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Wabtec R-150 Installation Manual

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Wabtec Components LLC
rd
535 West 3
Street, Berwick, Pa 18603
Tel: (570) 752-5901
Fax: (570) 752-6397
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
Issued May 2022 (Rev C)
Bulletin MI15RRD

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  • Page 1 Wabtec Components LLC 535 West 3 Street, Berwick, Pa 18603 Tel: (570) 752-5901 Fax: (570) 752-6397 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)
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Initial Preparation Section 1 Safety Precautions Installation Procedure Overview Preparations For Railgear Installation Railgear Installation Section 2 Front Railgear Mounting Plate Installation Front Railgear Installation Rear Railgear Mounting Plate Installation Rear Railgear Installation 2-10 Rail Wheel And Rail Sweep Installation 2-12 Front Railgear Bumper And Rail Sweep Arm Installation 2-14...

  • Page 4: Initial Preparation

    1: I ECTION NITIAL REPARATION AFETY RECAUTIONS NSTALLATION ROCEDURE VERVIEW REPARATIONS AILGEAR NSTALLATION G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 5: Safety Precautions

    AFETY RECAUTIONS 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.

  • Page 6: Installation Procedure Overview

    VERVIEW 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.

  • Page 7: Preparations For Railgear Installation

    REPARATIONS AILGEAR NSTALLATION 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.

  • Page 8: Railgear Installation

    2: R ECTION AILGEAR NSTALLATION RONT AILGEAR OUNTING LATE NSTALLATION RONT AILGEAR NSTALLATION AILGEAR OUNTING LATE NSTALLATION 2-10 AILGEAR NSTALLATION 2-12 HEEL WEEP NSTALLATION 2-14 RONT AILGEAR UMPER WEEP NSTALLATION G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 9: Front Railgear Mounting Plate Installation

    RONT AILGEAR OUNTING LATE NSTALLATION 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 R-1783-1 Front Frame Reinforcement Plate R-1783-2 Front Frame Reinforcement Plate R-1800D...
  • Page 10 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 11: Front Railgear Installation

    RONT AILGEAR NSTALLATION 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 R-1790E Rotating Front Railgear ½” UNC Gr. 8 Bolt x 2” Long ½”...
  • Page 12 16-3/8" TO GROUND G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 13: Rear Railgear Mounting Plate Installation

    AILGEAR OUNTING LATE NSTALLATION This section covers the installation of the rear railgear mounting plates. The installation procedure follows for each applicable vehicle model. 1999 – 2007 D ODGE AKOTA The hardware required for this installation is listed in table 2-3. Table 2-3: 1999 –...
  • Page 14 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 15 1999 – 2007 D ODGE URANGO The hardware required for this installation is listed in table 2-4. Table 2-4: 1999 – 2007 Dodge Durango Rear Railgear Mounting Hardware Part Number Description R-1695D Rear Mounting Plate (Left Side) R-1695P Rear Mounting Plate (Right Side) R-1698D Rear Adapter Angle (Left Side) R-1698P...
  • Page 16 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 17: Rear Railgear Installation

    AILGEAR NSTALLATION 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 R-1690D Rotating Rear Railgear R-1794-1 Shim R-1794-2 Shim R-1794-3 Shim R-1725 Handle Holder...
  • Page 18 6. On Durango Models: Using the original Dodge fasteners, re-install the rear bumper and torque the original fasteners to Dodge specifications. " TO GROUND NOTE: DURANGO SHOWN DAKOTA IS SIMILAR G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 19: Rail Wheel And Rail Sweep Installation

    HEEL WEEP NSTALLATION 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 R-1653 8”...
  • Page 20 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 21: Front Railgear Bumper And Rail Sweep Arm Installation

    RONT AILGEAR UMPER WEEP NSTALLATION This section covers the installation of the front railgear bumper and rail sweep arms. The hardware required for this installation is listed in table 2-7. Table 2-7: Front Railgear Bumper And Rail Sweep Arm Installation Hardware Part Number Description R-1722...
  • Page 22 5. Align the holes in the upper ends of the rail sweep arms with the slots in the rail sweep pivot plates. Fasten the rail sweep arms to the pivot plates as shown using two ½” x 2-½” long bolts, eight ½” washers, two ½” jam nuts and two ½” nuts (Item 11). Do not tighten the ½”...

