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

Size: px

Start display at page:

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

Scott Lawrence
5 years ago
Views:

1 INSTALLATION OF HYDRAULIC KIT Page of Bulletin MIH9RRGX080 (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. Always disconnect the vehicle s battery when welding on the vehicle or railgear in order to protect the vehicle s electrical system. 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. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

2 INSTALLATION OF HYDRAULIC KIT Page of Bulletin MIH9RRGX080 (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 R08 Hydraulic Pump And Manifold R965 Rear Pump Mounting Bracket R700 InCab Control Panel CO07 0 Amp Circuit Breaker CO0N Front Gear Up Decal CO0O Rear Gear Up Decal CO0P Front Gear Down Decal CO0Q Rear Gear Down Decal S0000 Double P.O. Check Valve R565 Flow Reducer S000 Railgear Operation Decal 89FSO00 ¼ Male ORing Boss to ¼ Male JIC FSO006 / 8 Male ORing Boss to ¼ Male JIC 90 5UA06 / 8 Male NPT to / 8 Male NPT 90 88FSO006 / 8 Male ORing Boss to ¼ Male JIC Straight 89FS006 / 8 Male NPT to ¼ Male JIC 90 70FSO0606 / 8 Male ORing Boss to / 8 Female NPT Straight HFS0 Hose 6 Long HFS0 Hose Long HFS0 Hose Long HFS0 Hose 60 Long HU00NJ ¼ Female JIC Straight Coupler (On Hoses) HU00NJ90T ¼ Female JIC 90 Coupler (On Hoses) / UNC Gr. 8 Bolt x Long / SAE Washer / Lock Washer 5 / 6 UNC Gr. 8 Bolt x 0.75 Long 5 / 6 SAE Washer 5 / 6 Lock Washer Not Supplied & Gauge Wire, Terminals, Loom, Etc. As Req d G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

3 Page of Bulletin MIH9RRGX080 (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.. Install a ¼ male ORing Boss to ¼ male JIC 90 fitting into each P, T, C, C, C and C ports of the manifold and into the T port of the pump.. Install a / 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 rear pump mounting bracket against the right side rear mounting plate as shown. Clamp it in place. Position the pump on top of the rear pump mounting bracket as shown with the tank towards the right side of the vehicle. Ensure the pump will not interfere with any part of the vehicle or railgear components. The hand pump handle receiver can be turned to point downwards to ease hand pump handle use. 6. Once the rear pump mounting bracket position is verified, remove the pump and weld the rear pump mounting bracket to the right side rear mounting plate all around. 7. Reposition and fasten the pump on top of the rear pump mounting bracket with four 5 / 6 x 0.75 long bolts, four 5 / 6 lock washers and four 5 / 6 washers. 8. Position the manifold on the left rear mounting plate as shown with the P and T ports facing upwards. Fasten the manifold to the left rear mounting plate with three ¼ x long bolts, three ¼ lock washers and three ¼ washers. 9. There are four directional valve manual overrides on the face of the manifold. The decal plates can be installed on the face of the manifold as shown. Stick the decal plates next to the respective overrides such that they are properly oriented. 0. Insert a flow reducer into the NPT end of two / 8 male NPT to ¼ male JIC 90 fittings. Install one of these fittings into the rod end port of each railgear cylinder. Use Teflon sealant on all NPT fittings.. Install a / 8 male NPT to / 8 male NPT 90 fitting and a / 8 male ORB to / 8 female NPT straight fitting between the U port of each check valve and the blind end port of each railgear cylinder. Use Teflon sealant on all NPT fittings. The check valves may have to be rotated away from the axis of the cylinders in order to avoid contact with the railgear in the road position. G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

4 Page of Bulletin MIH9RRGX080 (Rev 0). Install a / 8 male ORB to ¼ male JIC 90 fitting into the U port of each check valve and a / 8 male ORB to ¼ male JIC straight fitting into the D and D ports of each check valve.. Connect one 6 long hydraulic hose between the U port on the rear railgear cylinder check valve and the rod end port on the rear railgear cylinder.. Connect one 6 long hydraulic hose between the U port on the front railgear cylinder check valve and the rod end port on the rear railgear cylinder. 5. Connect one long hydraulic hose (straight and 90 ends) between the C port on the manifold and the D port on the rear railgear cylinder check valve. The 90 hose end should be at the check valve. 6. Connect one long hydraulic hose (straight and 90 ends) between the C port on the manifold and the D port on the rear railgear cylinder check valve. The 90 hose end should be at the check valve. 7. Connect one long hydraulic hose between the P port on the manifold and the P port on the pump. 8. Connect one long hydraulic hose between the T port on the manifold and the T port on the pump. 9. Connect one 60 long hydraulic hose to the C port on the manifold and mark the other end of this hose as D. 0. Connect one 60 long hydraulic hose to the C port on the manifold and mark the other end of this hose as D.. Route the two 60 long hydraulic hoses to the front 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.. Connect the end of the 60 long hydraulic hose marked D to the D port on the front railgear cylinder check valve.. Connect the end of the 60 long hydraulic hose marked D to the D port on the front railgear cylinder check valve.. 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. 5. Install the InCab Control panel in the cab in a convenient location under the dash. G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

