CONTINENTAL RAILWORKS 60 Series Instruction manual

ALIGNMENT TOOL MANUAL
FOR USE WITH
60, 35 ,20 AND 12 SERIES RAILGEAR
NOVEMBER 2020
Revision 1
CONTINENTAL RAILWORKS
7380 Vérité, St-Laurent, QC, Canada, H4S 1C5
Phone : [phone] Fax : [phone]

INTRODUCTION
General Description
INTRODUCTION
The following manual has been prepared to be used with the Continental Railworks Alignment tool
All Continental Railworks hi-rail kits are designed to make operation and service as simple as possible. There is
no adjustment required when varying loads are placed on a vehicle. The use of independent mounting plates
provides for easy complete unit removal and re-installation when required, as well as a complete range of
adjustment to tailor the hi-rail unit to the vehicle.
At any time technical assistance can be obtained from the hi-rail manufacturer. A simple phone call to
Continental Railworks can eliminate many time consuming problems or questions. Technical assistance is
available Monday to Friday, from 8:30 a.m. to 4:30 p.m. ET, by calling [phone], faxing [phone]
or emailing [e-mail]. Support personnel are frequently available during off-peak hours
as well, so please do not hesitate to call or fax outside the hours listed above, including nights and weekends.
It is also possible to leave a message at any time, and your call will be returned as soon as possible.
GENERAL DESCRIPTION
The Continental Railworks Alignment tool was designed to simplify the alignment process for all models of
continental rail gear. Continental recommends that all models of our rail gear be check with the string line
method. While the standard string line method has been used for many years, we have designed a way to
speed up this process. The Continental alignment tools will decrease the amount of time required to setup the
string line.
SPECIAL CONSIDERATIONS
VEHICLE CONDITION
Prior to installing hi-rail, it should be determined that the vehicle is in good working order. More specifically, the
vehicle’s suspension and frame need to be inspected and in good condition.
VEHICLE REAR SUSPENSION
If the vehicle is equipped with rear air bag suspension, a Pneumatic Suspension Kit will be required to bypass
the chassis’ OEM leveling valve. This will ensure that the vehicle provides consistent and reliable traction while
on rail. Vehicles equipped with leaf springs or rubber suspension only require proper height and pre-load
adjustment.
TIRE PRESSURE
Make sure to check the air pressure in the rear tires and make sure they are properly adjusted.
VEHICLE LOCATION
When performing the string line on trucks with dual rear wheels the process can be sped up if the chassis is
placed on blocks that will allow the rail gear to be lifted off the ground. This allows the rail gear to move without
weight on it. You can also use a jack, outriggers or on over head crane to take the weight off the rail gear.
! SAFETY WARNING!
DO NOT WELD ON THE VEHICLE FRAME. - TAKE PROPER INSULATION MEASURES IF WELDING ON THE VEHICLE
IS REQUIRED, INCLUDING DISCONNECTING BOTH BATTERY CABLES.
REFER TO BOLT TORQUE TABLE IN APPENDIX 1, AND TO MANUFACTURER’S SPECIFICATIONS FOR WHEEL
STUDS
NEVER REUSE NYLOC LOCKING NUTS OR STOVER LOCKING NUTS

INTRODUCTION
Alignment TOOL
ALIGNMENT TOOL
Continental Railworks provides an alignment tool to speed up the alignment process. Four alignment tools are
need for this way of string lining the Hi-rail. One should be bolt onto each wheel with welded on square tubing
facing towards the outside of the truck. Its important prior to installation that the hub caps and gasket be
removed.
Figure 1: Alignment Tool

INTRODUCTION
Alignment TOOL
INSTALLATION –ALIGNMENT TOOL
1- Make sure the chassis is parked on a level surface.
2- Remove the hub cap and hub cap gasket.
3- Position the alignment tool where the welded square tubes are facing towards the outside of the truck
and align slots in the mounting tool to the hup cab bolts on the rail wheel.
Figure #2: Slots for Wheels
4- Use the hub bolts to secure the alignment tool to the wheel
5- Position the horizontal bar so its is level with the ground.
6- Repeat the steps above on all four (4) wheels.
NOTE - Chassis equipped with tapered leaf springs. The shims should be positioned on the flat sections of the
leaf and not hanging over the edge.
14” Wheel Slots
16” Wheel Slots
12” Wheel Slots
8” &10” Wheel Slots

INTRODUCTION
Alignment Procedure
ALIGNMENT PROCEDURE
BOLT ON ALIGNMENT METHOD
SPINDLE ALIGNMENT
1. Looking down on the string check to see if the hole that is drilled into the alignment
tool is centered on the string.
Figure 3: Wheel properly aligned
2. If the string is not centered, loosen the bolts that hold the spindle to the axle.
3. Using the alignment tool, adjust the wheel until the string is centered in the hole.
4. Check the remaining rail wheels and use the steps above to adjust where needed.

INTRODUCTION
Alignment Procedure
SIDE TO SIDE ADJUSTMENT
1. Start at the rear of the truck. Measure from the string to the bead seat on the chassis
rear rims on passenger and drivers’ side.
2. Adjust the rear rail gear until the strings are equal on both the passenger side and
drivers’ side.
3. Go to the front of the chassis.
4. Using a 4-foot level measure from the edge of the alignment tool to the frame of the
chassis on both the drivers and passengers’ side. Note make sure the frame is
straight where the measurement is taken from.
5. Adjust the rail gear so the measurement is equal to the frame on both the passenger
and drivers’ side.
6. Recheck the rear to make sure the measurements are the same. If they have moved
redo the steps above.
7. Recheck each wheel to make sure the hole in the alignment tool is still centered on
the string. If they have moved, repeat the steps in the spindle alignment.

INTRODUCTION
Track Test
TRACK TEST
When putting the vehicle on track, first lower the rear unit and then lower the front unit after
re-positioning the vehicle as required (see OPERATION section below for details).
Verify the following items:
1- Ensure the units raise and lower easily, and that hydraulic hoses are all of adequate
length and that hydraulic fittings have adequate clearance.
2- Ensure the hi-rail units deploy completely, forming a straight and linear connection
from the top of the unit all the way to the wheel.
3- Adjust the front and rear rail sweep brackets as necessary so that the rubber sweeps
just contact the rail with the hi-rail in the lowered position.
4- Verify that there is 2” to 3” of clearance between the front tires and the rail head.
5- Verify that there is an 8” to 10” contact patch on the rearmost tires with the rail, with
the vehicle empty. (This dimension will increase with a loaded vehicle).
6- Ensure the vehicle tracks properly down the track, and that there is no excessive
flanging of the hi-rail wheels.
7- Ensure there is no excessive vibration of the vehicle when on track.

INTRODUCTION
Finalizing Alignment / Adjustment
FINALIZING ALIGNMENT / ADJUSTMENT
As explained in the sections above, ensure that the following steps are performed to finalize the
alignment and adjustment:
-Weld spindle housing cross bolts – Weld the thick washer installed on the ½” spindle
housing cross bolt to the spindle housing, on both sides, to transform the gauge adjustment
slot into a hole to lock in the gauge adjustment.
-Weld spindle housings – Tack weld (about 1”) the spindle housing top plate to the axle plate,
to lock in the toe adjustment.
Figure 4: Welded spindle housing (toe and gauge adjustment)

INTRODUCTION
Finalizing Alignment / Adjustment

INTRODUCTION
Finalizing Alignment / Adjustment

INTRODUCTION
Alignment tools Installed
ALIGNMENT TOOLS INSTALLED

INTRODUCTION
Alignment Diagram
ALIGNMENT DIAGRAM