Wabtec R-150 User manual

Issued May 2022 (Rev C) Bulletin MI15RRD
Wabtec Components LLC
535 West 3rd Street, Berwick, Pa 18603
Tel: [phone]
Fax: [phone]
MODEL R-150
"CUSHION-RIDE" RAILGEAR
INSTALLATION MANUAL
"ROTATING FRONT - ROTATING REAR"
READ THIS MANUAL BEFORE
INSTALLING RAILGEAR EQUIPMENT
Application Models: 1999 - 2007 Dodge Dakota (All Models)
1999 - 2007 Dodge Durango (All Models)
2013 Ford Ranger XLT

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
Note:
The appendix of this manual includes the latest changes to the installation and operation
of the railgear not included in the “body” of this manual.
Please refer to the appendix prior to installing and operating the railgear.
The information in the appendix supersedes whatever is mentioned in the “body” of this
manual.

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
TABLE OF CONTENTS
Initial Preparation Section 1
Safety Precautions 1-2
Installation Procedure Overview 1-3
Preparations For Railgear Installation 1-4
Railgear Installation Section 2
Front Railgear Mounting Plate Installation 2-2
Front Railgear Installation 2-4
Rear Railgear Mounting Plate Installation 2-6
Rear Railgear Installation 2-10
Rail Wheel And Rail Sweep Installation 2-12
Front Railgear Bumper And Rail Sweep Arm Installation 2-14
Auxiliary Installations Section 3
Steering Wheel Lock Installation 3-2
Hydraulic System Installation 3-4
Electrical System Installation 3-7
Railgear Set-Up And Adjustments 3-10
Pre-Delivery Check List 3-13
Appendix Section 4

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
SECTION 1: INITIAL PREPARATION
SAFETY PRECAUTIONS 1-2
INSTALLATION PROCEDURE OVERVIEW 1-3
PREPARATIONS FOR RAILGEAR INSTALLATION 1-4

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
1.0 SAFETY PRECAUTIONS
WARNING:
 Refer to the Operating, Service and Parts manual for installation related
warranty issues.
 Installation instructions provided below only address the Rafna
Industries railgear equipment. Applicable railway company procedures
and policies must be adhered to.
 Always disconnect the vehicle’s battery when welding on the vehicle or
railgear in order to protect the vehicle’s electrical system.
 Before performing any work under the vehicle or railgear, ensure the
engine 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.
 The following safety precautions should be taken before the vehicle is
tested or operated:
 Read the Operating, Service and Parts Manual
 Visually inspect the railgear for damaged or worn parts
 Perform the Alignment Procedure
 Check for loose wheels and fasteners
 Check for leaking hydraulic lines and cylinders
 Check for proper lubrication
Failure to heed to any of the above mentioned warnings could result in severe
bodily injury and/or equipment damage.
IF ANY INSTALLATION PROBLEMS ARE ENCOUNTERED, PLEASE CALL G&B
SPECIALTIES, INC. FOR TECHNICAL ASSISTANCE BEFORE CONTINUING WITH
THE INSTALLATION PROCESS.

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
2.0 INSTALLATION PROCEDURE OVERVIEW
This manual covers the installation of the Rafna Industries rotating front and rotating rear
R-150 railgear as applicable to multiple vehicles. If necessary, any difference in
installation for specific vehicle and/or railgear models is clearly detailed by separate
instructions for each. Otherwise the installation instructions are the same for all models.
Please refer to the appendix for the latest additions that have not been included in this
manual.
The Rafna Industries R-150 railgear is a hydraulically operated road-to-rail conversion
system applicable to vehicles of up to 6,500 lbs. gross vehicle weight rating (GVWR).
The front and rear railgear are frame mounted systems which are hydraulically raised and
lowered. The hydraulic power is supplied by a 12 VDC electrical / hydraulic pump.
The installation procedure consist of first installing the front and rear railgear. The
hydraulic and electrical installations follow and finally an adjustment of the equipment is
performed.
This manual uses the orientation convention for the vehicle as shown in figure 1-1.
FIGURE 1-1 : ORIENTATION CONVENTION
LEFT
RIGHT
FRONT REAR

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
3.0 PREPARATIONS FOR RAILGEAR INSTALLATION
The following steps must be performed on all vehicles prior to installation of the railgear
equipment:
1. Disconnect the negative battery terminal.
2. Remove the spare wheel from under the vehicle’s cargo box if so equipped. A new
location must be found for the spare wheel and the necessary brackets fabricated.
3. Remove the front bumper and all related mounting brackets. Retain all parts for re-
installation.
4. Remove the tail pipe section of the exhaust. Retain all parts for re-installation.

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
SECTION 2: RAILGEAR INSTALLATION
FRONT RAILGEAR MOUNTING PLATE INSTALLATION 2-2
FRONT RAILGEAR INSTALLATION 2-4
REAR RAILGEAR MOUNTING PLATE INSTALLATION 2-6
REAR RAILGEAR INSTALLATION 2-10
RAIL WHEEL AND RAIL SWEEP INSTALLATION 2-12
FRONT RAILGEAR BUMPER AND RAIL SWEEP ARM INSTALLATION 2-14

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
1.0 FRONT RAILGEAR MOUNTING PLATE INSTALLATION
This section covers the installation of the front railgear mounting plates. The hardware
required for this installation is listed in table 2-1.
Table 2
-
1: Front Railgear Mounting Hardware
Part Number Description Qty
R
-
1783
-
1
Front Frame Reinforcement Plate
2
R
-
1783
-
2
Front Frame Reinforcement Plate
2
R
-
1800D
Front Mounting Plate (Left Side)
1
R
-
1800P
Front Mounting Plate (Right Side)
1
½” UNC Gr. 8 Bolt x 2” Long
10
½” Gr. 8 Washer
20
½” UNC Gr. 8 Nylon Insert Lock Nut
10
The following procedure details the front mounting plate installation (refer to figure 2-1):
1. Position the front mounting plates (Item 1) around the frame rails (Item 2) as shown
so that they cradle the frame rails.
2. Position the original Dodge inner bumper brackets (Item 3) in their original position.
Slide the matching front frame reinforcement plates (Item 4) into the frame rails. The
three holes in the front frame reinforcement plate, in the frame, in the front mounting
plate and in the inner bumper bracket on each side should all align. Use six ½” x 2”
long bolts, twelve ½” washers, and six ½” nuts (Item 5) to fasten all parts in place.
3. Remove and discard the clip-on nuts from the original Dodge outer bumper brackets
(Item 6). Position the outer bumper brackets in their original position. Slide the
matching front frame reinforcement plates (Item 7) into the frame rails. The two
holes in the front frame reinforcement plate, in the frame rail, in the front mounting
plate and in the outer bumper bracket on each side should all align. Use four ½” x 2”
long bolts, eight ½” washers, and four ½” nuts (Item 8) to fasten all parts in place.
4. Ensure the front mounting plates are seated against the bottom of the frame and
aligned with each other. Torque all ½” fasteners to 100 ft-lbs.
5. Modify the front bumper as required so that it can be re-installed with the mounting
plates in place.
6. Re-install the front bumper using the original Dodge fasteners. Level the bumper and
torque the original fasteners to Dodge specifications.

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]