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Wabtec R-450 Installation Manual

Rotating rear railgear kit ford f-450/550 all models
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I
NSTALLATION OF
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 en-
gine 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 Ax-
le 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
Ford F-450/550 All Models
P
RECAUTIONS
rd
Street, Berwick, PA, USA Tel: (570) 752-5901 Fax: (570) 752-6397
-1-
MIO-R45XRFR4836 Rev E
R
R
K
EAR
AILGEAR
IT

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Summary of Contents for Wabtec R-450

  • Page 1 MIO-R45XRFR4836 Rev E R-450 R NSTALLATION OF OTATING AILGEAR Ford F-450/550 All Models NSTALLATION AFETY RECAUTIONS 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.
  • Page 2 AILGEAR The following procedure details the installation of the rear railgear kit. The hardware re- quired for the different kits are listed in the tables below. Table 1: K-R45XRFR4836CBL (R-450 Rotating Rear Railgear with Cable Actuated Lock-up) Part Number Description...
  • Page 3 The type of rear lock-up installed on this unit has no effect on installation. The installation procedure below is typical for all R-450 Rotating Rear Units. 1. To install the railgear at the correct height, ensure that the road wheels and tires have been installed on the vehicle and that the vehicle is resting on its properly inflated tires.
  • Page 4 14. Torque all fasteners as detailed in the R-450 Rotating Rear Railgear Kit Operation, Service and Parts manual. 15. Grease the railgear at all lubrication points as detailed in the R-450 Rotating Rear Railgear Kit Operation, Service and Parts manual.
  • Page 5 MIO-R45XRFR4836 Rev E 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-R45XRFR4836 Rev E ABLE NSTALLATION ROCEDURE For units equipped with a cable lock-up mechanism, use the following steps to install lock-up: 1. Remove lock-up cover. 2. Install the rear lock cable to the locking system by fastening the end of the cable through the cable support, then thru the pipe on the locking cable bar at the center of the railgear lock system as shown.
  • Page 7 MIO-R45XRFR4836 Rev E EVER NSTALLATION ROCEDURE For units equipped with a lever lock-up mechanism, use the following steps to install lock-up: Table 1: K-R45XXRX4836 (R-450 Rotating Rear Manual Lever Lockup Kit) Part Number Description R-4837B Axle Lockup Assembly (Assembled on Railgear)
  • Page 8 MIO-R45XRFR4836 Rev E 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 9 MIO-R45XRFR4836 Rev E R-450 R PERATION OF OTATING AILGEAR Ford F-450/550 All Models PERATION AFETY RECAUTIONS If any operating, services, or parts problems are encountered, please call G&B Special- ties, Inc. for technical assistance.  Failure to heed to any of the following warnings could result in severe bodily injury and/or equipment damage.
  • Page 10 MIO-R45XRFR4836 Rev E 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 11 MIO-R45XRFR4836 Rev E ERVICE OF OTATING AILGEAR The railgear kit must be serviced regularly to avoid damage to the equipment. Table 3 below provides the Recommended Service Schedule and the detailed service procedures follow. Figure 3 provides the Non-Standard Fastener Torque Values. Table 4 provides Standard Fas- tener Torque Values for all other fasteners.
  • Page 12 MIO-R45XRFR4836 Rev E Table 4: 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 13 MIO-R45XRFR4836 Rev E 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 -13-...
  • Page 14 MIO-R45XRFR4836 Rev E 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 15 MIO-R45XRFR4836 Rev E 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 16 MIO-R45XRFR4836 Rev E Table 5: Rail Wheel Load vs Jack Pressure and Bore Jack Pressure Jack Cylinder Bore Diameter (inches) (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 17 MIO-R45XRFR4836 Rev E 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 18 MIO-R45XRFR4836 Rev E Table 5: 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 19 MIO-R45XRFR4836 Rev E 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 20 MIO-R45XRFR4836 Rev E 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 -20-...
  • Page 21 MIO-R45XRFR4836 Rev E 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 -21-...
  • Page 22 MIO-R45XRFR4836 Rev E AILGEAR YSTEM DJUSTMENT ROCEDURE The rear lock-up adjustment procedure is the same for all rear lock-up types. 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 23 MIO-R45XRFR4836 Rev E 14. Repeat the above steps as necessary. 15. Tighten two outside 3/8” fasteners that secure the lock-up plate to the lock-up support. 16. Torque the 3/8” fasteners to 40 ft-lbs dry. Do not over torque. Note The rear railgear unit should be shipped with the lock-up assembly installed upside down (cover towards the ground).
  • Page 24 MIO-R45XRFR4836 Rev E 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 -24-...
  • Page 25 MIO-R45XRFR4836 Rev E 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 -25-...
  • Page 26 MIO-R45XRFR4836 Rev E 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 -26-...
  • Page 27 Below is recommended service schedule that should be followed to help ensure the proper operation of the rear lock-up system. Recommended Service Schedule – R-450 Rotating Rear Railgear ESCRIPTION 1. Visually inspect the rear lock-up system, prior to use, for damaged ...
  • Page 28 MIO-R45XRFR4836 Rev E 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-R45XRFR4836 Rev E R-450 R ARTS OF OTATING AILGEAR 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-R45XRFR4836 Rev E 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-R45XRFR4836 Rev E 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-...
  • Page 32 MIO-R45XRFR4836 Rev E 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 -32-...
  • Page 33 MIO-R45XRFR4836 Rev E 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 -33-...
  • Page 34 MIO-R45XRFR4836 Rev E 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 -34-...
  • Page 35 MIO-R45XRFR4836 Rev E 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 -35-...
  • Page 36 MIO-R45XRFR4836 Rev E 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 -36-...
  • Page 37 MIO-R45XRFR4836 Rev E 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 -37-...
  • Page 38 MIO-R45XRFR4836 Rev E 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 -38-...
  • Page 39 MIO-R45XRFR4836 Rev E 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 -39-...
  • Page 40 MIO-R45XRFR4836 Rev E 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 -40-...

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