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

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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.

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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

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SECTION 1: INITIAL PREPARATION
SAFETY PRECAUTIONS 1-2
INSTALLATION PROCEDURE OVERVIEW 1-3
PREPARATIONS FOR RAILGEAR INSTALLATION 1-4

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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

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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.

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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]

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
2.0 FRONT RAILGEAR INSTALLATION
This section covers the installation of the front railgear. The hardware required for this
installation is listed in table 2-2.
Table 2
-
2: Front Railgear Installation Hardware
Part Number Description Qty
R
-
1790E
Rotating Front Railgear
1
½” UNC Gr. 8 Bolt x 2” Long
4
½” Gr. 8 Washer
8
½” UNC
Gr. 8 Nylon Insert Lock Nut
4
The following procedure details the front railgear installation (refer to figure 2-2):
1. Position the front railgear (Item 1) in front of the vehicle with the railgear mounting
brackets (Item 2) facing the front mounting plates (Item 3) already installed on the
vehicle.
2. The railgear has six mounting holes on each side to fit a wide variety of vehicle
heights. The front mounting plates have four mounting slots and also have an
adjustable height angle (Item 4). If the angles are moved on the front mounting plates,
ensure that the ½” fasteners holding them in place are torqued to 100 ft-lbs. Ensure
the vehicle is resting on its four properly inflated tires. Raise the railgear to the
vehicle. Align the mounting holes such that the center of the railgear pivot point is
approximately 16-38” from the ground. Fasten the railgear to the mounting plates
using four ½” x 2” long bolts, eight ½” washers, and four ½” nuts (Item 5). The
fasteners should span at least three mounting holes in height.
3. Tighten but do not torque the four ½” fasteners as they will be torqued following the
railgear alignment procedure.

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16-3/8" TO GROUND

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3.0 REAR RAILGEAR MOUNTING PLATE INSTALLATION
This section covers the installation of the rear railgear mounting plates. The installation
procedure follows for each applicable vehicle model.
3.1 1999 – 2007 DODGE DAKOTA
The hardware required for this installation is listed in table 2-3.
Table 2
-
3: 1999
–
2007 Dodge Dakota Rear Railgear Mounting Hardware
Part Number Description Qty
R
-
1731D
Rear Mounting Plate (Left Side)
1
R
-
1731P
Rear Mounting Plate (Right Side)
1
R
-
1733
Rear Operating Valve Support
1
½” UNC Gr. 8 Bolt x 2” Long
6
½” GR. 8 Washer
12
½” UNC Gr. 8 Nylon Insert Lock Nut
6
The following procedure details the rear mounting plate installation (refer to figure 2-3):
1. Place each rear mounting plate (Item 1) against the outside of the frame rails (Item 2)
just forward of the rear spring hangers (Item 3). The rear edge of the mounting plates
should be 13-½” from the end of the frame and the top edge of the mounting plates
should be flush with the top of the frame. Ensure the mounting plates are level and
aligned with each other.
2. Using the mounting plates as templates, drill three 1732” holes (Item 4) through each
frame rail.
3. Place the rear operating valve support (Item 5) over the rear most two holes on the
left side mounting plate as shown.
4. Fasten the mounting plates and operating valve support to the frame using six ½” x 2”
long bolts, twelve ½” washers and six ½” nuts (Item 6). Torque the ½” fasteners to
100 ft-lbs.

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13.5"

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3.2 1999 – 2007 DODGE DURANGO
The hardware required for this installation is listed in table 2-4.
Table 2
-
4: 1999
–
2007 Dodge Durango Rear Railgear Mo
unting Hardware
Part Number Description Qty
R
-
1695D
Rear Mounting Plate (Left Side)
1
R
-
1695P
Rear Mounting Plate (Right Side)
1
R
-
1698D
Rear Adapter Angle (Left Side)
1
R
-
1698P
Rear Adapter Angle (Right Side)
1
R
-
1723
Rear Operating Valve Support
1
5
8
” UNC Gr. 8 Bolt x 1
-
¾” Long
4
5
8
” GR. 8 Washer
8
5
8
” UNC Gr. 8 Nylon Insert Lock Nut
4
The following procedure details the rear mounting plate installation (refer to figure 2-4):
1. Remove the rear bumper, the two rear most bumper brackets (Item 1) and the two
forward most bumper brackets (Item 2) from the frame rails (Item 3). Leave the
bumper bracket retaining bolts (Item 4) in the frame. Retain all parts for re-
installation.
2. Place each rear mounting plate (Item 5) against the outside of the frame rails around
the rear spring hangers (Item 6). The holes in the mounting plates should align with
the bumper bracket retaining bolts in the frame.
3. Place the rear operating valve support (Item 7) over the left side forward bumper
bracket retaining bolts as shown.
4. Place the bumper brackets back in their original position. The mounting plates and
operating valve support should now be between the frame and the bumper brackets.
5. Fasten the mounting plates, operating valve support and bumper brackets to the frame
using the original fasteners (Item 8). Ensure the mounting plates are level and
aligned with each other. Torque the original fasteners to Dodge specifications.
6. Place and center the adapter angles (Item 9) against the inside of the mounting plates
as shown.
7. Fasten the adapter angles to the mounting plates using four 58” x 1-¾” long bolts,
eight 58” washers and four 58” nuts (Item 10). Tighten but do not torque the 58”
fasteners yet.