  • Page 23: Auxiliary Installations

    3: A ECTION UXILIARY NSTALLATIONS TEERING HEEL NSTALLATION YDRAULIC YSTEM NSTALLATION LECTRICAL YSTEM NSTALLATION 3-10 AILGEAR DJUSTMENTS 3-13 ELIVERY HECK G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 24: Steering Wheel Lock Installation

    TEERING HEEL NSTALLATION This section covers the installation of the steering wheel lock. The hardware required for this installation is listed in table 3-1. Table 3-1: Steering Wheel Lock Installation Hardware Part Number Description R-1623A Steering Wheel Lock Retainer R-1623C Steering Wheel Lock Steering Wheel Lock Decal ...
  • Page 25 FIGURE 3-1: STEERING WHEEL LOCK G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...

  • Page 26: Hydraulic System Installation

    YDRAULIC YSTEM NSTALLATION This section covers the installation of the pump and hoses. The hardware required for this installation is listed in table 3-2. Table 3-2: Hydraulic System Installation Hardware Part Number Description R-060 Pump ” Male O-Ring Boss to ¼” Male JIC Straight Fitting ¼”...
  • Page 27 The following procedure details the hydraulic hose installation (refer to figure 3-3 or refer to the Operating, Service and Parts manual for more detailed hydraulic schematics): IMPORTANT:  When routing hydraulic hoses, ensure that the hoses do not contact any sharp edges or hot surfaces.
  • Page 28 3. Connect one 243” long hydraulic hose (straight & 90° ends) to the upper A port on the pump and mark the other end of this hose as A. The 90° hose end should be at the pump port. 4. Connect another 243” long hydraulic hose (straight & 90° ends) to the upper B port on the pump and mark the other end of this hose as B.

  • Page 29: Electrical System Installation

    LECTRICAL YSTEM NSTALLATION This section covers the installation of the electrical system. The hardware required for this installation is listed in table 3-3. Table 3-3: Electrical System Installation Hardware Part Number Description R-1567 Dash Switch R-1577 5 Amp In-Line Fuse Not Supplied 14 Gauge Stranded Copper Wire As Req’d...
  • Page 30 d) Connect another black wire from the dash switch power terminal through the firewall to the in-line fuse. e) Connect a ground wire from the dash switch ground terminal to a suitable ground location on the vehicle. 4. Using suitable 4 gauge wire, cable loom, connectors, solder and heat shrink tubing: a) Connect one wire from the vehicle’s battery to the power terminal on the railgear pump solenoid.
  • Page 31 FIGURE 3-4: ELECTRIC SYSTEM INSTALLATION REAR CONTROL BOX FRONT CONTROL BOX PUMP DASH SWITCH 3 FT CABLE 35 FT CABLE BLACK WHITE BLACK 5 AMP FUSE WHITE WHITE SOLENOID MOTOR TANK BATTERY ROCKER SWITCH CONFIGURATIONS (VIEWED FROM REAR OF ROCKER SWITCHES) RAISE NEUTRAL LOWER...

