Wabtec Ricon FoldOver FR2SS Series, Quick Start Manual

Page 1: ...nual 04 29 21 32DFR108 C 2021 RICON CORPORATION All Rights Reserved U S and Foreign Patents Pending Printed in the United States of America FoldOver FR2SS Series Low Floor Vehicle Access Ramp for Tran...

Page 2: ...ce information which supports qualified technicians in the correct installation and maintenance of Ricon products Qualified service technicians have the training and knowledge to perform maintenance w...

Page 3: ...8 C 2 1 Removed FLUID LEVEL SENSOR INSTALLATION 9300 3 8 Added Point 7 FLUID SENSOR under RAMP COMPONENT INFORMATION section 4 5 Added Wrong fluid sensor output in TROUBLESHOOTING GUIDE table 5 19 Upd...

Page 4: ...FLOW CONTROL VAVLE PRESSURE SETTING ADJUSTMENT 2 1 2 ADJUSTING SENSOR TARGET FOR POSITION AND GAP 2 2 3 FINAL INPSECTION 2 3 III FOLDOVER RAMP MAINTENANCE 3 1 A GENERAL SAFETY PRECAUTIONS 3 1 B DAILY...

Page 5: ...iv TABLE OF CONTENTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL This page intentionally left blank...

Page 6: ...cle interlock circuitry to prevent vehicle departure when ramp is deployed The ramp interlock circuitry senses the position of the ramp stowed or deployed and makes this information available at the J...

Page 7: ...ricondealer wabtec com Ricon Corporation 1135 Aviation Place San Fernando CA 91340 818 267 3000 Outside 818 Area Code 800 322 2884 Website http ricondealer wabtec com Vapor Ricon Europe Ltd Meadow La...

Page 8: ...rform 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 p...

Page 9: ...the 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...

Page 10: ...G HT HEATER PAD WIRING ACCESS COVER OPTIONAL COMPONEN T ACCESS COVER FLOOR PL ATE FLOW CONTRO L VALVES ELECTRONIC CONTROLLER SENSOR TARGETS STOW DEPLOY PROXIMIT Y SENSORS STOW DEPLOY DRIVE ARM DRIVEN...

Page 11: ...rs are oilite material Heater mat optional Helps keep ramp floor clear of ice and snow Heater mat wiring access cover optional Provides access to wiring for optional heater mat Hinge Pivoting connecti...

Page 12: ...None 1 flange 2 Black 3 White Heater 0 None 1 Heater 24VDC only Control Panel 0 No control panel internal counter 1 Dash panel w internal counter Floor material 0 Supplied by others 1 RCA TR 852 Manu...

Page 13: ...ipped loose Side barrier trim color 0 Yellow 1 None 1 flange 2 Black 3 White Heater 0 None 1 Heater 24VDC only Control Panel 0 No control panel internal counter 1 Dash panel w internal counter Floor m...

Page 14: ...ow Heater 0 None 1 Heater 24VDC only Control Panel 0 No control panel 1 Dash panel Floor material 0 Supplied by others 1 RCA Ribbed TR 452 2 Altro Chroma 2731 SCR Yel Nose 3 Altro Chroma CE27MTS SCR Y...

Page 15: ...1 10 INTRODUCTION APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL This page intentionally left blank...

Page 16: ...or surface and is sealed to it with a bead of sealer or a gasket The typical gap between the side mounting faces and the bus structure is 1 8 inch use shims to fill gap Mount ramp with six grade 5 scr...

Page 17: ...verify that target is correctly installed on actuator driveshaft the small stow seg ment points at the actuator and the larger deploy segment is adjacent to the pillow block The target must be lateral...

Page 18: ...SENSOR GAP ADJUSTMENT LEFT SIDE VIEW 3 FINAL INSPECTION a Visually inspect ramp for loose or missing hardware and fittings and confirm that pockets are free of debris b Verify that bottom cover is ins...

Page 19: ...tious 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...

Page 20: ...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...

Page 21: ...er is converted to hydraulic force which is used to move the ramp Electrical and hydraulic components are de scribed below Please refer to Figures 3 7 3 8 and 3 9 for hydraulic schematics and flow dia...

Page 22: ...provides a timing signal to the auxiliary counter Refer to Figure 3 1 for locations of J1 J2 J3 J4 and J5 connectors The controller cover is sealed with silicone rubber and is not easily removed Note...

Page 23: ...own Power to stowed sensor 24 volts 24 volts 2 Not used 3 Blue Ground Ground Ground 4 Black Stowed sensor controller input 0 volts sensor off 24 volts when sensor is activated J3 1 Brown Power to depl...

