Wabtec Ricon Faiveley FoldOver FR2E Series, Service Manual

Page 1: ...l 05 20 20 32DFRE02 C 2020 RICON CORPORATION All Rights Reserved U S and Foreign Patents Pending Printed in the United States of America FoldOver Electric FR2E Series Low Floor Vehicle Access Ramp for Transit Buses ...

Page 2: ...rmation which supports qualified technicians in the correct installation and maintenance of Ricon products Ricon dealers or qualified service technicians have the training and knowledge to perform maintenance work properly and safely For the location of a Ricon dealer or qualified service technician in your area call Ricon Product Support at 1 800 322 2884 or visit our website at http ricondealer ...

Page 3: ...CRIPTION OF CHANGE ECO 32DFRE02 C Cvr Update to company logo 9239 All Revised all title bars footers 1 3 Update to company logo 4 1 Text update 4 7 Update to Figure 4 2 4 4 9 4 10 Update to Figure 4 2 Parts List 4 15 Update to Figure 4 4 Parts List 4 16 Update to Table 2 4 4 17 Update to Table 2 5 ...

Page 4: ... BRACKETS ON BUS FRAME 2 1 2 INSTALLING RAMP IN FLOOR 2 1 3 INSTALLING VEHICLE WIRING HARNESS 2 3 B FOLDOVER RAMP ADJUSTMENTS 2 3 1 CHAIN ASSEMBLY REPLACEMENT 2 3 2 FINAL INPSECTION 2 4 III FOLDOVER ELECTRIC FR2E SERIES RAMP MAINTENANCE 3 1 A GENERAL SAFETY PRECAUTIONS 3 1 B DAILY INSPECTION 3 2 C MAINTENANCE SCHEDULE 3 2 D RAMP COMPONENT INFORMATION 3 3 1 MOTOR DRIVE SYSTEM 3 3 2 TRAY POSITION SW...

Page 5: ...iv TABLE OF CONTENTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL This page intentionally left blank ...

Page 6: ...lectronics can interface with the vehicle interlock circuitry to prevent vehicle departure when ramp is deployed The electric ramp interlock circuitry senses the position of the ramp stowed or deployed and makes this information available by the controller and through the 55 pin amp harness connector A vehicle interlock circuit typically requires that the following conditions be met before operati...

Page 7: ...e 818 area code John Condon National Sales Manager Telephone Email jcondon wabtec com 209 603 5189 Mike O Neill Eastern Area Sales Manager Telephone Email moneill wabtec com 847 224 5087 Justin Millikin Central Area Sales Manager Telephone Email jmillikan wabtec com 916 206 7456 Vapor Ricon Europe Ltd Meadow Lane Loughborough Leicestershire LE 1HS United Kingdom Telephone 044 1509 635 920 C RICON ...

Page 8: ...onths or sooner if necessary Perform required maintenance at this time WARNING THIS PRODUCT HAS BEEN DESIGNED AND MANUFACTURED TO EXACT SPECIFICATIONS ANY MODIFICATION OF THIS PRODUCT CAN BE HAZARDOUS This Warranty is Void If The product is not installed and maintained by a Ricon dealer or qualified service technician The product is modified in any respect from its original design without written ...

Page 9: ...he included bill of material Please report any missing items immediately to Ricon Product Support Save bill of material for later reference Return the completed warranty and owner registration cards to Ricon within 20 days to validate warranty NOTE The Sales or Service personnel must review the Warranty and this Operator Manual with the user to be certain that they understand how to safely operate...

Page 10: ...ajor components of the Ricon FoldOver Electric FR2E Series ramp A description of each component is provided in Table 1 1 Refer to Chapter IV Parts Diagrams and Lists for more details RSM0067200 14 1 3 4 5 5 8 8 8 15 11 12 13 9 10 16 18 7 6 7 6 17 2 17 19 FIGURE 1 3 ELECTRIC FR2E SERIES RAMP MAJOR COMPONENTS ...