  • Page 32: Railgear Set-Up And Adjustments

    AILGEAR DJUSTMENTS This section covers the railgear set-up and adjustments required before the vehicle can be put in service. Read the entire Operating, Service and Parts Manual before operating the railgear equipped vehicle. 1. Manually rotate the front railgear up to the highway position. Take note of if and where the railgear contacts the front bumper (refer to figure 3-5) and trim accordingly.
  • Page 33 FIGURE 3-6: DAKOTA REAR FENDER MODIFICATION TRIM HERE FIGURE 3-7: DURANGO REAR BUMPER TRIMMING TRIM HERE G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 34 3. Re-install the tail pipe section of the exhaust. Take note of if and where the railgear contacts the exhaust and modify accordingly. Ensure that any modifications to the exhaust conform to applicable laws and regulations. 4. Fill the hydraulic system and bleed the air out: a) Fill the pump tank with ESSO Univis N-22 (or equivalent) hydraulic fluid.
  • Page 35 ELIVERY HECK RAFNA R-150 HD PRE-DELIVERY CHECK LIST Railgear Serial #: Vehicle Year: Model: Vehicle Make: Date Received: Vehicle Model: Date Completed: Vehicle V.I.N. : Installation By: Inspection By: Check List Item Approved/Value Remarks Hydraulic pump attached properly Hydraulic system bled of air Railgear pump relief set at 1800 PSI Split loom used on all exposed hyd.
  • Page 36 RAFNA R-150 HD PREDELIVERY CHECK LIST Railgear Serial #: Vehicle Year: Model: Vehicle Make: Date Received: Vehicle Model: Date Completed: Vehicle V.I.N. : Installation By: Inspection By: Check List Item Approved/Value Remarks Steering wheel lock system installed Bumpers installed level with body...

