Wabtec R-450 User manual

MIO-R45XRFR4836 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
-1-
INSTALLATION OF R-450 ROTATING REAR RAILGEAR KIT
Ford F-450/550 All Models
INSTALLATION SAFETY PRECAUTIONS
If any installation problems are encountered, please call G&B Specialties, Inc. for
technical assistance before continuing with the installation process.
 Failure to heed to any of the following warnings could result in severe bodily
injury and/or equipment damage.
 Read and understand this manual completely before attempting installation
and operation of the equipment.
 Installation and operation instructions provided below only address the G&B
Specialties railgear equipment. Applicable railway company procedures and
policies must be adhered to.
 Before performing any work under the vehicle or railgear, ensure that the en-
gine is turned off and the parking brake is set.
 Beware of all pinch points on the railgear and keep all parts of the body clear.
 Always disconnect the vehicle’s battery when welding on the vehicle or railgear
in order to protect the vehicle’s electrical system.
 Railway company rules governing rail travel must be observed at all times.
 Ensure that the position and function of all railgear controls are known before
attempting operation.
 Ensure the railgear is locked in road position before starting road travel.
 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.
 Before performing any work under the vehicle or railgear, ensure the engine is
turned off and the parking brake is set.
 Never operate the vehicle if the Gross Vehicle Weight Rating (GVWR), Gross Ax-
le Weight Rating Front or Rear (GAWR), or the wheel or tire load ratings are
exceeded.
!

MIO-R45XRFR4836 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
-2-
REAR RAILGEAR KIT
The following procedure details the installation of the rear railgear kit. The hardware re-
quired for the different kits are listed in the tables below.
Table 1: K-R45XRFR4836CBL (R-450 Rotating Rear Railgear with Cable Actuated Lock-up)
Part Number Description Qty
R-4836G Rotating Rear Railgear 1
R-4836GBRZ Rotating Rear Railgea
r
(Bronze Bushings)
R-4837E Axle Loc
k
-up Assembly 1
R-001 10" Wheel Assembly 2
R-4646R Rail Sweep Right Side 1
R-4646L Rail Sweep Left Side 1
R-4838 Push/Pull Cable 1
S-001031 Railgea
r
Operation Decal 1
R-990KIT-204
Rail Wheel Mounting
1/2" UNC Gr. 8 Bolt x 2.25" Long 8
1/2" Gr. 8 Washer 16
1/2" UNC Gr. 8 Nylon Insert Lock Nut 8
R-990KIT-021
Rail Gear Mounting
5/8" UNC Gr. 8 Bolt x 2" Long 6
5/8" Gr. 8 Washer 12
5/8" UNC Gr. 8 Nylon Insert Lock Nut 6
3/4" UNC Gr. 8 Bolt x 2.25" Long 4
3/4" Gr. 8 Washer 8
3/4" UNC Gr. 8 Nylon Insert Lock Nut 4
Table 2: K-R45XRFR4836LVR (R-450 Rotating Rear Railgear with Lever Actuated Lock-Up)
Part Number Description Qty
R-4836G Rotating Rear Railgear 1
R-4836GBRZ Rotating Rear Railgea
r
(Bronze Bushings)
R-4837B Axle Loc
k
-up Assembly 1
K
-R45XXRX4836 Lever Loc
k
-up Kit 1
R-001 10" Wheel Assembly 2
R-4646R Rail Sweep Right Side 1
R-4646L Rail Sweep Left Side 1
S-001031 Railgear Operation Decal 1
R-990KIT-204
Rail Wheel Mounting
1/2" UNC Gr. 8 Bolt x 2.25" Long 8
1/2" Gr. 8 Washer 16
1/2" UNC Gr. 8 Nylon Insert Lock Nut 8
R-990KIT-021
Rail Gear Mounting
5/8" UNC Gr. 8 Bolt x 2" Long 6
5/8" Gr. 8 Washer 12
5/8" UNC Gr. 8 Nylon Insert Lock Nut 6
3/4" UNC Gr. 8 Bolt x 2.25" Long 4
3/4" Gr. 8 Washer 8
3/4" UNC Gr. 8 Nylon Insert Lock Nut 4

