Wabtec R-290 User manual

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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RAFNA R-290 RAILGEAR
2011 to 2019 GM 2500/3500 Short/Long Bed
STANDARD/IN-CAB/FULL IN-CAB/MANUAL VALVES
INSTALLATION /OPERATIONS /SERVICE MANUAL

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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CONTENTS
SECTION DESCRIPTION Pg.
1.0 General Railgear Information........................................................................ 7
Safety Precautions............................................................................... 7
General Railgear Information ................................................................. 9
Placing the Vehicle on Rail – General Info:.............................................10
Driving the Vehicle on Rail – General Info:.............................................11
Removing the Vehicle from Rail – General Info: ......................................11
General Service Information .................................................................12
General Parts Information ....................................................................12
G&B Specialties, Inc.Limited Warranty ....................................................13
Warranty Policies and Procedures For Installers and Customers .....................14
Installers & Customer Warranty:.........................................................14
Additional Billing, Installers & Customers:.............................................14
Warranty Claim information and requirements:......................................14
Labor Warranty and /or additional labor charges: ...................................15
Faulty Railgear Installations:..............................................................15
Parts Warranty:..............................................................................15
Warranty Claim Form ..........................................................................16
Technical Service Bulletins...................................................................17
2.0 Wheel Kit & Tire Pressure Monitoring System ..................................................27
Installation Safety Precautions ..............................................................27
Installation of Aluminum Wheels, TPMS, Tire Stems, and Tires ......................28
Installation of Steel Wheels and Tires......................................................32
Installation of 2011-2016 Tire Pressure Monitoring system ...........................35
Tire Pressure Monitoring Sensor (TPMS)................................................35
Installation of Tire Pressure Monitoring Sensor (TPMS) .............................35
Tire Inflation .................................................................................36
Programming the TPMS.....................................................................36
Tire Rotation .................................................................................36
Installation of 2017, 2018-19 Tire Pressure Monitoring System (Steel Rims)......40
Tire Pressure Monitoring Sensor (TPMS)................................................40
Installation of Tire Pressure Monitoring Sensor (TPMS) .............................40
Spare Tire.....................................................................................41
Tire Inflation .................................................................................41
Programming the TPMS.....................................................................41
Tire Rotation .................................................................................41
Operation Safety Precautions................................................................48
Operation of Wheel Kit........................................................................49
Service of Wheel Kit ...........................................................................49
Warning/Caution.............................................................................49
3.0 Front & Rear Mounting kit ..........................................................................51
Installation Safety Precautions ..............................................................51
Installation of Front Mounting Kit...........................................................52
Installation of Rear Mounting Kit ............................................................61
Operation Safety Precautions................................................................75
Operation of Front/Rear Mounting Kit......................................................76

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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Service of Front/Rear Mounting Kit.........................................................76
4.0 Front & Rear Railgear kit............................................................................77
Installation Safety Precautions ..............................................................77
Railgear Kits .....................................................................................78
Installation of Railgear Kit ....................................................................79
Installation of Front Railgear Lever Lock Kit..............................................83
Operation of Front Railgear Lever Lock Kit...............................................84
Lever Lock Adjustment ....................................................................84
Removing the Vehicle from Rail – To Raise the Railgear: ...........................85
Parts of Front Railgear Lever Lock Kit .....................................................86
Installation of Rear Railgear Rod Lock Kit .................................................90
Operation of Rear Railgear Rod Lock Kit...................................................91
Placing the Vehicle on Rail – To Lower the Railgear: ................................91
Parts of Rear Railgear Rod Kit................................................................92
Operation Safety Precautions................................................................96
Operation of Railgear Kit (Standard/In-Cab Controls)...................................97
Placing the Vehicle on Rail – To Lower the Railgear: ................................97
Removing the Vehicle from Rail – To Raise the Railgear: ...........................97
Operation of Railgear Kit (Full In-Cab Controls)..........................................98
Service of Railgear Kit .........................................................................99
Railgear Over-Center Adjustment.........................................................101
Rail Wheel Bearing Adjustment............................................................102
Rail Sweep Adjustment......................................................................102
Rail Wheel Load Adjustment ...............................................................103
Check each rail wheel load as follows: ...............................................103
Adjust each rail wheel load as follows:...............................................104
Railgear Alignment ...........................................................................106
Wheel Wear Standards and Recommendations.........................................107
Nominal Rail Wheel Diameter (inches)...................................................107
Min. Allowable Wheel Diameter (inches) ................................................107
R-290 Railgear – Pre-Delivery Check List ................................................108
Parts of Railgear Kit..........................................................................112
5.0 Hydraulic Kit (STD, ICC, & Manual Valve Controls)...........................................129
Installation Safety Precaution..............................................................129
Installation of Hydraulic Manifold Steel Box w/ Insulator ............................131
Pump/Manifold Install/Modification Instructions .......................................139
Installation of Hydraulic Kit ................................................................149
Installation of Hydraulic Kit (STD) .....................................................149
Installation of Hydraulic Kit (ICC Controls)..............................................155
Installation of Hydraulic Kit (FICC Controls) ............................................164
Installation of Hydraulic Kit with Manual Valves .......................................171
Operation Safety Precautions..............................................................181
Operation of Hydraulic Kit..................................................................182
Operation of Standard Railgear Hydraulic System Controls: .....................182
Operation of the Emergency Hand Pump:............................................182
Operation of The Emergency Hand Pump (Locking Manual Valve only): ......183
Service of Hydraulic Kit .....................................................................184
Hydraulic System Relief Valve Setting ................................................184