Page 24: ...e caused by accumulated debris beneath the ramp within the frame The following information will provide an aide to troubleshoot ramp problems using the indicator lights on each sensor Refer to Figure...

Page 25: ...cuit breaker for 12V applica tions to protect ramp control circuits Two fuses protect the controller and are located inside its sealed enclosure Please refer to Figure 3 2 for their lo cations The fus...

Page 26: ...el is low not detecting fluid and 0 25vdc when fluid level is OK Refer to table 3 6 below for status of LED lights on sensor body TABLE 3 6 FLUID SENSOR LED STATUS LED ON OFF GREEN POWER ON POWER OFF...

Page 27: ...raulic sys tem in its inactive deploy and stow modes The diagrams show the direction and path of fluid flow and valve posi tions The diagrams are located on the following pages Refer to Figure 3 12 fo...

Page 28: ...is feature is optional and may not be connected INTERLOCK Signal to vehicle interlock circuit when ramp is fully stowed 24V when ramp is stowed signal is generated by the electronic controller INTERLO...

Page 29: ...R P U M P P U M P M O T O R R E S E R V O IR R O T A R Y A C T U A T O R F L O W C O N T R O L VA L V E D E P L O Y S 1 H Y D R A U L IC P U M P A SS Y A B S T O W S 2 F L O W C O N T R O L VA L V E...

Page 30: ...3 12 MAINTENANCE APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL FIGURE 3 10 HYDRAULIC FLUID FLOW DURING DEPLOY MOTION...

Page 31: ...3 13 MAINTENANCE APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL FIGURE 3 11 HYDRAULIC FLUID FLOW DURING STOW MOTION...

Page 32: ...3 14 MAINTENANCE APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL 50A FIGURE 3 12 FR2SS SERIES RAMP ELECTRICAL DIAGRAM...

Page 33: ...3 15 MAINTENANCE APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL FIGURE 3 13 FR2N SERIES RAMP ELECTRICAL DIAGRAM...

Page 34: ...3 16 MAINTENANCE APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL FIGURE 3 14 FR2G SERIES RAMP ELECTRICAL DIAGRAM...

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Page 36: ...ipped Reset circuit breaker Vehicle battery charge too low Check vehicle battery If necessary operate ramp with vehicle engine running No power to ramp har ness connector pin P1 6 blue lead Check for...

Page 37: ...draulic fluid level refill as required Pump directional valve defective Replace hydraulic pump assy Low hydraulic pres sure Check that hydraulic pump pressure output is 1400 PSI Adjust pump relief val...

Page 38: ...connector pin P1 2 Repair wiring as required STOW DEPLOY switch defective Replace or repair STOW DEPLOY switch Main ramp power switch defective Replace or repair main ramp power switch Pump solenoid...

Page 39: ...k that hydraulic pump pressure out put is 1400 PSI Adjust pump relief valve as necessary Check hydraulic lines for leaks or ob structions Repair as required Replace hydraulic pump Hydraulic pump wirin...

Page 40: ...ad on STOW DEPLOY switch is connected to bus harness connector pin B and the black DEPLOY lead is connected to pin D Refer to Figure 3 10 in Chapter 3 Ramp will function in one direction but not the o...

Page 41: ...RESPONSE FROM RAMP No response from ramp Is ramp control panel on bus on Is bus on ramp control panel activated No Disconnect connector P1 from electronic controller Check for system power at pin P1...

Page 42: ...witch and door open switch Turn on ramp power at control panel Is ramp power indicator light on No Yes Set STOW DEPLOY switch to DEPLOY Check for signal at ramp harness connector pin P1 5 black lead I...

Page 43: ...Check for power on pin J3 1 of controller Is proper voltage present on pin J3 1 Yes No Possible defective or damaged controller Is ground present on pin J3 3 No Yes When the ramp is deployed between 0...

Page 44: ...within range No Deploy sensor is out of adjustment or defective Yes Disconnect hydraulic pump harness connector P4 from controller Set STOW DEPLOY switch to DEPLOY Check for power on pin J4 1 of cont...

Page 45: ...lic pump directional solenoid S1 Is the pump solenoid operating No Possible defective pump directional solenoid possible shorted wire Yes Set STOW DEPLOY switch to DEPLOY Check for proper voltage at h...

Page 46: ...rcuit breaker Yes No F Open door disengage door switch turn off ramp power disconnect bus harness connector from ramp interface connector J6 Disconnect red 4 AWG lead from positive red terminal post T...

Page 47: ...oor closed switch Does circuit breaker trip when door is closed Yes No Set main ramp power switch to ON Short in wire from door switch to ramp STOW DEPLOY switch Does circuit breaker trip when switch...

