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I
NSTALLATION OF
2019-P
I
S
NSTALLATION
AFETY
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.
G&B Specialties Inc. 535 West 3
US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com
R-450 R
OTATING
R
4500/5500 C
RESENT
AM
P
RECAUTIONS
rd
Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397
-1-
R
R
K
EAR
AILGEAR
U
P
HASSIS
MIO-R45XRDR19061B Rev C
/ C
L
IT W
ABLE
OCK
C
AB
-

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Summary of Contents for Wabtec R-450

  • Page 1 MIO-R45XRDR19061B Rev C R-450 R NSTALLATION OF OTATING AILGEAR IT W ABLE 2019-P 4500/5500 C RESENT HASSIS NSTALLATION AFETY RECAUTIONS If any installation problems are encountered, please call G&B Specialties, Inc. for technical assistance before continuing with the installation process.
  • Page 2 MIO-R45XRDR19061B Rev C AILGEAR 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 R-19061B Rotating Rear Railgear R-18021 Rear Support Bracket R-001...
  • Page 3 MIO-R45XRDR19061B Rev C NSTALLATION OF AILGEAR 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.
  • Page 4 MIO-R45XRDR19061B Rev C 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.
  • Page 5 MIO-R45XRDR19061B Rev C Figure 1 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com...
  • Page 6 MIO-R45XRDR19061B Rev C IGURE G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com...
  • Page 7: Operation

    MIO-R45XRDR19061B Rev C R-450 R PERATION OF OTATING AILGEAR IT W ABLE 2019-P 4500/5500 C RESENT HASSIS PERATION AFETY RECAUTIONS 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.
  • Page 8 MIO-R45XRDR19061B Rev C PERATION OF OTATING AILGEAR 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.
  • Page 9 MIO-R45XRDR19061B Rev C ERVICE OF OTATING AILGEAR 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.
  • Page 10 MIO-R45XRDR19061B Rev C Table 3: Standard Fastener Torque Values Fastener Size Fastener Torque Value (ft-lbs) Dry 1” UNC Gr. 8 Fasteners ¾” UNC Gr. 8 Fasteners ” UNC Gr. 8 Fasteners ½” UNC Gr. 8 Fasteners ” UNC Gr. 8 Fasteners ¼”...
  • Page 11 MIO-R45XRDR19061B Rev C Figure 4 Railgear Lubrication Points G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -11-...
  • Page 12 MIO-R45XRDR19061B Rev C HEEL EARING DJUSTMENT 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.
  • Page 13 MIO-R45XRDR19061B Rev C HEEL DJUSTMENT 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.
  • Page 14 MIO-R45XRDR19061B Rev C Table 4: Rail Wheel Load vs Jack Pressure and Bore Jack Jack Cylinder Bore Diameter (inches) Pressure (PSI) 15/16 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1010 1040 1070 1000 1100 1030 1130 1060 1160...
  • Page 15 MIO-R45XRDR19061B Rev C 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.
  • Page 16 MIO-R45XRDR19061B Rev C AILGEAR LIGNMENT 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.
  • Page 17 MIO-R45XRDR19061B Rev C Figure 5: Railgear Alignment Rack G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -17-...
  • Page 18 MIO-R45XRDR19061B Rev C Figure 6: Railgear Alignment Portable G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -18-...
  • Page 19 MIO-R45XRDR19061B Rev C AILGEAR YSTEM DJUSTMENT ROCEDURE The rear railgear lock system provides a mechanical locking mechanism to hold the railgear axle in the road position. For the system to function properly, the contact surface of the angle plate on the axle and the top surface of the locking pins must have a contact length of approximately 3/4”...
  • Page 20 MIO-R45XRDR19061B Rev C Figure 7 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -20-...
  • Page 21 MIO-R45XRDR19061B Rev C Figure 8 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -21-...
  • Page 22 They are used as go/no go gauges. When placed on rail wheels they will indicate how much wear is still permissible or if the rail wheels need to be replaced. The gauge for the R-450 model railgear can be ordered using the following part number; S-001200 ...
  • Page 23 MIO-R45XRDR19061B Rev C R-450 R ARTS OF OTATING AILGEAR Figure 9 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -23-...
  • Page 24 MIO-R45XRDR19061B Rev C Figure 10 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -24-...
  • Page 25 MIO-R45XRDR19061B Rev C Figure 11 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -25-...
  • Page 26 MIO-R45XRDR19061B Rev C Figure 12 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -26-...
  • Page 27 MIO-R45XRDR19061B Rev C Figure 13 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -27-...
  • Page 28 MIO-R45XRDR19061B Rev C Figure 14 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -28-...
  • Page 29 MIO-R45XRDR19061B Rev C Figure 15 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -29-...
  • Page 30 MIO-R45XRDR19061B Rev C Figure 16 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -30-...
  • Page 31 MIO-R45XRDR19061B Rev C Figure 17 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397 US Field Service: 570-441-6988; CAN Field Service 570-854-0482; www.rafna.com -31-...