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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Electrical System Troubleshooting.....................................................185
6.0 Steering Wheel Lock Kit...........................................................................193
Installation Safety Precautions ............................................................193
Installation of Steering Wheel Lock.......................................................194
Operation Safety Precautions..............................................................197
Operating of Steering Wheel Lock ........................................................198
Placing the Vehicle on The Track:.....................................................198
Traveling on Rail:..........................................................................198
Removing the Vehicle from The Track:...............................................198
Service of Steering Wheel Lock............................................................198
7.0 Railgear Kits/Parts Lists ...........................................................................199

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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RAFNA "CUSHION-RIDE" RAILGEAR
OPERATION, SERVICE AND
PARTS MANUALS
&
INSTALLATION MANUALS
READ THESE MANUALS BEFORE
INSTALLING THE RAILGEAR EQUIPMENT
AND/OR BEFORE OPERATING THE
RAILGEAR EQUIPPED VEHICLE
THIS SET OF MANUALS IS FOR RAILGEAR
SERIAL NUMBERS:
____________________ &____________________

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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1.0 GENERAL RAILGEAR INFORMATION
SAFETY PRECAUTIONS
If any problems are encountered, please call G&B Specialties, Inc. for technical
assistance.
 Failure to heed to any of the following warnings could result in severe bodily
injury and/or equipment damage.
 Read and understand all manuals completely before attempting operation of
the railgear equipped vehicle or service or installation of the railgear.
 Generic instructions provided below only address RAFNA railgear equipment.
Applicable railway company procedures and policies must be adhered to.
 Ensure that the position and function of all railgear controls are known before
attempting operation.
 Railway company rules governing rail travel must be observed at all times.
 Rail travel speed should always be in conformance with railway company
regulations and should be reduced during inclement weather, passing through
road crossings, switches, frogs, bridges, and curves. Curves of greater than 20
degrees should be negotiated with extreme caution. Operation of this vehicle
at unsafe speeds could result in derailment.
 Ensure the railgear is locked in road or rail position before starting road or rail
travel respectively.
 This vehicle will not operate crossing signals. At level crossings, ensure that no
other vehicles are approaching and flag the crossing to ensure safety. Use
caution when approaching and traversing level crossings.
 Never operate the vehicle if the Gross Vehicle Weight Rating (GVWR), Gross
Axle Weight Rating Front or Rear (GAWR), or the wheel or tire load ratings are
exceeded.
 Before performing any work under the vehicle or railgear, ensure the engine is
turned off and the parking brake is set.
 Ensure all body parts and loose clothing are clear of any moving parts of the
equipment.
 If misalignment of the railgear equipment is indicated, promptly perform the
alignment procedure. Note that excessively worn rail wheels, vehicle pulling to
one side while on rail, and vibration through the vehicle while on rail are
indicators of railgear misalignment.
!

