Failure to heed to any of the following warnings could result in severe bodily injury and/or equipment damage.

Transcription

1 INSTALLATION OF HYDRAULIC KIT Page of Bulletin MIH9RRFR08B (Rev 0) SAFETY PRECAUTIONS 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 of the equipment. Installation instructions provided below only address the Rafna Industries 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 rd Street, Berwick, PA, USA Tel: Fax: (570)

2 INSTALLATION OF HYDRAULIC KIT Page of Bulletin MIH9RRFR08B (Rev 0) The following procedure details the installation of the hydraulic kit. The hardware required for this installation is listed in table. Table : Hydraulic Kit Installation Parts Part Number Description Qty R08B Hydraulic Pump And Manifold R958 Pump Mounting Bracket R959 Pump Mounting Bracket Shim R567 Dash Switch R577 InLine Fuse 5 Amp CO30G Railgear Pump Decal CO30N Front Gear Up Decal CO30O Rear Gear Up Decal CO30P Front Gear Down Decal CO30Q Rear Gear Down Decal R868 Locking Cable Holding Collar R565 Flow Reducer S00030 Railgear Operation Decal R979 Lock Cable And Control Bracket 89FSO00 ¼ Male ORing Boss to ¼ Male JIC FSO006 3 / 8 Male ORing Boss to ¼ Male JIC 90 89FS006 3 / 8 Male NPT to ¼ Male JIC 90 HFS0 Hose 3 Long HFS0 Hose 33 Long HFS0 Hose 360 Long HU00NJ ¼ Female JIC Straight Coupler (On Hoses) / UNC Gr. 8 Bolt x 0.75 Long / SAE Washer / Lock Washer 5 / 6 UNC Gr. 8 Bolt x 0.75 Long 5 / 6 SAE Washer 5 / 6 Lock Washer 3 / 8 UNC Gr. 8 Bolt x.5 Long 3 / 8 SAE Washer 8 3 / 8 UNC Gr. 3 Nylock Nut 83 Mach. Screw x 0.75 Long Zinc Plated 83 UNC Zinc Plated Nylock Nut Not Supplied & Gauge Wire, Terminals, Loom, Etc. As Req d G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

3 Page 3 of Bulletin MIH9RRFR08B (Rev 0). The pump is shipped with a manifold, a hand pump handle, a solenoid, and a rubber terminal boot.. Locate and install the solenoid in a convenient location under the hood near the vehicle s battery using installer supplied hardware. Ensure that the solenoid s body is electrically grounded. 3. Install a ¼ male ORing Boss to ¼ male JIC 90 fitting into each P, T, C, C, C3 and C ports of the manifold and into the T port of the pump.. Install a 3 / 8 male ORing Boss to ¼ male JIC 90 fitting into the P port of the pump. Ensure that the check valve components remain in the port cavity. 5. Position the pump mounting bracket between the forward front mounting plates previously installed on the vehicle. The two holes in each end of the pump mounting bracket should align with the two slots in the flange of each forward front mounting plate. 6. Use the supplied pump mounting bracket shims as necessary so that the pump mounting bracket is snug between the forward front mounting plates. Fasten in place with four 3 / 8 x.5 long bolts, eight 3 / 8 washers, and four 3 / 8 nuts. Torque the 3 / 8 fasteners to 0 ftlbs dry. Do not over torque. 7. Position the pump on top of the left end of the pump mounting bracket as shown with the tank towards the left side of the vehicle, so that the holes in the pump mounting bracket align with the threaded holes in the pump. Fasten the pump to the pump mounting bracket using four 5 / 6 x 0.75 long bolts, four 5 / 6 washers, and four 5 / 6 lock washers. 8. Position the manifold on the front right end of the pump mounting bracket as shown with the P and T ports pointing downwards. Fasten the manifold to the pump mounting bracket using four ¼ x 0.75 long bolts, four ¼ washers, and four ¼ lock washers. 9. There are four directional valve manual overrides on the top face of the manifold. The decal plates can be installed on the top face of the manifold as shown. Stick the decal plates next to the respective overrides such that they are properly oriented while standing in front of the vehicle. 0. Insert a flow reducer into the NPT end of two 3 / 8 male NPT to ¼ male JIC 90 fittings. Install one of these fitting into the rod end port of each railgear cylinder. Use Teflon sealant on all NPT fittings. G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

