Power Parking Brake Service Manual
Contents
1. 32DPPB02 A 2 5 2 6 INSTALLATION VERIFICATION Clear the vehicle floor of all loose material high plush carpet strands etc which may interfere with the operation of the power parking brake Make sure that all fasteners are tightened properly Run the Power Parking Brake through several cycles CUSTOMER ORIENTATION IMPORTANT Customer Orientation Ricon Sales Service Personnel must review the Warranty and Operator Manual with the customer to be certain he she understands the safe operation of the product In struct the customer to always follow the operating instructions without exception 32DPPB02 A Ill MAINTENANCE AND TROUBLESHOOTING maintenance will reduce the need for repairs Since Ricon products are highly specialized it is important that maintenance and repairs be performed by an authorized Ricon service technician using Ricon replacement parts We recommend maintenance inspections at least every six months A MAINTENANCE SCHEDULE R outine maintenance of the RICON R1250 Power Parking Brake will provide optimum performance Regular SIX MONTHS OF OPERATION Check for loose nuts and bolts Tighten as needed B TROUBLESHOOTING GUIDE The troubleshooting guide is designed to provide a logical starting point to locate general problems that could occur with the power parking brake However not all possible problems or combinations of problems are listed The guide does not incorporate routine safety p2. 75 RICON
3. CT CAN BE DANGEROUS The product has been installed or maintained by someone other than an authorized Ricon service techni cian The product has been modified or altered in any respect from its original design without written authoriza tion by Ricon Ricon disclaims liability for any personal injury or property damage that results from operation of a Ricon product that has been modified from the original Ricon design No person or company is au thorized to change the design of this Ricon product without written authorization by Ricon Ricon s obligation under this warranty is exclusively limited to the repair or exchange of parts that fail within the applicable warranty period Ricon assumes no responsibility for expenses or damages including incidental or consequential damages Some states do not allow the exclusion or limitation of incidental or consequential dam ages so the above limitation or exclusion may not apply Important The warranty registration card must be completed and returned to Ricon within 20 days after installation of this Ricon product for the warranty to be valid The warranty is not transferable The warranty gives specific legal rights and there may be other rights that vary from state to state 1 2 32DPPB02 A SHIPMENT INFORMATION Ricon does not sell directly to the user because of the specialized nature of the product Instead the prod uct is distributed through the worl
4. RICON l INNOVATION IN MOBILITY R1250 Power Parking Brake PRINT Service Manual 03 25 02 32DPPB02 A 92 2002 RICON Corporation All Rights Reserv Printed in the United States of America This Ricon service manual is for use by qualified service technicians and is not intended for use by non professionals do it yourselfers The manual provides es sential instructions and reference information which sup ports qualified technicians in the correct installation and maintenance of Ricon products Qualified service technicians have the training and knowl edge to perform maintenance work properly and safely For the location of a Ricon authorized service technician in your area call Ricon Product Support at 1 800 322 2884 Customer Name Installing Dealer Date Installed AA Serial 32DPPB02 A Revision Record DATE DESCRIPTION OF CHANGE Misi an 03 25 02 Release 4901 TABLE OF CONTENTS Chapter Page 1 ANTBODUETMOM 1 1 A RICON ONE YEAR LIMITED WARRANTY ccccsccccssscecseceeseeceeeecsaeesesseceeeecsseesesaeeseaeeceeeessaeesesaeeseneeses 1 1 B SHIPMENT 1 3 C GENERAL SAFETY PREGAUTIONS oc nein mann alsan 1 3 Dy PRODUCT SE MY anna a a 1 4 11 INSTAELATION 22 2222022 Heisse 2 1 REQUIRED TOULS editt iani ern r