5 Page 5 of Bulletin MIH9RRGX080 (Rev 0) 6. Install the circuit breaker under the hood near the previously installed railgear pump solenoid. 7. The pump manifold has three wire harnesses and two wires connected to it: a) One wire harness for the rear railgear with a control box on the end. b) One 5 wire harness for the front railgear with a control box on the end. c) One 0 wire harness for the incab controls with terminated wires on the end. d) One white and one black wire each with ring terminals on the ends. 8. 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 from the manifold through the firewall to the load terminal on the railgear switch on the InCab Control panel. c) Connect another length of black wire from the power terminal on the railgear switch through the firewall to the Aux terminal on the circuit breaker. d) Connect another black wire from the Bat terminal on the circuit breaker to the power terminal on the solenoid. e) Connect another wire from the ground terminal on the railgear 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 and tar on the frame. g) Lengthen the 0 wire harness if required and route it from the manifold through the firewall to the InCab Control panel. Connect the wires to the InCab Control switches as shown. 9. 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. 0. Route the 5 wire harness from the pump along the frame 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. Fabricate a bracket and G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

6 Page 6 of Bulletin MIH9RRGX080 (Rev 0) mount the front railgear control box with installersupplied hardware in a protected vertical position in a suitable location.. Route the wire harness from the pump 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 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.. Affix the supplied railgear operation decals in a suitable location adjacent to the front and rear control boxes.. Ensure all wires and terminals are soldered, heat shrink sealed, enclosed in protective cable loom and secured with tiewraps. 5. Ensure all holes in the firewall are sealed and protected with a grommet. 6. 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. 7. Follow the Hydraulic System Relief Valve Setting procedure detailed in the Hydraulic Kit Operating, Service and Parts Manual. 8. 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. 9. Locate and store the hand pump handle in a secure location in the vehicle cab. G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

7 Page 7 of Bulletin MIH9RRGX080 (Rev 0) ITEM PART NO. DESCRIPTION R08 HYDRAULIC PUMP & MANIFOLD R965 REAR PUMP MOUNTING BRACKET CO0N "FRONT GEAR UP" DECAL CO0O "REAR GEAR UP" DECAL 5 CO0P "FRONT GEAR DOWN" DECAL 6 CO0Q "REAR GEAR DOWN" DECAL 7 S000 RAILEAR OPERATION DECAL (NOT SHOWN) ITEM PART NO. DESCRIPTION 8 /" UNC GR. 8 BOLT X " LONG 9 /" LOCK WASHER 0 /" SAE WASHER 5/6" UNC GR. 8 BOLT X 0.75" LONG 5/6" SAE WASHER 5/6" LOCK WASHER RAILGEAR MOUNTING PLATE (AS PER MOUNTING KIT) N/A RAFNA INDUSTRIES LTD. 900 CLARKGRAHAM BAIE D'URFE, QUEBEC (5) 577 DESCRIPTION: HYDRAULIC KIT REFERENCE: HYDRAULIC KIT PARTS MAT'L: P/N: KH9RRGX080 DATE: JUN//0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRGX080 G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

8 Page 8 of Bulletin MIH9RRGX080 (Rev 0) REAR RAILGEAR HYD. CYLINDER U D D U U D D U FRONT RAILGEAR HYD. CYLINDER ITEM PART NO. DESCRIPTION R08 HYDRAULIC PUMP & MANIFOLD S0000 DOUBLE P.O. CHECK VALVE R565 FLOW REDUCER 5UA06 /8" MALE NPT TO /8" MALE NPT FS006 /8" MALE NPT TO /" MALE JIC FSO006 /8" MALE ORING BOSS TO /" MALE JIC STRAIGHT 7 89FSO00 /" MALE ORING BOSS TO /" MALE JIC FSO006 /8" MALE ORING BOSS TO /" MALE JIC 90 7 ITEM P C C T MANIFOLD C C P T PUMP TANK PART NO. DESCRIPTION 70FSO0606 /8" MALE ORING BOSS TO /8" FEMALE NPT STRAIGHT HU00NJ /" FEMALE JIC STRAIGHT COUPLER HU00NJ90T /" FEMALE JIC 90 COUPLER HFS0 HOSE 6" LONG HFS0 HOSE " LONG HFS0 HOSE " LONG HFS0 HOSE 60" LONG RAFNA INDUSTRIES LTD. 900 CLARKGRAHAM BAIE D'URFE, QUEBEC (5) 577 DESCRIPTION: HYDRAULIC KIT REFERENCE: HYDRAULIC LAYOUT MAT'L: P/N: KH9RRGX080 DATE: JUN//0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRGX080 "L" G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