MIO-R45XRFR4836 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
-3-
INSTALLATION OF REAR RAILGEAR
Note
The axle lock-up assemblies for these units has been pre-installed at the factory prior to
shipping, it will be necessary to install the push/pull cable or Lever Lock-up Kit during
vehicle installation. The procedure for installing the cable and lever can be located in the
installation section of this manual.
Note:
The following procedure details the installation of the rotating rear railgear kit. The
hardware required for each installation is listed in the tables above.
The type of rear lock-up installed on this unit has no effect on installation. The installation
procedure below is typical for all R-450 Rotating Rear Units.
1. To install the railgear at the correct height, ensure that the road wheels and tires have
been installed on the vehicle and that the vehicle is resting on its properly inflated tires.
2. Position and support the railgear so that the railgear mounting boxes are on either side of
the rear of the vehicle frame with the blind end of the hydraulic cylinders facing the rear
of the vehicle. The mounting boxes should be flush with the rear of the vehicle frame and
fit around the vehicle’s suspension hangers. The holes in the mounting boxes should align
with existing holes in the vehicle frame. It may be necessary to loosen or remove the 1/2”
fasteners that support the railgear lock system to be able to fit the railgear on the frame.
Once the railgear is on the frame, tighten and torque the 1/2” fasteners securing the
railgear lock system to the railgear to 100 ft-lbs dry. Do not over torque.
3. Ensure that there is approximately 21.5” between the railgear-to-mounting box interface
and the ground as shown. If this height cannot be achieved, the vehicle suspension will
need to be modified. This modification is not included with the RAFNA railgear.
4. Fasten each railgear mounting box to the vehicle frame using three 5/8” x 2” long bolts,
six 5/8” washers and three 5/8” nuts through the existing frame holes at the rear as
shown.
5. Using the front-most hole in each railgear mounting box as a guide, drill a 25/32” hole
through the vehicle frame.
6. Fasten each railgear mounting box to the vehicle frame using two 3/4” x 2.25” long bolts,
four 3/4” washers and two 3/4” nuts through the drilled hole and the existing hole as
shown.
7. Torque the 5/8” fasteners to 150 ft-lbs dry and the 3/4” fasteners to 175 ft-lbs dry. Do
not over torque.
8. Place the rail wheels below the mounting tables on the railgear axle. Place the rail
sweeps to the rear of the rail wheels and on top of the mounting tables. Fasten the rail
wheels and rail sweeps to the mounting tables with eight 1/2” x 2.25” long bolts, sixteen
1/2” washers and eight 1/2” nuts.

MIO-R45XRFR4836 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
-4-
9. Tighten but do not torque the 1/2” fasteners as they will be torqued following the railgear
alignment procedure.
Proceed to install the railgear hydraulic system as per the Hydraulic Kit Installation manual
before continuing with the following steps.
10. Follow the Rail Wheel Load Adjustment procedure detailed in the R-450 Rotating Rear
Railgear Kit Operation, Service and Parts manual.
11. Follow the Railgear Alignment procedure detailed in the R-450 Rotating Rear Railgear Kit
Operation, Service and Parts manual.
12. Follow the Railgear Lock System Installation/Adjustment Procedure detailed in the
Railgear Lock System Installation/Adjustment section of this manual.
13. Follow the Rail Sweep Adjustment procedure detailed in the R-450 Rotating Rear Railgear
Kit Operation, Service and Parts manual.
14. Torque all fasteners as detailed in the R-450 Rotating Rear Railgear Kit Operation, Service
and Parts manual.
15. Grease the railgear at all lubrication points as detailed in the R-450 Rotating Rear Railgear
Kit Operation, Service and Parts manual.