5. dwide network of authorized Ricon dealers who perform sales and installation NOTE When the product is received unpack the product and check for freight damage Claims for any damage should be made to the carrier immediately Be sure the installation kit contains all items listed on the kit packing list Please report any missing items immediately to Ricon Product Support The warranty and owner registration cards must be completed and returned to Ricon within 20 days for the warranty to be valid The Sales Service Personnel must review the Warranty and this Service Manual with the user to be certain that they understand the safe operation of the product Instruct the user to follow the operat ing instructions without exception GENERAL SAFETY PRECAUTIONS The following general safety precautions must be followed during installation operation service and main tenance Under no circumstances can installation maintenance repair or adjustments be attempted without the presence of a person capable of rendering aid An injury no matter how slight must be attended to Always administer first aid or seek medical at tention immediately Protective eyeshields and appropriate clothing must be worn at all times To avoid injury exercise caution when operating and be certain that hands feet legs and clothing are clear of brake operator Batteries contain acid that can burn If acid comes in contact with skin flush affected a
6. ede den aio ui te dece de e bx aman 2 1 B PREPARATION OF POWER PARKING 2 1 VEHICLE PREPARA TION E HR 2 1 D MECHANICAL INSTALLA TON uoces terae en ice de sled kocht endet ia rane peas 2 2 E ELEGIHIGAL INSTALLEER OM een a ett eter kn 2 4 INSTALLATION VERIFICATION ea a a dd 2 5 G CUSTOMER ORIENTA MON Ec een 2 5 MAINTENANCE AND TROUBLESHOOTING nnee nneneennnnnnenenensennennnnnnneeneenennn 3 1 MAINTENANCE SCHEDULE usa ee eh ehe 3 1 B TROUBLESHOOTING GUIDE nirsistu ernannten 3 1 IV PARTS DIAGRAMS AND LISTS une 4 1 32DPPB02 A iii This page intentionally left blank 32DPPB02 A I INTRODUCTION mounted switch the factory parking brake pedal is electrically actuated The Power Parking Brake does not need to interface with any other equipment and can be used with a variety of products This manual provides information necessary for authorized Ricon service technicians to install repair and maintain the Power Parking Brake Please follow these instructions exactly and call Ricon Product support if you have any problems or require assistance RICON R1250 Power Parking Brake adds hand control to foot operated parking brakes Using the dash mL IS SS The installation is a two phase process 1 Power Parking Brake installation 2 Instructing the customer in the proper a
7. epair or replace at its option any parts that fail by reason of defective material or workmanship as follows Repair or replace parts for a period of one year from date of purchase A complete list of parts covered by this warranty can be obtained from an authorized Ricon dealer If You Need to Return a Product Return this Ricon product to the installing dealer Please give as much advance notice as possible and allow a reasonable amount of time for repairs If You are Traveling All authorized Ricon dealers honor this warranty Consult telephone directory or call our Product Support department for the name of the nearest authorized Ricon dealer This Warranty does not Cover C Labor or service charges these may be covered separately by the installing dealer Malfunction or damage to product parts caused by accident misuse lack of proper maintenance neglect improper adjustment modification alteration the mechanical condition of vehicle road hazards over loading failure to follow operating instructions or acts of Nature i e weather lightning flood Note Ricon recommends that this product be inspected by an authorized Ricon service technician at least once every six months or sooner if necessary Any required maintenance should be performed at that time This Warranty is Void if N WARNING THIS PRODUCT HAS BEEN DESIGNED AND MANUFACTURED TO EXACT SPECIFICATIONS MODIFICATION OF THIS PRODUCT IN ANY RESPE