4 Page of Bulletin MIH9RRFR08B (Rev 0). Install a 3 / 8 male NPT to ¼ male JIC 90 fitting into the blind end port of each railgear cylinder. Use Teflon sealant on all NPT fittings.. Connect one 3 long hydraulic hose between the C port on the manifold and the blind end port on the front railgear cylinder. 3. Connect one 3 long hydraulic hose between the C port on the manifold and the rod end port on the front railgear cylinder.. Connect one 33 long hydraulic hose between the P port on the manifold and the P port on the pump. 5. Connect one 33 long hydraulic hose between the T port on the manifold and the T port on the pump. 6. Connect one 360 long hydraulic hose to the C3 port on the manifold and mark the other end of this hose as Blind. 7. Connect one 360 long hydraulic hose to the C port on the manifold and mark the other end of this hose as Rod. 8. Route the two 360 long hydraulic hoses to the rear of the vehicle along the left side of the frame and secure in place with tiewraps. Where necessary, fasten the hose to the frame with installer supplied hose clips and hardware. 9. Connect the end of the 360 long hydraulic hose marked Blind to the blind end port on the rear railgear cylinder. 0. Connect the end of the 360 long hydraulic hose marked Rod to the rod end port on the rear railgear cylinder.. Ensure that none of the hoses contact any sharp edges or hot surfaces. Tiewrap all hoses securely leaving enough slack for the railgear to function.. Install the dash switch and Railgear Pump decal in a convenient location on the dash. 3. The pump manifold has two wire harnesses and two wires connected to it: a) One 3 wire harness for the front railgear with a control box on the end. b) One 35 wire harness for the rear railgear with a control box on the end. c) One white and one black wire each with ring terminals on the ends. G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

5 Page 5 of Bulletin MIH9RRFR08B (Rev 0). Using suitable gauge wire, cable loom, connectors, solder and heat shrink tubing: a) Lengthen the white wire if required, and connect it from the manifold to the switching terminal on the railgear pump solenoid previously mounted under the hood. b) Lengthen the black wire if required, and connect it from the manifold through the firewall to the load terminal on the dash switch. c) Connect another length of black wire from the power terminal on the dash switch through the firewall to the inline fuse. d) Connect another length of black wire from the inline fuse to the power terminal on the solenoid. e) Connect another wire from the ground terminal on the dash switch to a suitable ground location on the vehicle. f) Ensure the manifold is properly grounded to the vehicle chassis by connecting a wire from the manifold to a suitable ground location on the vehicle. The railgear may not be properly grounded due to paint on the mounting plates or tar on the frame. 5. Using suitable gauge wire, cable loom, connectors, solder and heat shrink tubing: a) Connect one wire from the vehicle s battery to the power terminal on the railgear pump solenoid. b) Connect another wire from the load terminal on the solenoid to the power terminal on the pump motor. Use the supplied rubber boot to protect the pump power terminal from shorting out. c) Ensure the pump motor base is properly grounded to the vehicle chassis by connecting a wire from the pump motor base to a suitable ground location on the vehicle. The railgear may not be properly grounded due to paint on the mounting plates or tar on the frame. 6. Route the 35 wire harness from the pump along the frame to the rear of the vehicle and secure in place with tiewraps. If necessary, the control box can be removed from and reinstalled on the wire harness to facilitate routing. Fabricate a bracket and mount the rear railgear control box with installersupplied hardware in a protected vertical position in a suitable location. Ensure the control box is within reach of the railgear locking cable handle. 7. Route the 3 wire harness from the pump to the front of the vehicle and secure in place with tiewraps. If necessary, the control box can be removed from and reinstalled on the wire harness to facilitate routing. Mount the front railgear control box on the lock cable and control box bracket using installer supplied hardware. Install the control box vertically and at the back of the lock cable and control box bracket so that the holes in the bracket align with the threaded holes in the control box. Ensure the control box is within reach of the railgear locking cable handle. G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

