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.