Wabtec R-450 User manual

MIO-R45XRDR19061B Rev C
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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INSTALLATION OF R-450 ROTATING REAR RAILGEAR KIT W/CABLE LOCK-
UP
2019-PRESENT RAM 4500/5500 CHASSIS CAB
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
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.
 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
Axle Weight Rating Front or Rear (GAWR), or the wheel or tire load ratings are
exceeded.
!

MIO-R45XRDR19061B Rev C
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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REAR RAILGEAR KIT
The following procedure details the installation of the rotating rear railgear kit. The hardware
required for this installation is listed in Table 1.
Table 1: Rotating Rear Railgear Kit Installation Parts
Part Number Description Qty
R-19061B Rotating Rear Railgear 1
R-18021 Rear Support Bracket 2
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-18103 Wrench 1
R-4837E Rear Axle Lockup, Cable Lock Up 1
R-4838 Locking Cable Assembly 1
R-990KIT-443
Railgear Mounting
7/16" UNC Gr. 8 Bolt x 1 1/2" Long 6
7/16" UNC Gr. 8 Bolt x 1 3/4" Long 4
1/2" UNC Gr. 8 Bolt x 1 3/4" Long 4
1/2" UNC Gr. 8 Bolt x 2" Long 8
5/8" UNC Gr. 8 Bolt x 2 1/4" Long 4
3/4" UNC Gr. 8 Bolt x 2 1/4" Long 4
7/16" Gr. 8 Washer 20
1/2" Gr. 8 Washer 24
5/8" Gr. 8 Washer 8
3/4" Gr. 8 Washer 8
7/16" UNC Gr. 8 Nylon Insert Lock Nut 10
1/2" UNC Gr. 8 Nylon Insert Lock Nut 12
5/8" UNC Gr. 8 Nylon Insert Lock Nut 4
3/4" UNC Gr. 8 Nylon Insert Lock Nut 4

MIO-R45XRDR19061B Rev C
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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INSTALLATION OF REAR RAILGEAR KIT
1. To install the railgear at the correct height, ensure that the vehicle is resting on its six
properly inflated tires. Remove tail lights.
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 and top surface of the
vehicle frame (as a starting point) and fit around the vehicle’s suspension hangers. The
holes in the mounting boxes should align with existing holes in the rear of the vehicle
frame. It may be necessary to loosen or remove the fasteners that support the railgear
axle 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 in Figure 1. The slots in the mounting boxes will allow for
approx. 1/4” of vertical adjustment, either up or down. If the 21.5” mounting 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 two 5/8” x 2” long bolts,
four 5/8” washers and two 5/8” nuts through the existing frame holes at the rear as
shown.
5. Repeat step four for two 7/16” x 1 3/4” long bolts, washer and nuts through the existing
frame holes as shown.
6. Using the front-most bottom holes in each railgear mounting box as a guide, drill a 25/32”
hole through the vehicle frame.
7. Fasten each railgear mounting box to the vehicle frame using through the drilled hole
using 3/4” supplied hardware as shown.
8. Using the center hole in each railgear mounting box as a guide, repeat steps 6 and 7.
9. Fasten each rear support bracket to each railgear mounting box using two 1/2” x 1.75”
long bolts, four 1/2” washers and two 1/2” nuts. Slide support bracket up until the top of
the bracket is resting on the bottom of the truck frame. Torque the 1/2” fasteners to 100
ft-lbs dry. Do not over torque.
10. Torque the 5/8” fasteners to 150 ft-lbs dry and the 3/4” fasteners to 175 ft-lbs dry. Do
not over torque.
11. 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-R45XRDR19061B Rev C
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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12. 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.
13. Follow the Rail Wheel Load Adjustment procedure detailed in the Operation, Service and
Parts section of this manual.
14. Follow the Railgear Alignment procedure detailed in the Operation, Service and Parts
section of this manual.
15. Follow the Railgear Lock System Adjustment Procedure detailed in the Operation, Service
and Parts section of this manual.
16. Follow the Lockup Kit installation procedure detailed in the Lockup Kit Installation and
Operation manual.
17. Follow the Rail Sweep Adjustment procedure detailed in the Operation, Service and Parts
section of this manual.
18. Torque all fasteners as detailed in the Operation, Service and Parts section of this
manual.
19. Grease the railgear at all lubrication points as detailed in the Operation, Service and Parts
section of this manual.

MIO-R45XRDR19061B Rev C
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-R45XRDR19061B Rev C
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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FIGURE 2

MIO-R45XRDR19061B Rev C
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-
OPERATION OF R-450 ROTATING REAR RAILGEAR KIT W/CABLE LOCK-UP
2019-PRESENT RAM 4500/5500 CHASSIS CAB
OPERATION SAFETY PRECAUTIONS
If any operating, services or parts 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 this manual completely before attempting operation of
the railgear equipped vehicle.
 Operating instructions provided below only address the RAFNA railgear
equipment. 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
Axle 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-R45XRDR19061B Rev C
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-
OPERATION OF ROTATING REAR RAILGEAR KIT
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 section of this 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. Do not force
the locking cable. If the lock pins cannot be disengaged, raise the railgear slightly.
2. Hold the locking cable handle in the disengaged position.
3. Lower the railgear and release the locking cable handle 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 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-R45XRDR19061B Rev C
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-
SERVICE OF ROTATING REAR RAILGEAR KIT
The railgear kit must be serviced regularly to avoid damage to the equipment. Table 2 below
provides the Recommended Service Schedule and the detailed service procedures follow.
Figure 3 provides the Non-Standard Fastener Torque Values. Table 3 provides Standard
Fastener 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 2: Recommended Service Schedule
Description
Daily
Weekly
Monthly
3Months
6 Months
12 Months
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 lock-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
lubrication is required.

MIO-R45XRDR19061B Rev C
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-
Table 3: 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