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Wabtec R-290 Installation Manual

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I
F
-I
-C
ULL
N
AB
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, Inc. 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
NSTALLATION OF
C
(FICC) F
ONTROLS
L
OCATION
P
RECAUTIONS
rd
Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397
YDRAULIC
R
RONT OR
EAR
-1-
MIO-H29RRGX048-03 Rev C
K
IT
P
/M
UMP
ANIFOLD
2500/3500
AM

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Summary of Contents for Wabtec R-290

  • Page 1 MIO-H29RRGX048-03 Rev C R-290 H NSTALLATION OF YDRAULIC (FICC) F ONTROLS RONT OR ANIFOLD OCATION F-250/350, GM 2500HD/3500 HD, & R 2500/3500 NSTALLATION AFETY RECAUTIONS If any installation problems are encountered, please call G&B Specialties, Inc. for technical assistance before continuing with the installation process.
  • Page 2 MIO-H29RRGX048-03 Rev C  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-H29RRGX048-03 Rev C 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-048 Hydraulic Pump and Manifold R-700 In-Cab Control Panel R-2965...
  • Page 4 MIO-H29RRGX048-03 Rev C RONT OR OUNTING OF YDRAULIC 1. The pump is shipped with a manifold, a hand pump handle, a solenoid, and a rubber terminal boot. 2. Locate and install the solenoid in a convenient location under the hood near the vehicle’s battery using installer supplied hardware.
  • Page 5 MIO-H29RRGX048-03 Rev C YDRAULIC NSTALLATION NSTRUCTION FOR RONT OR OCATION 1. Connect one 16” long hydraulic hose between the U2 port on the rear railgear cylinder check valve and the rod end port on the rear railgear cylinder. 2. Connect one 16” long hydraulic hose between the U2 port on the front railgear cylinder check valve and the rod end port on the front railgear cylinder.
  • Page 6 MIO-H29RRGX048-03 Rev C 15. The pump manifold has three wire harnesses and two wires connected to it: a) One 4’ wire harness for the front or rear railgear with a control box on the end. b) One 36’ wire harness for the front or rear railgear with a control box on the end. c) One 22’...
  • Page 7 MIO-H29RRGX048-03 Rev C 21. Affix the supplied railgear operation decals in a suitable location adjacent to the front and rear control boxes. 22. Ensure all wires and terminals are soldered, heat shrink sealed, enclosed in protective cable loom and secured with tie-wraps. 23.
  • Page 8 MIO-H29RRGX048-03 Rev C 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 9 MIO-H29RRGX048-03 Rev C 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 10 MIO-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C R-290 H PERATION AND ERVICE OF YDRAULIC (FICC) F ONTROLS RONT OR ANIFOLD OCATION 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 3. Select and open the manual over-ride for the respective railgear and desired direction of movement. 4. Remove the locking cable holding collar from storage. It can be slipped in between the locking cable handle and the locking cable bulkhead fitting to hold the locking cable in the disengaged position.
  • Page 17 MIO-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-H29RRGX048-03 Rev C 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-...
  • Page 21 MIO-H29RRGX048-03 Rev C 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 -21-...
  • Page 22 MIO-H29RRGX048-03 Rev C 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 -22-...