Page 11: ...to ramp 8 Flange Kit Perimeter trim pieces that are installed after the ramp has been installed in vehi cle 9 Floor Plate Access Cover Portion of ramp that passenger traverses over to enter and exit vehicle which also provides access to electro mechanical ramp components 10 Front Cover Front edge of ramp that opens and closes when platform is deployed or stowed 11 Harness Integrates conduits relay...

Page 12: ... ramp motion to be erratic Set the height of the ramp flooring surface flush to the surrounding floor structure to prevent a tripping hazard 2 INSTALLING ELECTRIC FR2E SERIES LOW FLOOR VEHICLE ACCESS RAMP IN FLOOR The location of the ramp depends on its path of motion The ramp must be positioned so it can move un obstructed through its required range of travel a Trim away floor material to allow r...

Page 13: ...ture install appropriate shim spacers accordingly FOLLOW SEQUENCE FOR SECURING RAMP ONTO BUS STRUCTURE DEVIATION FROM THE INSTALLATION SEQUENCE CAN CAUSE RAMP WARPAGE e Install and tighten hardware to secure ramp enclosure within bus structure NOTE Installation of ramp into bus may vary by manufacturer and configuration of ramp f Refer to Figure 2 3 Install left and right trim pieces with attachin...

Page 14: ...gnal when ramp not stowed Ground when ramp stowed B 2 Red Stow Attempt Input 12V 24V to controller to engage stow functions C 3 Orange Interlock Output 12V 24V when ramp not stowed 0V when ramp stowed D 4 Black Deploy Attempt Input 12V 24V to controller to engage deploy functions E 5 Brown Heater Mat Optional 12V 24V to heater mat Grounded internally B FOLDOVER FR2E ELECTRIC RAMP COMPONENT REPLACE...

Page 15: ...tension of chain by adjusting position of Tray Position Switch Assembly h Tighten two screws to secure Tray Position Switch Assembly i Test the chain assembly by deploying and stowing ramp 2 3 cycles 2 FINAL INSPECTION a Visually inspect ramp for loose or missing hardware and fittings and confirm that pockets are free of debris b Verify that slanted plated cover is secure and closed on ramp c Veri...

Page 16: ...he user must be cautious when operating the ramp Be certain that hands feet legs and clothing are not in the path of ramp movement Batteries contain acid that can burn Wear protective clothing and eye protection at all times If acid comes in contact with skin immediately flush affected area with water and wash with soap Do not place anything electrically conductive on top of battery Do not smoke o...

Page 17: ... Maintain the ramp as directed in Table 3 2 Perform ramp maintenance more frequently during heavy use more than 20 cycles per day CAUTION This Ricon Product Is Complex Required warranty period maintenance and repairs must be done at a Ricon dealer or qualified service facility Improper maintenance use of non Ricon replacement parts or product modification will void warranty and can result in unsaf...

Page 18: ...programmed in the motor drive system and is preset at Ricon The motor drive system converts electrical power into mechanical force through the crank shafts when either the DEPLOY or STOW micro switches are activated and controlled by an electronic controller Ricon recommends op erating the ramp while the vehicle engine is running in order to minimize current drain on the vehicle battery 2 TRAY POS...

Page 19: ...amp when it is not stowed completely as well as preventing the bus from operating or moving when ramp is deployed Refer to Table 3 3 The status of the interlock output GND or 12VDC 24VDC occur when the ramp is either STOWED or DEPLOYED Note that the interlock output has both a normal and an inverted output This table ap plies to the normal output TABLE 3 3 INTERLOCK OUTPUT STATUS POSITION INTERLOC...

Page 20: ... INDICATED DIODE DUETSCH CONNECTOR 12 PIN DUETSCH CONNECTOR WIRE CROSSINGS NOT CONNECTED CONNECTED BATTERY POWER SOURCE COMMON RSM0068900 FIGURE 3 2 SCHEMATIC SYMBOLS TABLE 3 4 HARNESS FUSES FUSE RATING CIRCUIT F1 5 AMP Lift Enable Ramp Switch F2 15 AMP 12V 24V High Voltage Motor Power END OF TABLE ...