MIO-R45XRFR4836 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
-5-
Figure 1

MIO-R45XRFR4836 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
-6-
REAR LOCK-UP CABLE INSTALLATION PROCEDURE
For units equipped with a cable lock-up mechanism, use the following steps to install lock-up:
1. Remove lock-up cover.
2. Install the rear lock cable to the locking system by fastening the end of the cable through
the cable support, then thru the pipe on the locking cable bar at the center of the
railgear lock system as shown.
3. Fabricate and install a bracket to hold the lock cable handle. Ensure that the handle will
be mounted near the railgear controls.
4. Install lock-up cover on rear lock-up assembly. Torque ¼” fasteners to 12 ft-lbs dry.
5. Follow the railgear lock system adjustment procedure.
Figure 2

MIO-R45XRFR4836 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
-7-
REAR LOCK-UP LEVER INSTALLATION PROCEDURE
For units equipped with a lever lock-up mechanism, use the following steps to install lock-up:
Table 1: K-R45XXRX4836 (R-450 Rotating Rear Manual Lever Lockup Kit)
Part Number Description Qty
R-4837B Axle Lockup Assembly (Assembled on Railgear) 1
R-18109 Rod Support 1
R-18108 Lockup Rod 1
R-18107 Clevis 1
R-18106 Handle 1
R-990KIT-228
1/2"-13 UNC GR.8 Bolt x 3.50" Long 1
1/2" Flat Washer, Type-A GR. 8 2
1/2" - 13 UNC Nylock Nut, GR. 8 1
3/8" Flat Washer, Type-A GR. 8 1
3/8" - 16 UNC Hex Nut GR. 8 1
3/8" - 16 UNC Nylock Nut, GR. 8 1
1. Remove lock-up cover.
2. Fasten the clevis (R-18107) to the threaded Lockup Rod (R-18108) with the short-threaded
end using a 3/8” hex nut to secure the clevis.
3. Remove the cotter pin on the clevis and clevis pin and fasten the handle (R-18106) to the
clevis using the clevis pin and cotter pin that were just removed as shown.
4. Insert the Lockup Rod that is attached to the handle into the spring plate and fasten the
handle to the rod support (R-18109) using one ½” x 3-1/2” bolt, two ½” washers, and a
½” nylock nut as shown.
Do not over tighten the nylock nut or the handle will be hard to move or may not move
at all. Handle will need to be removed for bending and/or trimming for desired location.
5. Adjust the rod support up or down by loosening the bolts and nuts that hold the rod sup-
port so that the handle is parallel with the ground and tighten the ½” bolts and nylock
nuts that hold the rod support.
6. Place one 3/8” washer and nylock nut on the end of the lockup rod as shown. Use a 5/16
wrench to keep the lockup rod from turning when fastening the nylock nut.
7. Move the handle to the desired location making sure nothing will be in the way when
engaging the lockup and tighten the nylock nut so the 3/8” washer is against the spring
plate.
8. Test the lockup to ensure proper functionality.
9. Bend and/or trim the handle to desired location.

MIO-R45XRFR4836 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
-8-

MIO-R45XRFR4836 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
-9-
OPERATION OF R-450 ROTATING REAR RAILGEAR KIT
Ford F-450/550 All Models
OPERATION SAFETY PRECAUTIONS
If any operating, services, or parts problems are encountered, please call G&B Special-
ties, 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 this manual completely before attempting operation of
the railgear equipped vehicle.
 Operating instructions provided below only address the RAFNA railgear equip-
ment. Applicable railway company procedures and policies must be adhered to.
 Railway company rules governing rail travel must be observed at all times.
 Ensure that the position and function of all railgear controls are known before
attempting operation.
 Ensure the railgear is locked in road or rail position before starting road or rail
travel respectively.
 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.
 Before performing any work under the vehicle or railgear, ensure the engine is
turned off and the parking brake is set.
 Never operate the vehicle if the Gross Vehicle Weight Rating (GVWR), Gross Ax-
le Weight Rating Front or Rear (GAWR), or the wheel or tire load ratings are
exceeded.
 Always disconnect the vehicle’s battery when welding on the vehicle or railgear
in order to protect the vehicle’s electrical system.
!

