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Wabtec R-230 Installation Manual

Hydraulic kit w/ manual operating valves std controls w/ detent

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I
NSTALLATION OF
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 of
the equipment.
Installation 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.
Beware of all pinch points on the railgear and keep all parts of the body clear.
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.
G&B Specialties Inc. 535 West 3
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
R-230 H
YDRAULIC
STD C
ONTROLS W
P
RECAUTIONS
rd
Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397
K
/ M
IT W
ANUAL
/ D
ETENT
-1-
MIO-H18S004270 Rev C
O
V
PERATING
ALVES

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Summary of Contents for Wabtec R-230

  • Page 1 MIO-H18S004270 Rev C R-230 H NSTALLATION OF YDRAULIC IT W ANUAL PERATING ALVES STD C ONTROLS W ETENT 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-H18S004270 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 S-003041 Hydraulic Pump P-00136 Pump Mounting Bracket P-00137 Pump Spacer...
  • Page 3 MIO-H18S004270 Rev C OUNTING OF YDRAULIC MOUNT PUMP USING SUPPLIED BRACKETS OR FABRICATE YOUR OWN. PUMP WILL NEED TO BE INSTALLED AT A LOCATION CHOSEN BY INSTALLER IF NOT USING SUPPLIED BRACKETS. CHOOSE A LOCATION ON THE VEHICLE WHICH WILL ACCOMMODATE YOUR END USERS REQUIREMENTS. 1.
  • Page 4 MIO-H18S004270 Rev C Figure 1: Pump Sub-Assembly 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 5 MIO-H18S004270 Rev C Figure 2: Pump Brackets and Welding 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 MIO-H18S004270 Rev C NSTALLATION NSTRUCTIONS FOR YDRAULICS 1. The pump is shipped with 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. Ensure that the solenoid’s body is electrically grounded. 3.
  • Page 7 MIO-H18S004270 Rev C 14. 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 8 MIO-H18S004270 Rev C Figure 3: Hydraulic Schematic 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-H18S004270 Rev C Figure 4: R-31595 Manual Valve 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-H18S004270 Rev C Figure 5: Wiring Schematic 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-H18S004270 Rev C R-230 H PERATION ERVICE ARTS OF YDRAULIC IT W ANUAL STD C PERATING ALVES ONTROLS W ETENT PERATION AND ERVICE AFETY RECAUTIONS If any operating, service or parts problems are encountered, please call G&B Specialties, Inc. for technical assistance.
  • Page 12 MIO-H18S004270 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 13 MIO-H18S004270 Rev C ERVICE OF YDRAULIC The hydraulic kit must be serviced regularly to avoid damage to the equipment. The recommended oil for the railgear hydraulic system is DEXRON III or equivalent. In extremely cold weather areas/seasons, Tellus S4 VX32 or equivalent may be used. Table 2: Recommended Service Schedule Service Required Inspect hydraulic kit fasteners (re-torque if required)
  • Page 14 MIO-H18S004270 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 15 MIO-H18S004270 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 16 MIO-H18S004270 Rev C ARTS OF YDRAULIC Figure 6: S-003041 Hydraulic Pump 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 -16-...
  • Page 17 MIO-H18S004270 Rev C Figure 7: PO Check Valve Assembly 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 -17-...