Page 21: ...ing diagram of the ramp system The wiring diagram is located at the end of this chapter RSM0068600 MICROSWITCH 6 PL SW1 SW6 SW3 SW2 SW5 SW4 COUNTER CONTROLLER 55 PIN AMP CONNECTOR 15 AMP FUSE WITH FUSE HOLDER 5 AMP FUSE WITH FUSE HOLDER 24V CONTROL BOX 6 PIN CONNECTOR FIGURE 3 3 CONNECTOR CONFIGURATION ...

Page 22: ... R1 R2 12V 24V 1 SUPPLY GND 5 OUTPUT DC 40 RAMP STOWED IN 39 STOW OUT 38 RAMP STOWED OUT 24 TEST 23 SUPPLY DC 55 COUNTER OUT 54 DEPLOY OUT 41 STOW IN 52 DEPLOY IN 2 GND 1 12 24V PULSED CURRENT TRANSDUCER FR2E RAMP ASSY 3A COUNTER CONN COUNTER 1 2 1 2 1 1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10 11 12 N C N C N C N C N C N C CONTROLLER BLACK 14 RED 14 RED 12 CONFIG CONN N C N C BLACK 12 BLACK 14...

Page 23: ...HMT BRN OPTIONAL HEATER MAT _ REQUEST SIGNALS INT GND INT DPA STA HMT INTERLOCK OUTPUT NO SIGNAL WHEN RAMP NOT STOWED GROUND WHEN RAMP STOWED INTERLOCK OUTPUT 12 24V WHEN RAMP NOT STOWED 0V WHEN RAMP STOWED DEPLOY ATTEMPT INPUT 12 24V TO CONTROLLER TO ENGAGE DEPLOY FUNCTIONS STOW ATTEMPT INPUT 12 24V TO CONTROLLER TO ENGAGE STOW FUNCTIONS HEATER MAT OPTIONAL 12 24V TO HEATER MAT GROUNDED INTERNALL...

Page 24: ...e purposes only and are not sold for spare parts NOTE Most items that are described as kits contain a single part plus hardware Therefore you may need to order more than one kit if the part is used more than once on the assembly shown Small inexpensive hardware items are supplied in a minimum quantity of ten and are packaged in a bag A single bag may provide more parts than you need or you may nee...

Page 25: ...4 2 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067300 1 2 2 1 FIGURE 4 1 FR2E DECAL LOCATIONS ...

Page 26: ... MANUAL FIGURE 4 2 FR2E SERIES RAMP ASSEMBLY FIG ITEM DESCRIPTION QTY CONFIG PART NO 1 DECAL SERIAL CE UNIVERSAL 2 32 10 166 2 DECAL CAUTION PINCH POINT F OVER RAMP 2 18618 NOTE REF in QTY column is for Referenced Parts Only and are not sold as spare parts ...

Page 27: ...4 4 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067400 G B C A 1 2 REF 3 FIGURE 4 2 1 FR2E SERIES RAMP ASSEMBLY SHEET 1 OF 5 ...

Page 28: ...4 5 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067500 A OPTIONAL B 1A 4 FIGURE 4 2 2 FR2E SERIES RAMP ASSEMBLY SHEET 2 OF 5 ...

Page 29: ...4 6 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067600 C D E E F 6 7 8 9 D F 10 11 5 FIGURE 4 2 3 FR2E SERIES RAMP ASSEMBLY SHEET 3 OF 5 ...

Page 30: ...4 7 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067701 H G H 14 15 16 17 18 19 J FIGURE 4 2 4 FR2E SERIES RAMP ASSEMBLY SHEET 4 OF 5 ...

Page 31: ...4 8 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067800 20 1 PL 20 3 PL 20 2 PL 22 23 21 J FIGURE 4 2 5 FR2E SERIES RAMP ASSEMBLY SHEET 5 OF 5 ...

Page 32: ...rt Ramp 1 FR2E12 MX7903C001020 57684 4 KIT FLANGE TRIM 34 4 x20 L Short Ramp 1 FR2E12 MA7903C001010 57684 4 KIT FLANGE TRIM 34 4 x20 L Short Ramp 1 FR2E12 MA7903C001020 57684 4A KIT FLANGE TRIM 32 x54 L Long Ramp 1 FR2E13 SA0000C011000 58158 4A KIT FLANGE TRIM 32 x54 L Long Ramp 1 FR2E13 SB0000C011000 58158 4B KIT FLANGE TRIM 30 x20 L Short Ramp 1 FR2E14 MY2229C011100 60730 4C KIT FLANGE RAMP 34 W...