  • Page 37: Appendix

    4: A ECTION PPENDIX G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 38 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 39 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 40 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 41 Wabtec Components LLC 535 West 3 Street, Berwick, Pa 18603 Tel: (570) 752-5901 Fax: (570) 752-6397 MODEL R-150 "CUSHION-RIDE" RAILGEAR OPERATING, SERVICE AND PARTS MANUAL "ROTATING FRONT - ROTATING REAR” READ THIS MANUAL BEFORE OPERATING RAILGEAR EQUIPPED VEHICLE Application Models: 1999 - 2002 Dodge Dakota (All Models)
  • Page 42 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.
  • Page 43 TABLE OF CONTENTS General Information Section 1 Safety Information Description Warranty Warranty Claim Form Serial Numbers Specifications Operation Section 2 Inspections Before Operation Placing The Vehicle On Rail Travelling On Rail Braking On Rail Removing The Vehicle From Rail Service Section 3 Rail Wheel Bearing Adjustment Rail Wheel Load Adjustment...
  • Page 44 1: G ECTION ENERAL NFORMATION AFETY NFORMATION ESCRIPTION ARRANTY ARRANTY LAIM ERIAL UMBERS PECIFICATIONS G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 45 AFETY NFORMATION WARNING:  Read this manual completely before attempting operation of the railgear equipped vehicle.  Before any maintenance or adjustments are performed under the vehicle or railgear, ensure the vehicle engine is turned off and the parking brake is set. ...
  • Page 46 This manual covers the operation, service and parts of the Rafna Industries rotating front and rotating rear R-150 railgear as applicable to multiple vehicles. If necessary, any difference in operation, service or parts for specific vehicle and/or railgear models is clearly detailed by separate instructions for each.
  • Page 47 ARRANTY Rafna Industries Ltd., Limited Warranty Rafna Industries’ warranty covers a period of TWELVE (12) months after the date of the railgear’s entry into service. The warranty asserts that each new railgear sold will be free from defects in material and workmanship under normal use and service.
  • Page 48 ARRANTY OLICIES ROCEDURES NSTALLERS USTOMERS Installers & Customer Warranty: To prevent unnecessary delays or misunderstandings in handling Installers’ or Customers’ warranty claims, it is required that all warranty requests be authorized prior to any repairs, modifications or adjustments being started. Warranty information and authorization can be obtained from Rafna Industries - Engineering Manager or Customer Service Manager who can be contacted at 1-888-525- 3660.
  • Page 49 On approval of warranty claim, and where return of parts is requested by Rafna, the Installer or Customer will issue a Purchase Order to Rafna Industries Ltd. to cover the defective parts and out bound freight for part values exceeding $50.00 US and $75.00 CDN.
  • Page 50 ARRANTY LAIM This form must be completed prior to starting any warranty work Warranty # Customer Date Tel/Fax Railgear S/N Vehicle No. Vehicle VIN End User Date of Purchase P.O. Number Ref # Inv. Address Ship to Address Inv. Address Ship to Address Inv.
  • Page 51 ERIAL UMBERS Following receipt of this manual, the serial numbers, model numbers and date of manufacture for both the front and rear railgear should be recorded below for future reference. This information is located on the identification plate (figure 1-2) mounted on each railgear.
  • Page 52 PECIFICATIONS Item Metric Installed Weight…...……………………………………... 249 Kg 550 lbs Maximum Gross Vehicle Weight Rating (GVWR)…..…. 2,948 Kg 6,500 lbs Track Gauge……………………………………………... 1,435 mm 56-½ in Wheel Diameter………………………………………….. 203 mm 8 in G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 53 2: O ECTION PERATION NSPECTIONS EFORE PERATION LACING EHICLE RAVELLING RAKING EMOVING EHICLE G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 54 NSPECTIONS EFORE PERATION Prior to each use of the railgear equipment, the following items should be inspected:  Check for damaged or worn parts  Check for loose wheels and/or fasteners  Check for leaking or damaged hydraulic lines, fittings, and cylinders ...
  • Page 55 LACING EHICLE WARNING:  Operating instructions provided below only address the Rafna Industries railgear equipment. Applicable railway company procedures and policies must be adhered to.  At level rail crossings, ensure that no other vehicles are approaching and flag the crossing to ensure safety. This vehicle will not activate crossing signals.
  • Page 56 g) Ensure that the rear railgear is properly deployed and that the lock pin is completely engaged before proceeding. WARNING: While the railgear is taking some of the vehicle’s load, the railgear suspension (Item 5) should be observed compressing. With the vehicle unloaded, the bolt heads (Item 6) should be about ¾”...