6 Page 6 of Bulletin MIH9RRFR08B (Rev 0) 8. Ensure that the control boxes are mounted vertically so that the controls do not fill with water and freeze. They should also be mounted in a location protected from road spray etc. 9. Affix the supplied railgear operation decals in a suitable location adjacent to the front and rear control boxes. 30. Ensure all wires and terminals are soldered, heat shrink sealed, enclosed in protective cable loom and secured with tiewraps. 3. Ensure all holes in the firewall are sealed and protected with a grommet. 3. Fill the hydraulic system and bleed the air out: a) Fill the pump tank with ESSO Univis Extra (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). c) Refill the pump tank and repeat the above step until all air is removed from the front hydraulic system. d) Operate the rear 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). e) Refill the pump tank and repeat the above step until all air is removed from the rear hydraulic system. f) With both front and rear railgear locked in the road position, fill the pump tank to the full line. 33. Follow the Hydraulic System Relief Valve Setting procedure detailed in the Hydraulic Kit Operating, Service and Parts Manual. 3. Test the fit of the locking cable holding collar in both the front and rear locking cables. Ensure that the locking cable holding collar keeps the railgear locking pin fully disengaged. Grind the locking cable holding collar or adjust the locking cable handle on the cable to fit if necessary. 35. Test the operation of the controls and directional valve manual overrides. Refer to the operation procedure in the Railgear Kit and Hydraulic Kit Operation, Service, and Parts manuals. 36. Locate and store the hand pump handle and the locking cable holding collar in a secure location in the vehicle cab. G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

7 Page 7 of Bulletin MIH9RRFR08B (Rev 0) ITEM PART NO. DESCRIPTION R08B HYDRAULIC PUMP & MANIFOLD R958 PUMP MOUNTING BRACKET 3 5 R959 R868 R979 PUMP MOUNTING BRACKET SHIM LOCKING CABLE HOLDING COLLAR LOCK CABLE & CONTROL BRACKET (NOT SHOWN) 6 CO30N "FRONT GEAR UP" DECAL 7 CO30O "REAR GEAR UP" DECAL 8 CO30P "FRONT GEAR DOWN" DECAL 9 0 CO30Q S00030 "REAR GEAR DOWN" DECAL RAILEAR OPERATION DECAL (NOT SHOWN) /" UNC GR. 8 BOLT X 0.75" LONG /" LOCK WASHER ITEM PART NO. DESCRIPTION /" SAE WASHER 5/6" UNC GR. 8 BOLT X 0.75" LONG 5/6" LOCK WASHER 5/6" SAE WASHER 3/8" UNC GR. 8 BOLT X.5" LONG 3/8" SAE WASHER 3/8" UNC GR. 3 NYLOCK NUT 83 MACH. SCREW X 0.75" LONG ZINC PLATED (NOT SHOWN) 83 UNC ZINC PLATED NYLOCK NUT (NOT SHOWN) RAILGEAR MOUNTING PLATE (AS PER MOUNTING KIT) RAILGEAR LOCK CABLE (AS PER RAILGEAR KIT) 8 N/A N/A RAFNA INDUSTRIES LTD CLARKGRAHAM BAIE D'URFE, QUEBEC (5) DESCRIPTION: HYDRAULIC KIT REFERENCE: HYDRAULIC KIT PARTS MAT'L: P/N: KH9RRFR08B DATE: APR/06/0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRFR08B G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

8 Page 8 of Bulletin MIH9RRFR08B (Rev 0) FRONT RAILGEAR HYD. CYLINDER P C C T MANIFOLD C3 C P T PUMP TANK REAR RAILGEAR HYD. CYLINDER ITEM PART NO. DESCRIPTION R08B HYDRAULIC PUMP & MANIFOLD R565 FLOW REDUCER 3 89FS006 3/8" MALE NPT TO /" MALE JIC FSO00 89FSO006 /" MALE ORING BOSS TO /" MALE JIC 90 3/8" MALE ORING BOSS TO /" MALE JIC HU00NJ /" FEMALE JIC STRAIGHT COUPLER 7 HFS0 HOSE 3" LONG 8 HFS0 HOSE 33" LONG 9 HFS0 HOSE 360" LONG FRONT REAR C C C3 C CV CV DV DV DV3 DV P T P T M RAFNA INDUSTRIES LTD CLARKGRAHAM BAIE D'URFE, QUEBEC (5) DESCRIPTION: HYDRAULIC KIT REFERENCE: HYDRAULIC LAYOUT MAT'L: P/N: KH9RRFR08B DATE: APR/06/0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRFR08B "L" G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