MIO-R45XRFR4836 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
-10-
OPERATION OF ROTATING REAR RAILGEAR
With the railgear kit installed on this vehicle, it may be operated as normal, however the
vehicle has decreased ground clearance and angles of approach and departure due to the
railgear. Caution must be used when operating the vehicle.
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.
Refer to the Hydraulic Kit Operation, Service, and Parts manual for information on the
location and operation of the railgear hydraulic system controls.
Placing the Vehicle on Rail – To Lower the Railgear:
1. Disengage the mechanical locking pins by pulling on the locking cable handle or lever. Do
not force the locking cable/lever. If the lock pins cannot be disengaged, raise the railgear
slightly.
2. Hold the locking cable handle/lever in the disengaged position.
3. Lower the railgear and release the locking cable handle/lever once the railgear has
rotated past the road locked position.
4. As the railgear is being deployed, it will start taking some of the vehicle’s load. (If this is
not the case, DO NOT use the railgear. Inspect the railgear for lubrication and damage.)
5. Continue lowering the railgear until the hydraulic cylinders are fully extended. In this
position, the railgear should be about 2-3º over center.
Removing the Vehicle from Rail – To Raise the Railgear:
1. Raise the railgear.
2. Continue raising the railgear until the lock pins click into the road locked position. The
hydraulic cylinders should be completely retracted.
3. Ensure that the lock pins are engaged.

MIO-R45XRFR4836 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
-11-
SERVICE OF ROTATING REAR RAILGEAR
The railgear kit must be serviced regularly to avoid damage to the equipment. Table 3 below
provides the Recommended Service Schedule and the detailed service procedures follow.
Figure 3 provides the Non-Standard Fastener Torque Values. Table 4 provides Standard Fas-
tener Torque Values for all other fasteners.
Grease fittings are provided at all railgear lubrication points as shown in Figure 4. The
recommended lubricant for all lubrication points on this railgear is MYSTIK JT-6 LOW TEMP
grease or equivalent. In cold weather areas/seasons, SHELL DARINA XL102 or equivalent may
be used.
Table 3: Recommended Service Schedule
Description
Daily
Weekly
Monthly
3Months
6 Month
s
1
2 Month
s
1 Visually inspect the railgear prior to use for damaged or worn parts 
2 Check for loose wheels and fasteners 
3 Ensure the rail gear loc
k
-up system is functioning properly in both the
road and rail positions. 
4 Check and adjust truck tire pressure as per requirements 
5 Ensure the vehicle is in good operating condition based on the vehicle
operating and maintenance instructions 
6 Check and adjust rail wheel end play (0.005” max.) 
7 Inspect railgear wheel flanges for wear. Use the “RAFNA Wheel Flange
Indicator” for measurement 
8 Inspect all hydraulic fittings and hoses for leaks or wear 
9 Inspect rail sweeps for proximity to rail head 
10 Grease hydraulic cylinder pivot points 
11 Grease inner tube lower pivot points 
12 Grease inner tubes 
13 Lubricate locking mechanism   
14 Check level on hydraulic reservoir. Top off with appropriate filtered fluid 
15 Inspect and grease railgear wheel bearings 
16 Check and correct rail wheel alignment, if gear is removed or damaged,
or every 12 months 
Note:
For continuous service at ambient temperatures above 40°C (105°F), more frequent lubrica-
tion is required.

MIO-R45XRFR4836 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
-12-
Table 4: Standard Fastener Torque Values
Fastener Size Fastener Torque Value (ft-lbs) Dry
1” UNC Gr. 8 Fasteners 250
¾” UNC Gr. 8 Fasteners 175
5/8” UNC Gr. 8 Fasteners 150
½” UNC Gr. 8 Fasteners 100
3/8” UNC Gr. 8 Fasteners 40
¼” UNC Gr. 8 Fasteners 12
Figure 3: Non-Standard Fastener Torque Values

MIO-R45XRFR4836 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
-13-
Figure 4: Railgear Lubrication Points