8. f the excess YELLOW wire and attach the terminal to the 1 terminal on the limit switch 8 Route the YELLOW wire from the limit switch to the motor Cut the wire to leave about 2 slack and crimp a blue slip on terminal to the wire Connect the terminal to the motor terminal 9 Route the GREEN wire from the toggle switch to the motor Cut the wire to leave about 2 slack and crimp a blue slip on terminal to the wire Connect the terminal to the unused motor terminal 10 Route the RED wire from the toggle switch through an existing hole in the firewall and into the engine compartment If possible route the wire through an existing grommet If not possible drill a 3 8 di ameter hole and use the snap in grommet provided 11 At engine compartment mount the supplied circuit breaker within 10 12 inches 25 30 cm of bat tery 12 Run the RED wire to the circuit breaker Cut the wire to leave about 2 slack and crimp a blue ring terminal Save the excess wire Connect the ring terminal to the circuit breaker AUX terminal 13 Crimp a blue ring terminal to the excess red wire Connect the ring terminal to the BAT terminal on the circuit breaker 14 Route the RED wire to the positive terminal of the vehicle battery Cut the wire to leave about 2 slack and crimp a large blue ring terminal to it Connect the ring terminal to the positive terminal of the battery 15 Use the cable ties provided to secure all installed wires
9. ll vehicle carpet floor mats molding wall panels or other materials that were removed for the installation 32DPPB02 A ELECTRICAL INSTALLATION TOGGLE SWITCH BOTTOM VIEW y LIMIT SWITCH QA I x V 2 1 7 AN 6 N BLACK fa ft amp gt p SLIP ON TERMINAL YELLOW YELLOW 10 BLUE 516 RING RING CONNECTOR CONNECTOR 4 CIRCUIT BREAKER FIGURE 2 7 ELECTRICAL WIRING DIAGRAM 1 Crimp blue slip on terminals to one end of the RED BLACK YELLOW and GREEN wires 2 Attach the slip on terminals to the rear of the toggle switch as shown 3 Permanently mount the toggle switch its mounting hole 4 Attach the other end of the BLACK wire to a good chassis ground 5 Route the YELLOW wire from the toggle switch to the limit switch Cut the wire to leave about 2 slack save the excess wire and crimp a blue ring terminal to the end Connect the terminal to the 2 terminal on the limit switch 6 Cut a small section of the YELLOW excess wire and crimp slip terminals to each end Attach the terminals to the limit switch 1 and 2 terminals as shown 7 Crimp a blue ring terminal to one end o
10. nd safe use of the product This manual contains installation service and maintenance instructions for the Power Parking Brake The installation instructions must be followed exactly no steps should be eliminated nor should the product be modified It is important to user safety that the installation is thorough and correct It is equally important that the operator be completely familiar with the Operating Instructions chapter of the operator manual Once the Power Parking Brake is installed it is very impor tant that it be properly maintained by following the Ricon recommended cleaning lubrication and inspection instructions If there are questions about this manual or additional copies are needed please contact Ricon Product Support at one of the following locations Ricon Corporation 7900 Nelson Road Panorama City CA 91402 818 267 3000 Quitside 818 Area etae a Eo Tante hos aamen tean eiai apaia 800 322 2884 World Wide Website www riconcorp com Ricon U K Ltd Littlemoss Business Park Littlemoss Road Droylsden Manchester United Kingdom M43 7EF 22 22 44 161 301 6000 RICON ONE YEAR LIMITED WARRANTY refer to following page 32DPPB02 A 1 1 RICON CORPORATION ONE YEAR LIMITED WARRANTY Ricon Corporation Ricon warrants to the original purchaser of this product that Ricon will r