9 Page 9 of Bulletin MIH9RRFR08B (Rev 0) EXTERIOR CONTROL REAR CONTROL BOX UP FRONT CONTROL BOX UP DOWN WHITE DOWN WHITE RED MANIFOLD BLACK WHITE INSTALLATION NOTES: PUMP RAFNA INDUSTRIES LTD CLARKGRAHAM BAIE D'URFE, QUEBEC (5) DESCRIPTION: ITEM PART NO. PART DESCRIPTION R08B HYDRAULIC PUMP R577 5 AMP FUSE R567 DASH SWITCH CO30G "RAILGEAR PUMP" DECAL (NOT SHOWN) SOLENOID (PART OF R08B) MANIFOLD (PART OF R08B) FRONT CONTROL BOX REAR CONTROL BOX HYDRAULIC KIT REFERENCE: ELECTRICAL LAYOUT UP NEUTRAL DOWN MAT'L: DATE: APR/06/0 P/N: KH9RRFR08B APPR: DRAWN: MER SCALE: : DIM: INCHES DWG#:KH9RRFR08B SHEET: 3 OF 6 TANK MOTOR ALL CONNECTIONS TO BE SOLDERED AND HEAT SHRINK SEALED ENSURE ALL WIRES ARE SECURED AWAY FROM HEAT AND SHARP EDGES RAILGEAR ON OFF BLACK GREEN BLACK BLACK BLACK 3 FT CABLE GREEN RED 35 FT CABLE SWITCH CONFIGURATIONS (VIEWED FROM REAR OF SWITCH) ON OFF 3 9 VEHICLE BATTERY (NOT SUPPLIED) N/A G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

10 Page 0 of Bulletin MIH9RRFR08B (Rev 0) ITEM PART NO. PART DESCRIPTION S /8" PIPE PLUG (NOT SHOWN TANK PLUG) 0 3 S S S S00300 S0030 S0030 S00303 S0030 SAE 06 ORING PLUG HAND PUMP BODY HAND PUMP MOUNTING SCREW PUMP HANDLE RETURN TUBE RESERVOIR CLAMP BALL BALL FOLLOWER S00300 BREATHER S00300 SUCTION ELBOW S MOTOR S00300 M5 MINI PUMP S PLASTIC RESERVOIR 6.5" LONG S003005A PLASTIC RESERVOIR " LONG T P P M 5 8 ITEM PART NO. PART DESCRIPTION S00305 S00306 S00307 S00308 S S00303 S00303 S S00303 S S S S S0030 SPRING SPRING RETAINER SAE 0 ORING PLUG ORING (NOT SHOWN AT HAND PUMP MOUNT) SOLENOID (NOT SHOWN) TERMINAL BOOT (NOT SHOWN) INTERMEDIATE SHAFT (NOT SHOWN) /" UNC SHSC SCREW X.5 LONG (NOT SHOWN) CU IN/REV MICRO PUMP (NOT SHOWN) /6" X /" X.375" ORING SEAL (NOT SHOWN) /" DOWELL PIN X.5" LONG (NOT SHOWN) /6" X /" X 5/8" ORING SEAL (NOT SHOWN) /6" X 3" X 3.3" ORING SEAL (NOT SHOWN) PUMP ASSEMBLY COMPLETE AS SHOWN RAFNA INDUSTRIES LTD CLARKGRAHAM BAIE D'URFE, QUEBEC (5) DESCRIPTION: HYDRAULIC KIT REFERENCE: PUMP PARTS MAT'L: P/N: KH9RRFR08B DATE: APR/06/0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRFR08B G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

11 Page of Bulletin MIH9RRFR08B (Rev 0) ITEM PART NO. PART DESCRIPTION S00309 MANIFOLD BODY S W / P CARTRIDGE VALVE 3 S0030 COIL S0030 DUAL PO CHECK CARTRIDGE VALVE 5 S00303 BOX 6 S0030 SCREW 7 S00305 STRAIN RELIEF 8 S00306 STRAIN RELIEF 9 S00307 STRAIN RELIEF NUT 0 S00308 BOOT S00300 MANIFOLD ASSEMBLY COMPLETE AS SHOWN BOX COVER & BOOTS NOT SHOWN IN TOP VIEW. RAFNA INDUSTRIES LTD. DESCRIPTION: REFERENCE: MAT'L: P/N: KH9RRFR08B DRAWN: MER DIM: INCHES SHEET: 5 OF CLARKGRAHAM BAIE D'URFE, QUEBEC (5) HYDRAULIC KIT PUMP MANIFOLD PARTS DATE: APR/06/0 APPR: SCALE: : DWG#:KH9RRFR08B G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)

12 Page of Bulletin MIH9RRFR08B (Rev 0) G&B Specialties Inc. 535 West 3 rd Street, Berwick, PA, USA Tel: Fax: (570)