MIO-R45XRFR4836 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
-14-
RAIL WHEEL BEARING ADJUSTMENT
The rail wheel bearings require periodic adjustment in order to keep the end-play within
specification. If the rail wheel bearings are not correctly adjusted, failure may occur that will
not be covered under the railgear warranty. Check and adjust the bearing end-play with the
railgear in the road position and with the rail wheels free to turn.
Use a magnetic base dial gauge to measure the end-play of each rail wheel bearing. The
bearing end-play must be between 0.001” and 0.005”. If this is not the case, adjust as
follows:
1. Remove the rail wheel hubcap and gasket by removing the three 1/4” bolts and 1/4” lock
washers.
2. Remove the spindle nut cotter pin.
3. Ensure that the wheel bearing cavity is full of grease.
4. While rotating the rail wheel forward, torque the spindle nut to 20 ft-lbs. Then loosen the
spindle nut and re-torque it to 6 ft-lbs. Re-check and re-adjust the bearing end-play if
required. If no torque wrench is available, tighten the spindle nut until the rail wheel is
difficult to turn by hand. Then loosen the spindle nut and retighten it just until no
looseness can be felt in the bearings. Re-adjust the bearing end-play with a torque wrench
as soon as possible.
5. Install a new 3/16” x 2” long cotter pin through the spindle nut. Tighten the spindle nut
slightly if needed to insert the cotter pin.
6. Re-install the hubcap and gasket using the 1/4” bolts and new 1/4” lock washers. Blue
Loctite can be used on the bolts as an added safety measure. Tighten and torque the 1/4”
fasteners to 12 ft-lbs dry. Do not over torque.
RAIL SWEEP ADJUSTMENT
The distance between the rail sweep rubber and the rail is adjustable and should be
maintained at approximately 1/8”. To adjust the rail sweep rubber, with the railgear in the
rail position, loosen the two 1/4” fasteners which secure the rail sweep rubber to the rail
sweep bracket. Slide the rail sweep rubber up or down for the correct clearance. Tighten and
torque the ¼” fasteners to 12 ft-lbs dry. Do not over torque.

MIO-R45XRFR4836 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
-15-
RAIL WHEEL LOAD ADJUSTMENT
During rail travel, the railgear removes a predetermined portion of the vehicle’s load from
the vehicle’s wheels and carries it on the rail wheels. A minimum amount of load must be
maintained on the rail wheels in order to avoid derailment. Likewise, a minimum amount of
load must be maintained on the vehicle wheels in order to provide traction for acceleration
and braking.
The rail wheel load should be adjusted following the installation of the railgear once the
vehicle has had all of its permanent load (service body, crane, welders, etc.) installed. The
rail wheel load requires periodic checks; however it should only require re-adjustment if the
railgear is moved, the vehicle equipment is changed, or the vehicle suspension settles or is
changed. As non-permanent load is added to and/or removed from the vehicle, the rail wheel
load will change also. This is acceptable as long as the weight ratings of the vehicle, axles,
wheels, tires and railgear are not exceeded and as long as the minimum rail wheel load is
maintained.
The rail wheel load must be a minimum of 800 lbs and is checked as described below using a
hydraulic bottle jack equipped with a gauge. If the gauge on the hydraulic bottle jack reads in
pounds per square inch (psi), use Table 5 along with the jack bore diameter to convert this
reading to pounds (lbs). If the gauge reads in pounds, then no conversion is required.
Check each rail wheel load as follows:
1. Place the vehicle on a straight and level section of rail with the railgear lowered to the
rail position. Ensure the railgear is taking load through the tread of the rail wheel and not
on the flange of the rail wheel. The vehicle should only be carrying the permanently
attached load (service body, crane, etc.) and any always carried non-attached load
(welders, etc.) during this procedure. Do not include the operator or passengers. Ensure
the vehicle tires have been inflated to the manufacturer’s recommended air pressure and
that they are not in contact with any obstructions except the rails.
2. Place the hydraulic bottle jack on a solid surface beneath the rail wheel spindle housing
and jack the rail wheel off the rail.
3. Insert a piece of paper between the rail and the rail wheel. Lower the jack until the rail
wheel squeezes the paper so that it cannot be pulled out.
4. Slowly jack up the rail wheel while pulling on the paper and observe the jack gauge. When
the paper can be pulled out, stop jacking.
5. Record the load or pressure reading on the jack gauge.
6. If necessary, convert the pressure reading to a load reading using the supplied table.