9 Page 9 of Bulletin MIH9RRGX080 (Rev 0) RAILGEAR ON INCAB CONTROL REAR GEAR UP FRONT GEAR UP FRONT CONTROL BOX UP EXTERIOR CONTROL REAR CONTROL BOX UP OFF DOWN 6 7 DOWN DOWN 5 WHITE BLUE YELLOW GREEN RED WHITE GREEN WHITE RED GREEN WHITE RED FT CABLE 5 FT CABLE 0 FT CABLE MANIFOLD FUSE / CIRCUIT BREAKER SOLENOID WHITE INSTALLATION NOTES: BATTERY PUMP ALL CONNECTIONS TO BE SOLDERED AND HEAT SHRINK SEALED ENSURE ALL WIRES ARE SECURED AWAY FROM HEAT AND SHARP EDGES ITEM PART NO. 8 PART DESCRIPTION UP NEUTRAL DOWN SWITCH CONFIGURATIONS (VIEWED FROM REAR OF SWITCH) UP NEUTRAL DOWN RAFNA INDUSTRIES LTD. DESCRIPTION: 900 CLARKGRAHAM BAIE D'URFE, QUEBEC (5) 577 HYDRAULIC KIT R08 HYDRAULIC PUMP & MANIFOLD CO07 0 AMP CIRCUIT BRAKER R700 INCAB CONTROL PANEL SOLENOID (PART OF R08) 5 MANIFOLD (PART OF R08) 6 FRONT CONTROL BOX REAR CONTROL BOX 8 VEHICLE BATTERY (NOT SUPPLIED) N/A 7 REFERENCE: ELECTRICAL LAYOUT IN CAB CONTROL RAILGEAR CONTROL BOX MAT'L: ON OFF P/N: KH9RRGX080 DATE: JUN//0 DRAWN: MER APPR: PUMP DASH SWITCH DIM: INCHES SHEET: OF 6 SCALE: : DWG#:KH9RRGX080 G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

10 Page 0 of Bulletin MIH9RRGX080 (Rev 0) 0 9 ITEM PART NO. PART DESCRIPTION 5 6 S00006 /8" PIPE PLUG (NOT SHOWN TANK PLUG) 0 S00007 S00008 S00009 S0000 SAE 06 ORING PLUG HAND PUMP BODY HAND PUMP MOUNTING SCREW PUMP HANDLE RETURN TUBE RESERVOIR CLAMP BALL BALL FOLLOWER S0000 BREATHER S0000 SUCTION ELBOW S0000 MOTOR S0000 M5 MINI PUMP S00005 PLASTIC RESERVOIR 6.5" LONG S00005A PLASTIC RESERVOIR " LONG S000 S000 S000 S000 T P P M 5 8 ITEM PART NO. PART DESCRIPTION S0005 S0006 S0007 S0008 S S000 S000 S000 S000 S S S S S000 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.75" ORING SEAL (NOT SHOWN) /" DOWELL PIN X.5" LONG (NOT SHOWN) /6" X /" X 5/8" ORING SEAL (NOT SHOWN) /6" X " X." ORING SEAL (NOT SHOWN) PUMP ASSEMBLY COMPLETE AS SHOWN RAFNA INDUSTRIES LTD. 900 CLARKGRAHAM BAIE D'URFE, QUEBEC (5) 577 DESCRIPTION: HYDRAULIC KIT REFERENCE: PUMP PARTS MAT'L: P/N: KH9RRGX080 DATE: JUN//0 DRAWN: MER APPR: DIM: INCHES SCALE: : SHEET: OF 6 DWG#:KH9RRGX080 G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

11 Page of Bulletin MIH9RRGX080 (Rev 0) ITEM PART NO. PART DESCRIPTION S0009 MANIFOLD BODY S0000 W / P CARTRIDGE VALVE S000 COIL S000 DUAL PO CHECK CARTRIDGE VALVE 5 S000 BOX 6 S000 SCREW 7 S0005 STRAIN RELIEF 8 S0006 STRAIN RELIEF 9 S0007 STRAIN RELIEF NUT 0 S0008 BOOT S0009 MANIFOLD ASSEMBLY COMPLETE AS SHOWN 0 6 BOX COVER & BOOTS NOT SHOWN IN TOP VIEW. RAFNA INDUSTRIES LTD. DESCRIPTION: REFERENCE: MAT'L: P/N: KH9RRGX080 DRAWN: MER DIM: INCHES SHEET: 5 OF CLARKGRAHAM BAIE D'URFE, QUEBEC (5) 577 HYDRAULIC KIT PUMP MANIFOLD PARTS DATE: JUNE//0 APPR: SCALE: : DWG#:KH9RRGX080 G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

12 Page of Bulletin MIH9RRGX080 (Rev 0) G&B Specialties Inc. 55 West rd Street, Berwick, PA, USA Tel: Fax: (570) 75697

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

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