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

G&B Specialties Inc. 535 West 3rd Street, Berwick, PA, USA Tel: [phone] Fax: [phone]
4.0 REAR RAILGEAR INSTALLATION
This section covers the installation of the rear railgear. The hardware required for this
installation is listed in table 2-5.
Table 2
-
5: Rear Railgear Installation Hardware
Part Number Description Qty
R
-
1690D
Rotating Rear Railgear
1
R
-
1794
-
1
Shim
2
R
-
179
4
-
2
Shim
2
R
-
1794
-
3
Shim
2
R
-
1725
Handle Holder
1
¼” UNC Gr. 8 Bolt x 1” Long
1
¼” SAE Washer
2
¼” UNC Gr. 3 Nylon Insert Lock Nut
1
½” UNC Gr. 8 Bolt x 2” Long
4
½” Gr. 8 Washer
8
½” UNC Gr. 8 Nylon Insert Lock Nut
4
The following procedure details the rear railgear installation (refer to figure 2-5):
1. Ensure the vehicle is resting on its four properly inflated tires. Position the rear
railgear (Item 1) below the rear mounting plates or adapter angles (Item 2) with the
hydraulic cylinder free end (Item 3) facing towards the front of the vehicle.
2. Raise the railgear to the mounting plates or adapter angles and align the mounting
holes in the railgear with the slots in the mounting plates or adapter angles. The
railgear should be installed so that the center of the railgear pivot point is
approximately 16-38” from the ground. Use the supplied shims (Item 4) between the
railgear and the mounting plates or adapter angles as necessary.
3. Fasten the railgear to the mounting plates or adapter angles using four ½” x 2” long
bolts, eight ½” washers and four ½” nuts (Item 5). Tighten but do not torque the four
½” fasteners as they will be torqued following the railgear alignment procedure.
4. On Durango Models: The railgear and adapter angles can be moved forwards and
backwards on the mounting plates in order to clear any obstructions. Attempt to
position the railgear as far forward as possible and perpendicular to the vehicle frame.
Torque the 58” fasteners (Item 6) holding the adapter angles to the mounting plates to
150 ft-lbs.
5. Remove the knob from the locking handle (Item 7) and slide the handle holder (Item
8) onto the locking handle as shown. Re-install the knob. Adjust the shape of the
handle holder so that the it can be fastened to the rear operating valve support using
one ¼” x 1” long bolt, two ¼” washers and one ¼” nut (Item 9) and the pre-drilled
holes. The locking handle should operate freely. Torque the ¼” fastener to 12 ft-lbs.

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6. On Durango Models: Using the original Dodge fasteners, re-install the rear bumper
and torque the original fasteners to Dodge specifications.
NOTE: DURANGO SHOWN
DAKOTA IS SIMILAR
16-38" TO
GROUND

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5.0 RAIL WHEEL AND RAIL SWEEP INSTALLATION
This section covers the installation of the front and rear rail wheels and rail sweeps. The
hardware required for this installation is listed in table 2-6.
Table 2
-
6: Rail Wheel & Rail Sweep Installation Hardware
Part Number Description Qty
R
-
1653
8” Wheel Assembly
4
R
-
1672R
Front Rail Sweep (Right Side)
1
R
-
1672L
Front Rail Sweep (Left Side)
1
R
-
1677R
Rear Rail Sweep (
Right Side)
1
R
-
1677L
Rear Rail Sweep (Left Side)
1
½” UNC Gr. 8 Bolt x 2” Long
16
½” Gr. 8 Washer
32
½” UNC Gr. 8 Nylon Insert Lock Nut
16
The following procedure details the rail wheel and rail sweep installation (refer to figure
2-6 and figure 2-7):
1. Place the rail wheels (Item 1) below the mounting tables (Item 2) on the railgear axles
(Item 3).
2. On the front railgear: Place the rail sweeps (Item 4) in front of the rail wheels and
on top of the mounting tables. At this point the rail sweeps will be free to pivot. The
rail sweep actuating mechanisms will be installed later.
3. On the rear railgear: Place the rail sweeps (Item 4) to the rear of the rail wheels
and on top of the mounting tables.
4. Fasten the rail wheels and rail sweeps to the mounting tables with sixteen ½” x 2”
long bolts, thirty-two ½” washers and sixteen ½” nuts (Item 5).
5. Tighten but do not torque the sixteen ½” fasteners as they will be torqued following
the railgear alignment procedure.

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