MIO-R45XRFR4836 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
-16-
7/8 15/16 1 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8
540 320 370 420 480 540 600 660 730 800
560 340 390 440 500 560 620 690 760 830
580 350 400 460 510 580 640 710 780 860
600 360 410 470 530 600 660 740 810 890
620 370 430 490 550 620 690 760 840 920
640 380 440 500 570 640 710 790 870 950
660 400 460 520 590 660 730 810 890 980
680 410 470 530 600 680 750 830 920 1010
700 420 480 550 620 700 780 860 950 1040
720 430 500 570 640 720 800 880 970 1070
740 440 510 580 660 740 820 910 1000 1100
760 460 520 600 670 760 840 930 1030 1130
780 470 540 610 690 780 860 960 1060 1160
800 480 550 630 710 800 890 980 1080 1190
820 490 570 640 730 820 910 1010 1110 1220
840 510 580 660 740 830 930 1030 1140 1250
860 520 590 680 760 850 950 1060 1160 1280
880 530 610 690 780 870 970 1080 1190 1310
900 540 620 710 800 890 1000 1100 1220 1340
920 550 640 720 820 910 1020 1130 1240 1370
940 570 650 740 830 930 1040 1150 1270 1400
960 580 660 750 850 950 1060 1180 1300 1430
980 590 680 770 870 970 1090 1200 1330 1460
1000 600 690 790 890 990 1110 1230 1350 1480
1020 610 700 800 900 1010 1130 1250 1380 1510
1040 630 720 820 920 1030 1150 1280 1410 1540
1060 640 730 830 940 1050 1170 1300 1430 1570
1080 650 750 850 960 1070 1200 1330 1460 1600
1100 660 760 860 980 1090 1220 1350 1490 1630
1120 670 770 880 990 1110 1240 1370 1520 1660
1140 690 790 900 1010 1130 1260 1400 1540 1690
1160 700 800 910 1030 1150 1280 1420 1570 1720
1180 710 810 930 1050 1170 1310 1450 1600 1750
1200 720 830 940 1060 1190 1330 1470 1620 1780
1220 730 840 960 1080 1210 1350 1500 1650 1810
1240 750 860 970 1100 1230 1370 1520 1680 1840
1260 760 870 990 1120 1250 1400 1550 1700 1870
1280 770 880 1010 1130 1270 1420 1570 1730 1900
1300 780 900 1020 1150 1290 1440 1600 1760 1930
1320 790 910 1040 1170 1310 1460 1620 1790 1960
1340 810 920 1050 1190 1330 1480 1640 1810 1990
1360 820 940 1070 1210 1350 1510 1670 1840 2020
1380 830 950 1080 1220 1370 1530 1690 1870 2050
1400 840 970 1100 1240 1390 1550 1720 1890 2080
1420 850 980 1120 1260 1410 1570 1740 1920 2110
1440 870 990 1130 1280 1430 1590 1770 1950 2140
1460 880 10101150129014501620179019802170
1480 890 10201160131014701640182020002200
1500 900 10401180133014901660184020302230
1520 910 10501190135015101680187020602260
1540 930 10601210137015301710189020802290
1560 940 10801230138015501730191021102320
1580 950 10901240140015701750194021402350
1600 960 11001260142015901770196021602380
1620 970 11201270144016101790199021902410
1640 990 11301290145016301820201022202440
1660 1000 1150 1300 1470 1650 1840 2040 2250 2460
1680 1010 1160 1320 1490 1670 1860 2060 2270 2490
1700 1020 1170 1340 1510 1690 1880 2090 2300 2520
1720 1030 1190 1350 1530 1710 1900 2110 2330 2550
1740 1050 1200 1370 1540 1730 1930 2140 2350 2580
Rail Wheel Load (lbs)
Jack
Pressure
(PSI)
Jack Cylinder Bore Diameter (inches)
Table 5: Rail Wheel Load vs Jack Pressure and Bore