  • Page 57 d) Disengage the lock pin (Item 2) by pulling the locking handle (Item 3). Do not force the handle. Raise the railgear further by selecting “Up” on the front control box if necessary. Hold the locking handle in the disengaged position. e) Lower the railgear by selecting “Down”...
  • Page 58 7. De-energize the pump by turning off the respective dash switch. 8. Engage the steering wheel lock: (refer to figure 2-3) a) Turn the steering wheel (Item 1) until the front tires point straight ahead. b) Pass the steering lock (Item 2) over the air bag / horn cover and onto the steering column lock retainer (Item 3).
  • Page 59 RAVELLING Before proceeding to travel on rail, ensure that the railgear lock pins are fully engaged, that the steering wheel lock has been installed with the front wheels pointing straight ahead, and that the pump has been de-energized. WARNING:  Railway company rules governing rail travel must be observed at all times.
  • Page 60 EMOVING EHICLE WARNING:  Operating instructions provided below only address the Rafna Industries railgear equipment. Applicable railway company procedures and policies must be adhered to.  At level rail crossings, ensure that no other vehicles are approaching and flag the crossing to ensure safety. This vehicle will not operate crossing signals.
  • Page 61 6. Raise the rear railgear: (refer to figure 2-1) a) Lower the railgear off the lock pin by selecting “Down” on the rear control box (Item 1). b) Disengage the lock pin (Item 2) by pulling the locking handle (Item 3). Do not force the handle.
  • Page 62 3: S ECTION ERVICE HEEL EARING DJUSTMENT HEEL DJUSTMENT AILGEAR LIGNMENT 3-15 OUTINE AILGEAR ERVICE 3-20 YDRAULIC YSTEM ELIEF ALVE ETTING 3-22 LECTRICAL YSTEM ROUBLESHOOTING G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 63 HEEL EARING DJUSTMENT The rail wheel bearings require periodic adjustment in order to keep the endplay within specification. If the rail wheel bearings are not correctly adjusted, failure may occur and will not be covered under the Rafna Industries Warranty. The following procedure details the adjustment of the rail wheel bearings (refer to figure 3-1): WARNING:...
  • Page 64 If a torque wrench is not available, the following procedure may be substituted for steps 6. b) through 6. d) above: b) Tighten the spindle nut until the wheel cannot be turned by hand. c) Loosen the spindle nut until the wheel can be turned by hand. d) Re-adjust when torque wrench is available.
  • Page 65 HEEL DJUSTMENT The percentage of the vehicle load carried by the railgear must be properly adjusted to ensure sufficient traction and guidance while avoiding overloading the railgear. The load on the rail wheels is an indicator of the amount of load carried by the railgear and is adjusted as described below using a hydraulic bottle jack equipped with a gauge.
  • Page 66 Table 3-2: Rail wheel Load vs Jack Pressure and Bore Jack Pressure Jack Cylinder Bore diameter (in) (psi) 15/16 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1010 1020 1040 1050 1070 1080 1000 1100 1010 1110 1030 1130...
  • Page 67 FIGURE 3-2: RAIL WHEEL PRESSURE MEASUREMENT 7. Compare the rail wheel load reading to the specifications in table 3-3. Table 3-3: Rail Wheel Load Specifications Minimum Maximum Rail Wheel Load 350 lbs 400 lbs 8. If the load on the rail wheels are not within the specifications, proceed to adjust as follows.
  • Page 68 h) Lower the railgear to the rail position. The upper lock nut should be about ¾” above the upper spring plate. i) Adjust the rail sweep arm in the slot on the rail sweep pivot plate so that the rail sweep is vertical when the railgear is in the rail position.
  • Page 69 h) Lower the railgear to the rail position. The upper lock nut should be about ¾” – 1” above the upper spring plate. 11. Remove the vehicle from rail. WARNING:  The rail wheels should be a minimum of 5-½” above the ground when in the highway position.
  • Page 70 AILGEAR LIGNMENT The Rafna railgear must be correctly aligned in order to perform properly, safely, and avoid excessive wear. All four rail wheels can be independently aligned while lateral adjustment of the front and rear railgear is accomplished through adjusting the railgear on the mounting plates.
  • Page 71 5. Set up the parallel string line system (refer to figure 3-6): a) Fasten the alignment bars to the head of the rail about 2’ ahead of and behind the vehicle. Ensure that the alignment bars are perpendicular to the rail and can be slid side to side for adjustment.
  • Page 72 FIG 3-6: RAILGEAR ALIGNMENT MEASUREMENTS ALIGNMENT MEASUREMENTS Truck Model Truck Number Rail Gear S/N A,B,C,D Must be Equal within 1/16". E,F,G,H Must be Equal within 1/16". (A,B,C,D May not be Equal to E,F,G,H). I and J Must be Equal within 1/16" K and L Must be Equal within 1/16"...