Page 48: ...ircuit breaker trip when connector P2 is reconnected Yes No H To page 4 14 Short between ramp harness connector P1 and vehicle interlock system Short in stow sensor assembly Disconnect stow sensor con...

Page 49: ...o Short in wire from STOW DEPLOY switch to ramp harness connector pin P1 2 red wire Reconnect connector P1 to controller Set STOW DEPLOY switch to STOW ramp will not operate Does circuit breaker trip...

Page 50: ...witch to DEPLOY Does circuit breaker trip Yes Short between STOW DEPLOY switch and either vehicle audio alert or pin P1 5 of ramp harness connector P1 No J From page 4 14 To page 4 16 Reconnect connec...

Page 51: ...ness connector P4 from controller Reconnect connector P1 to controller Set STOW DEPLOY switch to DEPLOY Does circuit breaker trip Yes No Defective controller Reconnect connector P3 to controller Set S...

Page 52: ...ES SERVICE MANUAL No Reconnect connector P4 to controller Set STOW DEPLOY switch to DEPLOY Does circuit breaker trip Yes No Short in hydraulic pump or in wiring to pump Examine controller harnesses fo...

Page 53: ...at pin P1 3 Is there continuity to ground at P1 3 No Yes Reconnect P1 to controller disconnect deploy sensor connector P3 from controller Check controller for continuity to ground at controller pin J3...

Page 54: ...with a 0 2000 PS I gauge and necessary adapters to connect to hydraulic pump port A Disconnect hydraulic line from port A of hydraulic pump Connect pressure gauge to pump port A Set STOW DEPLOY switc...

Page 55: ...ator Connect line to pressure gauge Set STOW DEPLOY switch to DEPLOY Does pressure gauge read 1400 PSI No N To page 4 21 Deploy flow control valve is closed or has internal obstruction or damage possi...

Page 56: ...IES SERVICE MANUAL N From page 4 20 Have ramp operations improved Yes No Verify correct fluid level in hydraulic pump reservoir Finish bleeding ramp system Verify that pressure remains at 1350 PSI Sea...

Page 57: ...4 22 TROUBLSHOOTING APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL This page intentionally left blank...

Page 58: ...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 sho...

Page 59: ...5 2 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0001100 FIGURE 5 1 FR2SS DECAL LOCATIONS...

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Page 61: ...5 4 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0001201 9 1 0 13 14 17 19 20 18 2 2 1 5 6 7 11 21 5 25 3 2 1 24 23 4 8 16 1 2 28 FIGURE 5 2 FR2SS SERIES RAMP ASSEMBLY...

Page 62: ...923 6C FLOOR PLATE 30 X49 REF FR2SS05 24867 6D FLOOR PLATE 30 X52 1 FR2SS16 11000000 35837 6E FLOOR PLATE 32 X32 1 FR2SS08 30402 6F FLOOR PLATE 32 X39 1 FR2SS09 31415 6G FLOOR PLATE 32 X41 1 FR2SS04 2...

Page 63: ...42048 9M KIT RAMP HINGE ASSY W HARDWARE 32 X32 1 FR2SS08 42056 9M KIT RAMP HINGE ASSY W HARDWARE 32 X32 1 FR2SS08 42060 9N KIT RAMP HINGE ASSY W HARDWARE 32 X39 1 FR2SS09 42049 10 SAFETREAD 2 X60FT RO...

Page 64: ...NG FLANGE LH or RH BAG OF 10 4 18691 17 KIT BUSHING REBUILD LH or RH 4 EA ITEM 14 4 1 19975 EA ITEM 15 W 3 8 16 BOLT 18 SPANNER WRENCH 1 18756 19 RECEPTACLE 1 4 TURN CLIP ON SST BAG OF 10 1 29250 20 S...

Page 65: ...ET ASSY 1 FR2SS01 23933 28A TRIM POCKET ASSY 1 FR2SS09 31451 28B TRIM POCKET ASSY 1 FR2SS18 45587 END OF TABLE NOTE REF in QTY column is for Referenced Parts Only and are not sold as spare parts New f...

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Page 67: ...5 10 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0007802 6 2 1 4 5 3 7 8 9 10 11 12 13 14 16 15 17 18 19 20 FIGURE 5 2 1 FR2G SERIES RAMP ASSEMBLY...

Page 68: ...X 065 SST BAG OF 10 1 13398 11 PLUG LOCKING HOLE 38 DIA BLK PLASTIC BAG OF 10 1 35440 12 KIT ARM ASSY RAMP LH W HRDWR 1 FR2G01 42063 12 KIT ARM ASSY RAMP LH W HRDWR 1 FR2G02 42063 13 KIT ARM ASSY RAMP...