MIO-R45XRFR4836 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
-17-
Adjust each rail wheel load as follows:
There are two rubber springs on the railgear located between each railgear outer tube
assembly and spring plate. Each spring is held in place by a nylock nut above it and a spring
plate with a jam nut below it. The spring plate can be lowered and raised on the threaded
rod to correspondingly decrease and increase the rail wheel load.
1. Raise the railgear until the rail wheels are off the rails.
2. Loosen the 1” nylock nut above each spring and the 1” jam nut under each spring plate.
3. To decrease the load on the rail wheels, lower the spring plates on the threaded rods. To
increase the load on the rail wheels, raise the spring plates on the threaded rods. Each
side should be adjusted the same amount.
4. Lower the railgear to the rail position and re-check the rail wheel loads. Re-adjust the rail
wheel loads if necessary.
5. Raise the railgear until the rail wheels are off the rails. Tighten the 1” jam nut on the
threaded rod so that they are tight against the spring plate.
6. Tighten the 1” nylock nuts above the springs so that the rubber springs are compressed to
3.75”.
7. Following the rail wheel load adjustment, the railgear may contact the vehicle if not
enough clearance was left during installation. Check the railgear clearance to all vehicle
components throughout the full range of railgear and railgear suspension movement. If
there is interference with the vehicle exhaust system, it can be bent to fit, ensuring any
exhaust system modifications conform to applicable laws and regulations. If there is
interference with any other vehicle components, please call G&B Specialties, Inc. for
technical assistance.

MIO-R45XRFR4836 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
-18-
7/8 15/16 1 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8
540 320 370 420 480 540 600 660 730 800
560 340 390 440 500 560 620 690 760 830
580 350 400 460 510 580 640 710 780 860
600 360 410 470 530 600 660 740 810 890
620 370 430 490 550 620 690 760 840 920
640 380 440 500 570 640 710 790 870 950
660 400 460 520 590 660 730 810 890 980
680 410 470 530 600 680 750 830 920 1010
700 420 480 550 620 700 780 860 950 1040
720 430 500 570 640 720 800 880 970 1070
740 440 510 580 660 740 820 910 1000 1100
760 460 520 600 670 760 840 930 1030 1130
780 470 540 610 690 780 860 960 1060 1160
800 480 550 630 710 800 890 980 1080 1190
820 490 570 640 730 820 910 1010 1110 1220
840 510 580 660 740 830 930 1030 1140 1250
860 520 590 680 760 850 950 1060 1160 1280
880 530 610 690 780 870 970 1080 1190 1310
900 540 620 710 800 890 1000 1100 1220 1340
920 550 640 720 820 910 1020 1130 1240 1370
940 570 650 740 830 930 1040 1150 1270 1400
960 580 660 750 850 950 1060 1180 1300 1430
980 590 680 770 870 970 1090 1200 1330 1460
1000 600 690 790 890 990 1110 1230 1350 1480
1020 610 700 800 900 1010 1130 1250 1380 1510
1040 630 720 820 920 1030 1150 1280 1410 1540
1060 640 730 830 940 1050 1170 1300 1430 1570
1080 650 750 850 960 1070 1200 1330 1460 1600
1100 660 760 860 980 1090 1220 1350 1490 1630
1120 670 770 880 990 1110 1240 1370 1520 1660
1140 690 790 900 1010 1130 1260 1400 1540 1690
1160 700 800 910 1030 1150 1280 1420 1570 1720
1180 710 810 930 1050 1170 1310 1450 1600 1750
1200 720 830 940 1060 1190 1330 1470 1620 1780
1220 730 840 960 1080 1210 1350 1500 1650 1810
1240 750 860 970 1100 1230 1370 1520 1680 1840
1260 760 870 990 1120 1250 1400 1550 1700 1870
1280 770 880 1010 1130 1270 1420 1570 1730 1900
1300 780 900 1020 1150 1290 1440 1600 1760 1930
1320 790 910 1040 1170 1310 1460 1620 1790 1960
1340 810 920 1050 1190 1330 1480 1640 1810 1990
1360 820 940 1070 1210 1350 1510 1670 1840 2020
1380 830 950 1080 1220 1370 1530 1690 1870 2050
1400 840 970 1100 1240 1390 1550 1720 1890 2080
1420 850 980 1120 1260 1410 1570 1740 1920 2110
1440 870 990 1130 1280 1430 1590 1770 1950 2140
1460 880 1010 1150 1290 1450 1620 1790 1980 2170
1480 890 1020 1160 1310 1470 1640 1820 2000 2200
1500 900 1040 1180 1330 1490 1660 1840 2030 2230
1520 910 1050 1190 1350 1510 1680 1870 2060 2260
1540 930 1060 1210 1370 1530 1710 1890 2080 2290
1560 940 1080 1230 1380 1550 1730 1910 2110 2320
1580 950 1090 1240 1400 1570 1750 1940 2140 2350
1600 960 1100 1260 1420 1590 1770 1960 2160 2380
1620 970 1120 1270 1440 1610 1790 1990 2190 2410
1640 990 1130 1290 1450 1630 1820 2010 2220 2440
1660 1000 1150 1300 1470 1650 1840 2040 2250 2460
1680 1010 1160 1320 1490 1670 1860 2060 2270 2490
1700 1020 1170 1340 1510 1690 1880 2090 2300 2520
1720 1030 1190 1350 1530 1710 1900 2110 2330 2550
1740 1050 1200 1370 1540 1730 1930 2140 2350 2580
Rail Wheel Load (lbs)
Jack
Pressure
(PSI)
Jack Cylinder Bore Diameter (inches)
Table 5: Rail Wheel Load vs Jack Pressure and Bore