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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 Following the first 100 km (62 miles) of combined road and rail travel, the
vehicle road wheel and spacer lug nuts should be re-torqued as per the Road
Wheels and Tires Kit Operation, Service, and Parts manual if applicable.
 On newly installed railgear, following the first eight (8) hours of rail travel,
inspect the rail wheel bearing end-play as per the Railgear Kit Operation,
Service, and Parts manual. During this time, the bearings will have seated and
may require adjustment of end-play. If the end-play is not in accordance with
specifications, bearing failure could occur and would not be covered under
warranty. Also check for sufficient grease in the wheel bearings.
 If the vehicle was derailed or involved in an accident, a thorough inspection of
the complete railgear package for damaged parts should be carried out before
the vehicle is put back in service.

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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GENERAL RAILGEAR INFORMATION
The RAFNA railgear is a hydraulically operated road-to-rail conversion system. The front and
rear railgear are mounted to the vehicle frame and hydraulically raise and lowered via a 12
VDC electric hydraulic pump or an alternative hydraulic pump (e.g. PTO driven pump). During
road travel, the front and rear railgear are mechanically locked in the road position. During
rail travel, the front and rear railgear are locked in rail position via hydraulic check valves or
mechanical locks, depending on model. A steering wheel lock keeps the vehicle front wheels
straight during rail travel. The railgear’s spring suspension system ensures constant rail wheel
to rail contact and a comfortable ride. Propulsion and braking on rail is provided by the
vehicle original systems through the vehicle’s wheels contact with the rail. Additional on rail
braking may be provided by an optional rail wheel brake package.
The RAFNA railgear is supplied with a group of Operation, Service, and Part Manuals and
Installation Manuals which are specific to the railgear, mounting, hydraulic, wheel, steering
wheel lock, and/or other or optional kits ordered. As a group, the manuals provide all the
information relative to the particular railgear package. The group of manuals may not be
interchangeable with other railgear equipped vehicles due to different options and/or
applications. If replacement manuals need to be ordered, the railgear serial number and/or
the kit numbers must be provided to G&B Specialties.
All the manuals should be read in their entirety before any installation or operation is
attempted. This will ensure that all the information is covered.
All manuals use the “Driver’s Seat” orientation convention. All directions, i.e. right, left,
front and back, are from sitting in the driver’s seat of the vehicle.
The railgear serial numbers, model numbers, and dates of manufacture for both the front and
rear railgear should be recorded below for future reference. This information is stamped on
the railgear identification plate riveted to each railgear.
Front Railgear Info Rear Railgear Info
Serial Number:
Model Number:
Date of Manufacture:

MIO-R290GM2011 Rev E
G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
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TECHNICAL SERVICE BULLETINS
Any changes and/or additional procedures that are issued for this equipment can be found in
the G&B Specialties Technical Service Bulletins. These technical service bulletins are
available on the RAFNA web site (www. RAFNA.com) as well as from G&B Specialties directly.
GENERAL INSTALLATION INFORMATION
The installation procedure consists of installing various supplied kits. Each kit is supplied with
an Installation Manual as well as an Operation, Service and Parts Manual. Consult the
respective kit manuals for installation instructions. The kits should be installed in the
following order, as applicable:
- Road Wheels & Tires Kit
- Steering Wheel Lock Kit
- Front & Rear Mounting Kits
- Front & Rear Railgear Kits
- Front Axle Lock-up Kit
- Hydraulics Kit
- Rail Wheel Brakes Kit
- Option Kits
Ensure the serial numbers on the railgear on the vehicle match the serial numbers on this set
of manuals and then ensure this entire set of manuals is given to the operator upon delivery
of the vehicle.
GENERAL OPERATION INFORMATION
The following are only general operation instructions. For detailed operation instructions,
consult the Operation, Service and Parts Manual provided with each individual kit.
Placing the Vehicle on Rail – General Info:
1. Prior to using the railgear equipment the following items should be inspected:
 Inspect the condition of steel or rubber tread rail wheels if applicable
 Check for damaged or worn parts
 Check for loose wheels and/or fasteners
 Check for leaking or damaged hydraulic hoses, fittings, cylinders, etc.
 Check for leaking or damaged air brake hoses, fittings, chambers, etc. if applicable
 Check for proper lubrication at the specified intervals
 Ensure the vehicle is in good operating condition as per the manufacturer’s operating
guide
2. At a level crossing, reverse the vehicle onto and parallel to the rails so that the rear
railgear rail wheels are aligned directly over the rails and the front railgear rail wheels
are somewhat aligned with the rails.
3. Deploy the rear railgear as per the Railgear Kit Operation, Service, and Parts manual.