Page 26 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS FIGURE 4-2: FR2E-SERIES RAMP ASSEMBLY FIG. ITEM DESCRIPTION CONFIG. PART NO. DECAL, SERIAL#, "CE" UNIVERSAL 32-10-166 DECAL, CAUTION, PINCH POINT, F/OVER RAMP 18618 NOTE: (REF) in QTY column is for Referenced Parts Only and are not sold as spare parts. 4 - 3 32DFRE02.C...
  • Page 27 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 RSM0067400 FIGURE 4-2.1: FR2E-SERIES RAMP ASSEMBLY (SHEET 1 OF 5) 4 - 4 32DFRE02.C...
  • Page 28 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS OPTIONAL RSM0067500 FIGURE 4-2.2: FR2E-SERIES RAMP ASSEMBLY (SHEET 2 OF 5) 4 - 5 32DFRE02.C...
  • Page 29 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 RSM0067600 FIGURE 4-2.3: FR2E-SERIES RAMP ASSEMBLY (SHEET 3 OF 5) 4 - 6 32DFRE02.C...
  • Page 30 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS RSM0067701 FIGURE 4-2.4: FR2E-SERIES RAMP ASSEMBLY (SHEET 4 OF 5) 4 - 7 32DFRE02.C...
  • Page 31 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 20 (2 PL) 20 (3 PL) 20 (1 PL) RSM0067800 FIGURE 4-2.5: FR2E-SERIES RAMP ASSEMBLY (SHEET 5 OF 5) 4 - 8 32DFRE02.C...
  • Page 32 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS FIGURE 4-2: FR2E-SERIES RAMP ASSEMBLY FIG. ITEM DESCRIPTION CONFIG. PART NO. KIT, FLOOR COVER 55497 KIT, FLOOR COVER 55497 FR2E12-MX7903C001000 KIT, FLOOR COVER 55497 FR2E12-MX7903C001010 KIT, FLOOR COVER 55497 FR2E12-MX7903C001020 KIT, FLOOR COVER 61759 FR2E14-MY2229C011100 KIT, FLOOR COVER WITH HEATING MAT...
  • Page 33 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 FIGURE 4-2: FR2E-SERIES RAMP ASSEMBLY (CONTINUED) FIG. ITEM DESCRIPTION CONFIG. PART NO. KIT, PLATE, SKID 55499 FR2E12-MX7903C001000 KIT, PLATE, SKID 55499 FR2E12-MX7903C001010 KIT, PLATE, SKID 55499 FR2E12-MX7903C001020 KIT, PLATE, SKID 61760 FR2E00-XYXXXXB001001 KIT, PLATE, SKID 61761 FR2E13-SA0000C011000 KIT, PLATE, SKID...
  • Page 34 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS This page intentionally left blank. 4 - 11 32DFRE02.C...
  • Page 35 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 RSM0067900 FIGURE 4-3: FR2E-SERIES MOTOR DRIVE ASSEMBLY 4 - 12 32DFRE02.C...
  • Page 36 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS FIGURE 4-3: FR2E-SERIES MOTOR DRIVE ASSEMBLY FIG. ITEM DESCRIPTION CONFIG. PART NO. KIT, 24V DRIVE ASSY 58513 KIT, 12V DRIVE ASSY 58516 KIT, SLOTTED DISC CRACK WITH SPIDER COUPLING, LH 58514 BEARING SUPPORT BRACKET, LH (SEE FIG.2) 58506 KIT, SPIDER COUPLING AND SHAFT, RH 58515...
  • Page 37 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 (6 PL) RSM0068100 FIGURE 4-4: FR2E-SERIES ELECTRICAL HARNESSES AND COMPONENTS 4 - 14 32DFRE02.C...
  • Page 38 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS FIGURE 4-4: FR2E-SERIES ELECTRICAL HARNESSES AND COMPONENTS FIG. ITEM DESCRIPTION CONFIG. PART NO. KIT, 24V CONTROLLER, FR2E RAMPS, 32”L AND UP FR2E13 62578 KIT, 24V CONTROLLER, FR2E RAMPS, 32”L AND UP FR2E15 62578 KIT, 24V CONTROLLER, FR2E SHORT RAMPS FR2E12 66416...
  • Page 39 FR2E-SERIES SERVICE MANUAL SPARE PARTS MAY 2020 APPENDIX 1 TABLE 2-4: ELECTRIC LOW-FLOOR-VEHICLE ACCESS SHORT RAMP SPECIFICATIONS Power System ....................Electro-mechanical motor drive system Power Requirements: Electric ................................24 VDC Continuous Current ............................1.5 amps Operating Current ............................5 amps Rated Load Capacity ...........................
  • Page 40 FR2E-SERIES SERVICE MANUAL MAY 2020 SPARE PARTS TABLE 2-5: ELECTRIC LOW-FLOOR-VEHICLE ACCESS LONG RAMP SPECIFICATIONS Power System ....................Electro-mechanical motor drive system Power Requirements: Electric ................................24 VDC Continuous Current ............................1.5 amps Operating Current ............................5 amps Rated Load Capacity .......................... 1000 lbs. (453kg) Ramp Weight ............................

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