Page 69: ...FR2G01 002701 32049 18D FLOORING RCA RIBBED 992 COLOR CODE REF FR2G02 RWX992AW0 32049 18D FLOORING RCA RIBBED 992 COLOR CODE REF FR2G04 RW0992BY0 32049 18E FLOORING ALTRO CYBER SCREAMING YELLOW NOSING...

Page 70: ...18U FLOORING ALTRO CHROMA 019 EP 1 FR2G04 CC2719BY0 35856 18U FLOORING ALTRO CHROMA 019 EP 1 FR2G04 CC2730BY0 35856 18V FLOORING ALTRO META 892 EP 1 FR2G01 000U00 36612 18V FLOORING ALTRO META 892 EP...

Page 71: ...G02 RWX604CW0 42488 18AK FLOORING RCA RIBBED TR604 BLK WHT NOSE REF FR2G04 RY0604AY0 42488 18AL FLOORING ALTRO META 2775 EP REF FR2G04 MC2775BY0 44463 18AM FLOORING ALTRO CHROMA 2761 EP REF FR2G04 CC2...

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Page 73: ...5 16 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0007900 1 2 3 4 6 8 10 11 5 7 14 16 17 17 13 12 15 9 FIGURE 5 2 2 FR2N01 SERIES RAMP ASSEMBLY...

Page 74: ...N01 ALL 42084 13 SAFETREAD 2 X60FT ROLL YELLOW SAFETY 1 17250 14 SCUFF PLATE 1 35048 15 BAR SUPPORT SCUFF PLATE 1 32537 16 KIT LIFTING STRAP 1 18625 17 FLOORING RCA RIBBED 452 1 FR2N01 10101010 35056...

Page 75: ...5 18 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0001300 1 2 3 4 6 4 5 FIGURE 5 3 HYDRAULIC COMPONENTS AND FITTINGS...

Page 76: ...01010 35051 02 2B PUMP ASSY 12V 1 FR2SS01 00000000 32881 2B PUMP ASSY 12V 1 FR2SS02 00000000 32881 2B PUMP ASSY 12V 1 FR2SS02 01000000 32881 2B PUMP ASSY 12V 1 FR2SS11 01000000 32881 2B PUMP ASSY 12V...

Page 77: ...32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0011000 B A A B B LK 18 A W G R E D 4 AW G W H T 18 A W G R E D 18 A W G R E D 10 A W G 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FIGURE 5 4 ELECTRICAL...

Page 78: ...6 10000200 18226 3B HARNESS ASSY J4 39 24V 1 FR2SS17 10000000 18226 3B HARNESS ASSY J4 39 24V 1 FR2N01 ALL 18226 4 HARNESS ASSY J1 PANEL MOUNT 1 22979 4A HARNESS ASSY J1 1 FR2SS07 10000001 28867 4A HA...

Page 79: ...G RED 11 1 FR2SS08 10000201 28869 9A JUMPER CABLE 4 AWG RED 11 1 FR2SS08 10000501 28869 9A JUMPER CABLE 4 AWG RED 11 1 FR2N01 ALL 28869 9B JUMPER CABLE 4 AWG RED 10 1 FR2G01 ALL 27493 9B JUMPER CABLE...

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Page 81: ...5 24 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL RSM0000X00 1 2 3 4 5 FIGURE 5 5 ROTARY ACTUATOR ASSEMBLY...

Page 82: ...FIGURE 5 5 ROTARY ACTUATOR ASSEMBLY FIG ITEM DESCRIPTION QTY CONFIG PART NO 1 PILLOW BLOCK W GREASE FITTING 2 98160 2 DRIVESHAFT RAMP 2 18741 3 KIT COUPLER SHAFT W HARDWARE 2 18614 4 ACTUATOR HYDRAUL...

Page 83: ...towed height above floor FR2SS00 4 3 10 9 35 1 89 1 47 2 119 9 30 0 76 2 48 0 122 0 1 2 5 FR2SS01 4 3 10 9 37 1 94 2 47 2 119 9 32 0 81 2 48 0 122 0 1 2 5 FR2SS02 4 3 10 9 37 1 94 2 43 2 109 7 32 0 81...

Page 84: ...2 119 9 30 0 76 2 48 0 122 0 1 2 5 FR2SS15 4 3 10 9 35 1 89 1 44 2 112 2 30 0 76 2 45 0 114 3 1 2 5 FR2SS16 4 3 10 9 37 1 94 2 43 2 109 7 32 0 81 2 44 0 111 7 1 2 5 FR2SS17 4 3 10 9 37 1 94 2 42 2 10...

Page 85: ...5 28 SPARE PARTS APRIL 2021 32DFR108 C FR2SS SERIES SERVICE MANUAL NOTES...