  • Page 73 6. Rail wheel alignment (refer to figure 3-6 and 3-7): a) Secure an 18” long straightedge to the backside of each rail wheel flange. b) Measure the distance between the front-most and rear-most points of each straightedge and the parallel lines (dimensions I, J, K, and L in the front and M, N, O, and P in the rear).
  • Page 74 WARNING:  When adjusting the lateral alignment of the front and rear railgear, do not use any force against the suspension guide tube assemblies. This may cause damage which would restrict the suspension movement of the railgear. 7. Front railgear lateral alignment (refer to figure 3-6 and 3-8): a) With a straightedge secured to the backside of each front rail wheel flange, measure the distance from the front-most and rear-most points of the two straightedges to the parallel lines (dimensions I, J, K, and L).
  • Page 75 8. Rear railgear lateral alignment (refer to figure 3-6 and 3-9): a) With a straightedge secured to the back side of each rear rail wheel flange, measure the distance from the front-most and rear-most points of the two straightedges to the parallel lines (dimensions M,N,O and P). b) Dimensions M and P should be equal to within 1/8”.
  • Page 76 OUTINE AILGEAR ERVICE The railgear must be serviced to ensure proper operation and avoid damage to the equipment. Refer to table 3-4 for the Recommended Service Schedule. Grease fittings are provided at all lubrication points on the Rafna railgear (refer to figures 3-10 and 3-11).
  • Page 77 Table 3-4: Recommended Service Schedule Service Required      Visually inspect the railgear prior to use for damaged or worn parts.      Check for loose rail wheels and fasteners.     ...
  • Page 78 FIGURE 3-10: FRONT RAILGEAR LUBRICATION POINTS VIEWED FROM REAR GREASE MONTHLY TYP. BOTH SIDES GREASE EVERY 3 MONTHS OR GREASE 3000 RAIL KM. MONTHLY TYP. BOTH SIDES TYP. BOTH SIDES FIGURE 3-11: REAR RAILGEAR LUBRICATION POINTS GREASE MONTHLY GREASE MONTHLY TYP.
  • Page 79 FIGURE 3-12: FRONT RAILGEAR NON-STANDARD BOLT TORQUES VIEWED FROM REAR CYLINDER ROD PIVOT SNUG DO NOT TORQUE UPPER SUSPENSION NUT SNUG - DO NOT PRECOMPRESS SPRING BEARING CAP 40 FT-LBS FIGURE 3-13: REAR RAILGEAR NON-STANDARD BOLT TORQUES BEARING CAP 40 FT-LBS CYLINDER ROD PIVOT SNUG DO NOT TORQUE G&B Specialties Inc.
  • Page 80 Table 3-5: Standard Bolt Torque Values Bolt Detail Bolt Torque Value (ft-lbs) ¾” UNC Gr. 8 Fasteners 5/8” UNC Gr. 8 Fasteners ½” UNC Gr. 8 Fasteners 3/8” UNC Gr. 8 Fasteners ¼” UNC Gr. 8 Fasteners G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 81 YDRAULIC YSTEM ELIEF ALVE ETTING This system is equipped with one relief valve located on the railgear pump. The relief valve will require adjustment at installation and if ever there appears to be inadequate hydraulic pressure to operate the railgear. Refer to figure 3-14 throughout the following adjustment procedure.
  • Page 82 FIGURE 3-14: HYDRAULIC SYSTEM RELIEF VALVE SETTING TANK PUMP FRONT REAR RAILGEAR RAILGEAR G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 83 LECTRICAL YSTEM ROUBLESHOOTING The following basic tests can be performed to check the integrity of the railgear electrical system. Refer to the electrical schematic in figure 3-15. Should the railgear pump fail to operate, first check the fuse or the circuit breaker and all wiring for shorts.
  • Page 84 d) The pump motor should run upon touching the shunt wire. e) If the pump does not run, the pump motor is defective. Should the pump motor start running immediately following turning on the respective dash switch, all wiring should be checked for shorts and the following should be performed.
  • Page 85 4: P ECTION ARTS OTATING RONT AILGEAR OWER SSEMBLY OTATING RONT AILGEAR PPER SSEMBLY OTATING RONT AILGEAR SSEMBLY OTATING RONT AILGEAR OUNTING SSEMBLY OTATING AILGEAR PPER SSEMBLY OTATING AILGEAR OWER SSEMBLY OTATING AILGEAR SSEMBLY OTATING AILGEAR AKOTA OUNTING SSEMBLY 4-10 OTATING AILGEAR URANGO...
  • Page 86 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 87 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 88 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 89 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 90 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 91 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 92 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 93 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 94 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 95 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 96 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 97 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 98 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
  • Page 99 G&B Specialties Inc. 535 West 3 Street, Berwick, PA, USA Tel: 1-570-752-5901 Fax: (570) 752-639...
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