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Wabtec R-290 Installation Manual

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I
NSTALLATION OF
STD C
ONTROLS W
F
F-250/350, GM 2500HD/3500 HD, & R
ORD
I
S
NSTALLATION
AFETY
If any installation problems are encountered, please call G&B Specialties for
technical assistance before continuing with the installation process.
Failure to heed to any of the following warnings could result in severe bodily
!
injury and/or equipment damage.
Read and understand this manual completely before attempting installation or
operation of the equipment.
Installation/Operation instructions provided below only address the Rafna
railgear equipment. Applicable railway company procedures and policies must
be adhered to.
Before performing any work under the vehicle or railgear, ensure the engine is
turned off and the parking brake is set.
When routing hydraulic hoses, ensure that the hoses do not contact any sharp
edges or hot surfaces.
When routing electrical wires, ensure that the wires do not contact any sharp
edges or hot surfaces.
All wire connections are to be soldered and heat shrink sealed to prevent
future corrosion related problems.
All wires must be covered with protective cable loom.
Railway company rules governing rail travel must always be observed.
Ensure all body parts and loose clothing are clear of any moving parts of the
railgear. Be aware of all pinch points.
Note that if the railgear is part way retracted or extended, opening the
manifold directional valve manual over-rides may cause the railgear to drop
suddenly causing personal injury. Ensure all body parts are clear of the railgear
if it should suddenly drop.
When operating the railgear using the emergency hand pump, ensure that the
correct manual valve over-ride is open for the desired railgear (front or rear)
and desired direction of operation (raise or lower).
G&B Specialties Inc. 535 West 3
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
R-290 H
YDRAULIC
/ F
R
RONT OR
P
RECAUTIONS
rd
Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397
K
/ M
IT W
ANUAL
P
L
EAR
UMP
OCATION W
-1-
MIO-H29RRXS004270 Rev D
O
V
PERATING
ALVES
/ D
ETENT
2500/3500
AM

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Summary of Contents for Wabtec R-290

  • Page 1 MIO-H29RRXS004270 Rev D R-290 H NSTALLATION OF YDRAULIC IT W ANUAL PERATING ALVES STD C ONTROLS W RONT OR OCATION W ETENT F-250/350, GM 2500HD/3500 HD, & R 2500/3500 NSTALLATION AFETY RECAUTIONS If any installation problems are encountered, please call G&B Specialties for technical assistance before continuing with the installation process.
  • Page 2 MIO-H29RRXS004270 Rev D  Do not use the emergency hand pump to raise and lower the railgear on a routine basis. If the hydraulic pump or manifold should fail, have it repaired as soon as possible.  If the emergency hand pump has been used to raise or lower the railgear, ensure the manifold directional valve manual over-rides are in the closed and locked position before starting road or rail travel.
  • Page 3 MIO-H29RRXS004270 Rev D NSTALLATION OF YDRAULIC The following procedure details the installation of the hydraulic kit. The hardware required for this installation is listed in Table 1. Table 1: Hydraulic Kit Installation Parts Part Number Description R-2965 Pump Mounting Bracket R-2965B Front Pump Mounting Spacer R-2965D...
  • Page 4 MIO-H29RRXS004270 Rev D RONT OUNTING OF YDRAULIC MOUNT PUMP USING SUPPLIED BRACKETS OR FABRICATE YOUR OWN. BRACKETS WILL NEED TO BE WELDED TO RAILGEAR AT LOCATIONS CHOSEN BY INSTALLER. CHOOSE A LOCATION ON FRONT OF VEHICLE WHICH WILL ACCOMMODATE YOUR END USERS REQUIREMENTS. PHOTOS ARE ATTACHED FOR REFERENCE USE ONLY.
  • Page 5 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com...

  • Page 6: Hydraulic Pump

    MIO-H29RRXS004270 Rev D OUNTING OF YDRAULIC 1. Position the pump mounting bracket against the right side rear mounting bracket as shown. Clamp it in place. Position the pump and spacer on top of the pump mounting bracket as shown with the tank towards the right side of the vehicle. Ensure the pump and spacer will not interfere with any part of the vehicle or railgear components.
  • Page 7 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com...
  • Page 8 MIO-H29RRXS004270 Rev D NSTALLATION NSTRUCTIONS RONT OR EAR LOCATION The pump is shipped with a hand pump handle, a solenoid, and a rubber terminal boot. 1. Locate and install the solenoid in a convenient location under the hood near the vehicle’s battery.
  • Page 9 MIO-H29RRXS004270 Rev D 13. Fill the hydraulic system and bleed the air out: a. Fill the pump tank with DEXRON III (or equivalent) hydraulic fluid. b. Operate the front railgear up and down briefly to circulate the fluid and bleed the system of air (refer to the Railgear Kit and Hydraulic Kit Operation, Service, and Parts manuals for operation instructions).
  • Page 10 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -10-...
  • Page 11 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -11-...
  • Page 12 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -12-...
  • Page 13 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -13-...

  • Page 14: Service Safety Precautions

    MIO-H29RRXS004270 Rev D R-290 H PERATION ERVICE ARTS OF YDRAULIC IT W ANUAL STD C PERATING ALVES ONTROLS W RONT OR OCATION W ETENT F-250/350, GM 2500HD/3500 HD, & R 2500/3500 PERATION AND ERVICE AFETY RECAUTIONS If any operating, service or parts problems are encountered, please call G&B Specialties, Inc.

  • Page 15: Hydraulic Kit

    MIO-H29RRXS004270 Rev D PERATION OF YDRAULIC With the hydraulic kit installed on this vehicle, it may be operated as normal. Never operate the vehicle if the Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating Front or Rear (GAWR), or the wheel or tire load ratings are exceeded. Refer to the Railgear Kit Operation, Service and Parts manual for information on the mechanical operation, service and parts of the railgear.
  • Page 16 MIO-H29RRXS004270 Rev D 4. Pump the emergency hand pump handle to move the railgear. It will require 50 to 100 full strokes to fully raise or lower each railgear. 5. Return the control valve handle to the middle position. 6. Remove and store the locking cable holding collar and the hand pump handle. 7.
  • Page 17 MIO-H29RRXS004270 Rev D YDRAULIC YSTEM ELIEF ALVE ETTING This system is equipped with one relief valve located on the railgear pump body next to the emergency hand pump. This relief valve protects the entire hydraulic system from over pressurization. The relief valve will require adjustment at installation and if ever there appears to be inadequate hydraulic pressure to operate the railgear.

  • Page 18: Electrical System Troubleshooting

    MIO-H29RRXS004270 Rev D LECTRICAL YSTEM ROUBLESHOOTING The following basic test can be performed to check the integrity of the railgear electrical system. Should the railgear pump fail to operate, first check the fuse or the circuit breaker and all wiring for shorts. Then the following test can be performed to verify the integrity of the pump motor and pump solenoid.
  • Page 19 MIO-H29RRXS004270 Rev D ARTS OF YDRAULIC G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -19-...
  • Page 20 MIO-H29RRXS004270 Rev D G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -20-...