11. ppropriate drawing and note the reference number The parts list that accompanies each drawing will list the stock number of the desired part PRODUCT NUMBER R1250 DOCUMENTATION KIT NUMBER 01047 DECAL SET NUMBER 26009 PARTS 2 2 2 PAGE FIGURE RISSOPOWERBRBDBME irte tob Renner 4 2 32DPPB02 A 4 1 POWER BRAKE 4 2 FIGURE 4 1 R1250 POWER BRAKE 32DPPB02 A POWER BRAKE MODEL R1250 SERIAL NO S 1001 PRESENT REF DESCRIPTION SETSCREW RECESS 1 4 28 1 4 28201 SPINDLE W HOLES PB 1031 BUSHING BRONZE 25315 MTG BKT WELD ASSY PB 1010 WASHER 1 4 SPLIT LOCK 28274 BOLT HEX 1 4 20 X 3 4 GR5 28166 NUT HEX 6 32 NYLON INSERT 28324 BKT LIMIT SWITCH WELD ASSY PB 1020 SWITCH LIMIT ROLLER LEVER 26452 MS 6 32 X 1 PHIL PAN 28046 SWITCH TOGGLE SPDT EXTRA LONG BAT SERIAL 5 1001 TO 2370 SERIAL NO S 2371 TO PRESENT STAR WASHER TOGGLE SWITCH U 109 NUT U 550 TOGGLE SWITCH WIRE ROPE MOTOR LEFT HAND DELCO SERIAL NO S 1001 TO 2370 SERIAL NO S 2371 TO PRESENT DECAL PATENT PENDING GENERIC DIODE ASSY CIRCUIT BREAKER 20A ND NW Wa ND 26430 26433 28346 28347 PB 1035 25408 V2 ES 040 32 10 171 R27 1003 26400 a i ao oo ak ek Item not shown 32DPPB02 A 4 4 This page intentionally left blank 32DPPB02 A
12. rea with water and wash with soap immediately Work in a properly ventilated area Do not smoke or use an open flame near a battery Do not lay anything metallic on top of battery Check under vehicle to avoid drilling into frame subframe members wiring hydraulic lines fuel lines fuel tank etc Read and thoroughly understand the operating instructions before attempting to operate Inspect the product before each use If an unsafe condition unusual noises or movements exist do not use operator until the problem is corrected Keep others clear during operation The product requires periodic maintenance A thorough inspection is recommended at least once every six months The product should be maintained at the highest level of performance 32DPPB02 A 1 3 D PRODUCT TERMINOLOGY The references used throughout this manual are illustrated in Figure 1 1 and defined in Table 1 1 Refer to Chapter IV for more details FIGURE 1 1 R1250 POWER PARKING BRAKE mk SCRIPTION 1 Hex screw 6 emma e 2 elemen SSC END OF TABLE 32DPPB02 A ll INSTALLATION Brake must be installed by an authorized Ricon service technician Make sure that these instructions are read and understood before proceeding Be certain that the installation instructions are followed exactly and do not eliminate any steps or modify the product Perform the procedures carefully and in the order that they are presented If any questions ari
13. recautions or preliminary procedures and as sumes that the vehicle battery is fully charged and the battery terminals connectors are clean and tight WARNING THE TROUBLESHOOTING GUIDE DOES NOT INCORPORATE ROUTINE SAFETY PRECAUTIONS OR PRELIMINARY PROCEDURES ONLY AUTHORIZED RICON DEALERS SHOULD PERFORM TROUBLESHOOTING TABLE 3 1 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE REMEDY REF SEC Partial operation Obstruction under Remove obstruction and check for NA p Power Parking Brake any damage Circuit breaker Reset circuit breaker Operator Manual tripped 2 Make sure limit switch releases nor Limit switch stuck mally If problem continues contact closed an authorized Ricon dealer for re No operation pair replacement Loose wire terminal Verify wire terminals are properly connection connected Control switch bad Contact an authorized Ricon dealer Motor assembly bad for replacement NA No BET section END BET TABLE 32DPPB02 A 3 1 3 2 This page intentionally left blank 32DPPB02 A IV PARTS DIAGRAMS AND LISTS his chapter contains parts diagrams and lists for the RICON R1250 Power Parking Brake parts diagrams are exploded views of the components referenced by numbers The accompanying parts list contains the part reference number description quantity used and the Ricon stock number For parts identification locate the part on the a