MIO-R45XRFR4836 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
-19-
RAILGEAR ALIGNMENT
The railgear must be correctly aligned to perform properly, safely, and avoid excessive wear
and derailment. The rail wheels can be independently aligned for toe-in/toe-out and the
railgear can be adjusted side to side (laterally) on the vehicle. A parallel line system and the
following procedure should be used to perform the railgear alignment.
The rail wheel loads should be checked and adjusted, the vehicle should have had a
four-wheel alignment (with the complete railgear package installed on the vehicle and any
suspension modifications done) and the tires should be properly inflated prior to performing
the railgear alignment.
The railgear alignment is done with the vehicle on a straight and level section of rail with the
railgear in the rail position and the vehicle wheels pointing straight ahead. The individual rail
wheel alignment should be done first, followed by the lateral alignment of the railgear.
Each rail wheel is aligned by loosening the four 1/2” fasteners that secure it to the railgear
axle. The rail wheel is then turned into alignment. The four 1/2” fasteners should then be
tightened and torqued to 100 ft-lbs dry. Do not over torque.
The railgear is aligned laterally by loosening the eight 5/8” fasteners that secure it to the
railgear mounting boxes. The railgear is then moved sideways into alignment. It may be
necessary to raise the railgear off the rails to move the railgear side to side. Do not use any
force against the railgear guide tubes as this may damage them and restrict suspension
movement. The eight 5/8” fasteners should then be tightened and torqued to 150 ft-lbs dry.
Do not over torque.
Refer to Figure 5 for alignment measurement and specifications. Use an 18” magnetic straight
edge on the back of each rail wheel to measure from.
Following the railgear alignment, the railgear may contact the vehicle if not enough
clearance was left during installation. Check the railgear clearance to all vehicle components
throughout the full range of railgear and railgear suspension movement. If there is
interference with the vehicle bumper, it can be trimmed and reinforced as required. If there
is interference with the vehicle exhaust system, it can be bent to fit, ensuring any exhaust
system modifications conform to applicable laws and regulations. If there is interference with
any other vehicle components, please call G&B Specialties, Inc. for technical assistance.

MIO-R45XRFR4836 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
-20-
Figure 5: Railgear Alignment Rack