Page 33: ... 66493 9 KIT HATCH HANDLE 1 FR2E00 XYXXXXB001001 58501 9 KIT HATCH HANDLE 1 FR2E12 MA7903C001020 58501 9 KIT HATCH HANDLE 1 FR2E12 MA7903C001010 58501 9 KIT HATCH HANDLE 1 FR2E12 MX7903C001000 58501 9 KIT HATCH HANDLE 1 FR2E12 MX7903C001010 58501 9 KIT HATCH HANDLE 1 FR2E12 MX7903C001020 58501 10 KIT DRIVE ARM LH 1 58502 11 KIT DRIVE ARM RH 1 58503 12 DELETED 13 DELETED 14 HARNESS ASSY ELECTRIC SE...

Page 34: ...4 11 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL This page intentionally left blank ...

Page 35: ...4 12 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0067900 1 2 4 3 5 FIGURE 4 3 FR2E SERIES MOTOR DRIVE ASSEMBLY ...

Page 36: ...IVE ASSY 1 58513 1A KIT 12V DRIVE ASSY 1 58516 2 KIT SLOTTED DISC CRACK WITH SPIDER COUPLING LH 1 58514 3 BEARING SUPPORT BRACKET LH SEE FIG 2 1 58506 4 KIT SPIDER COUPLING AND SHAFT RH 1 58515 5 BEARING SUPPORT BRACKET RH SEE FIG 2 1 58507 NOTE REF in QTY column is for Referenced Parts Only and are not sold as spare parts NOTE Item or configuration not shown ...

Page 37: ...4 14 SPARE PARTS MAY 2020 32DFRE02 C FR2E SERIES SERVICE MANUAL RSM0068100 1 2 3 4 5 6 PL FIGURE 4 4 FR2E SERIES ELECTRICAL HARNESSES AND COMPONENTS ...

Page 38: ... KIT 24V CONTROLLER FR2E SHORT RAMPS 1 FR2E14 66416 2 KIT 24V CONTROL BOX 1 FR2E13 58505 2A KIT 24V CONTROL BOX FR2E SHORT RAMPS 1 FR2E15 58505 2B KIT 24V CONTROL BOX FR2E SHORT RAMPS 1 FR2E12 61526 2C KIT 24V CONTROL BOX FR2E SHORT RAMPS 1 FR2E14 61526 3 KIT HARNESS ASSY 1 51034 4 KIT COUNTER CONNECTOR ASSY WITH HARDWARE 1 44219 5 KIT SWITCH LIMIT ROLLER SPDT 15A MAX 6 264104 6 KIT BLOCK POSITIVE...

Page 39: ...mp Weight 210 lbs 95kg RSM0068000 A B C D E F DIMENSIONS Inches MM A B C D E F MODEL Ramp Frame Height Ramp Trim Width Ramp Trim Length Useable Platform Width Sloped Surface Length Stowed Height Above Floor FR2E12 4 3 109 40 0 1016 21 9 556 34 4 874 20 0 508 0 10 2 5 FR2E14 4 3 109 35 5 902 21 7 551 30 0 762 20 0 508 0 10 2 5 END OF TABLE NOTE Ramp may be configured to meet specific requirements N...

Page 40: ...C E F DIMENSIONS Inches MM A B C D E F MODEL Ramp Frame Height Ramp Trim Width Ramp Trim Length Useable Platform Width Sloped Surface Length Stowed Height Above Floor FR2E00 4 5 114 35 2 894 48 2 1224 30 0 765 48 0 1219 0 10 2 5 FR2E13 4 5 114 37 5 953 52 3 1328 32 0 813 54 0 1372 0 10 2 5 FR2E15 4 5 114 39 5 1004 50 7 1288 34 0 864 48 0 1219 0 10 2 5 END OF TABLE NOTE Ramp may be configured to me...