14. se that are not covered in this chapter contact Ricon Product Support for assistance REQUIRED TOOLS C clamp or locking pliers 3 64 1 4 5 32 amp 1 2 drill bits Electric drill Round file Hammer with plastic tip Screwdrivers Phillips and flat Side cutter pliers Socket set his chapter provides instructions for installing the RICON R1250 Power Parking Brake The Power Parking Wire crimping tool Wrenches open end B PREPARATION OF POWER PARKING BRAKE Remove Power Parking Brake and all accessories from packaging Notify Ricon immediately if any part listed in the packing list is missing Notify shipper if any part has been damaged in shipment C VEHICLE PREPARATION a Safely park vehicle on a flat level surface and turn off engine a Be certain the transmission is set to PARK and the wheels are blocked a The Power Parking Brake must be mounted directly to the metal floor of the vehicle Clear vehicle floor area of all loose material Remove carpet floor mats molding wall panels or any other material that may interfere with the installation 32DPPB02 A 2 1 D MECHANICAL INSTALLATION To install the Power Parking Brake follow this procedure 1 2 MOTOR ASSEMBLY N FIGURE 2 1 Refer to Figure 2 3 If necessary drill a 1 4 hole in the parking brake lever just behind the pedal This hole will be used to attach the wire cable Refer to Figures 2 1 thru 2 3 Position the Power Parking Brake as
15. sembly under the parking brake lever as close as possible to the vehicle firewall and side panel If possible mount with the motor against the vehicle side panel Be certain to align the Power Parking Brake spindle under the hole drilled in the parking brake lever A LIMIT SWITCH WITH ROLLER WIRE ROPE 1 LIMIT SWITCH WITH ROLLER MOTOR ASSEMBLY WIRE ROPE FIGURE 2 2 FRONT VIEW RIGHT SIDE POWER PARKING BRAKE FRONT VIEW OF LEFT SIDE POWER PARKING BRAKE LIMIT SWITCH BRACKET LIMIT SWITCH MACHINE SCREW BRAKE LEVER WIRE HOLE OVAL SLEEVE MOTOR WIRE ROPE ML y Q 247 ASSEMBLY FIGURE 2 3 SIDE VIEW OF RIG HT INSTALLED POWER PARKING BRAKE Mark the three mounting holes and remove the Power Parking Brake N CAUTION Check vehicle before drilling Do not drill into factory wiring hydraulic lines fuel lines fuel tank etc 4 2 2 At the marked mounting hole locations drill three 3 64 holes through the vehicle floor 32DPPB02 A 5 Refer to Figure 2 4 Fasten the Power Parking Brake Use the three hex bolts washers and hex nuts supplied Be certain the bol
16. ts do not extend past the nuts into the wheel well Remove the ends MOTOR ASSEMBLY HEX BOLT 2 WASHER NUT FIGURE 2 4 VEHICLE FLOOR MOUNTING of the bolts if necessary 6 Refer to Figure 2 5 Using the two machine screws and hex nuts provided attach the limit switch with roller to limit switch bracket 7 The limit switch bracket is mounted on the underside of the vehicle dash control holes panel Posi tion the bracket so the limit switch is activated when the parking brake is released or not set 8 Drill two 164 5 32 holes and use two of the 8 sheet metal screws to attach the switch bracket 9 Refer to Figure 2 6 Be certain the parking brake lever is in the released position and place the Power Parking Brake clamp on the parking brake handle Secure the clamp to the parking brake handle and tighten SURE 2 6 PARKING BRAKESNAMP ATTACHMENMACHINE SCREW M 6 lt a 4 NYLON INSERT HEX NUT 9 2 3 ET 2 4 Place the oval sleeve around one end of the wire cable Thread the wire cable through the hole in the parking brake Tighten the oval sleeve Loosen the set screw on the spindle and feed the other end of the wire cable through the spindle Cut off excess wire and tighten the setscrew Position the toggle switch in a location that is safe and convenient for the user Drill a 1 2 hole Do not install the toggle switch at this time Reinsta
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