Page 1 MIO-R290GM2011 Rev E RAFNA R-290 R AILGEAR 2011 to 2019 GM 2500/3500 Short/Long Bed TANDARD ANUAL ALVES NSTALLATION PERATIONS ERVICE ANUAL 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 2 MIO-R290GM2011 Rev E THIS PAGE INTENTIONALLY LEFT BLANK 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 3: Table Of Contents
MIO-R290GM2011 Rev E ONTENTS SECTION DESCRIPTION 1.0 General Railgear Information ................ 7 Safety Precautions ................7 General Railgear Information ..............9 Placing the Vehicle on Rail – General Info: ..........10 Driving the Vehicle on Rail – General Info: ..........11 Removing the Vehicle from Rail – General Info: ........11 General Service Information ..............12 ...
Page 4 MIO-R290GM2011 Rev E Service of Front/Rear Mounting Kit ............76 4.0 Front & Rear Railgear kit ................77 Installation Safety Precautions ..............77 Railgear Kits ..................78 Installation of Railgear Kit ..............79 Installation of Front Railgear Lever Lock Kit..........83 Operation of Front Railgear Lever Lock Kit ..........84 Lever Lock Adjustment ..............84 ...
Page 5 MIO-R290GM2011 Rev E Electrical System Troubleshooting............. 185 6.0 Steering Wheel Lock Kit ................193 Installation Safety Precautions ............193 Installation of Steering Wheel Lock ............194 Operation Safety Precautions .............. 197 Operating of Steering Wheel Lock ............198 Placing the Vehicle on The Track: ............. 198 Traveling on Rail: ................
Page 6 MIO-R290GM2011 Rev E RAFNA "CUSHION-RIDE" RAILGEAR OPERATION, SERVICE AND PARTS MANUALS & INSTALLATION MANUALS READ THESE MANUALS BEFORE INSTALLING THE RAILGEAR EQUIPMENT AND/OR BEFORE OPERATING THE RAILGEAR EQUIPPED VEHICLE THIS SET OF MANUALS IS FOR RAILGEAR SERIAL NUMBERS: ____________________ & ____________________ G&B Specialties Inc.
Page 7: General Railgear Information
MIO-R290GM2011 Rev E 1.0 G ENERAL AILGEAR NFORMATION AFETY RECAUTIONS If any 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 all manuals completely before attempting operation of ...
Page 8 MIO-R290GM2011 Rev E Following the first 100 km (62 miles) of combined road and rail travel, the  vehicle road wheel and spacer lug nuts should be re-torqued as per the Road Wheels and Tires Kit Operation, Service, and Parts manual if applicable. ...
Page 9: General Railgear Information
MIO-R290GM2011 Rev E ENERAL AILGEAR NFORMATION The RAFNA railgear is a hydraulically operated road-to-rail conversion system. The front and rear railgear are mounted to the vehicle frame and hydraulically raise and lowered via a 12 VDC electric hydraulic pump or an alternative hydraulic pump (e.g. PTO driven pump). During road travel, the front and rear railgear are mechanically locked in the road position.
Page 10: Placing The Vehicle On Rail - General Info
MIO-R290GM2011 Rev E ECHNICAL ERVICE ULLETINS Any changes and/or additional procedures that are issued for this equipment can be found in the G&B Specialties Technical Service Bulletins. These technical service bulletins are available on the RAFNA web site (www. RAFNA.com) as well as from G&B Specialties directly. ENERAL NSTALLATION NFORMATION...
Page 11: Driving The Vehicle On Rail - General Info
MIO-R290GM2011 Rev E 4. Reverse the vehicle until the front railgear rail wheels are aligned with the rails. 5. Deploy the front railgear and front axle lock-up (if applicable) as per the Railgear Kit and Front Axle Lock-up Kit Operation, Service and Parts manuals. 6.
Page 12: General Service Information
MIO-R290GM2011 Rev E ENERAL ERVICE NFORMATION If any technical service issues arise, please contact the G&B Specialties, Inc. Also, please find attached the G&B Specialties Limited Warranty policy and procedures. ENERAL ARTS NFORMATION For general parts orders, please contact the G&B Specialties, Inc. G&B Specialties Inc.
Page 13: G&B Specialties, Inc.limited Warranty
MIO-R290GM2011 Rev E G&B S PECIALTIES IMITED ARRANTY G&B Specialties warranty covers a period of TWELVE (12) months after the date of the railgear’s entry into service. This warranty applies to the Railgear itself, along with the hydraulic pump/motor assembly provided with our R-290 Railgear. The warranty asserts that each new railgear sold will be free from defects in material and workmanship under normal use and service.
Page 14: Warranty Policies And Procedures For Installers And Customers
MIO-R290GM2011 Rev E ARRANTY OLICIES AND ROCEDURES NSTALLERS AND 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.
Page 15: Labor Warranty And /Or Additional Labor Charges
MIO-R290GM2011 Rev E On approval of warranty claim, and where return of parts is requested by G&B Specialties, the Installer or Customer will issue a Purchase Order to G&B Specialties, Inc. to cover the defective parts and out bound freight for part values exceeding $50.00 US and $75.00 CDN. G&B Specialties will in turn ship all required parts pre-paid ground direct to the Installer or Customer.
Page 16: Warranty Claim Form
MIO-R290GM2011 Rev E 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.
Page 17: Technical Service Bulletins
MIO-R290GM2011 Rev E ECHNICAL ERVICE ULLETINS PLEASE READ ALL OF THE FOLLOWING TSB & BULLETINS PRIOR TO INSTALLATION 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-...
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Page 19 MIO-R290GM2011 Rev E TECHNICAL REFERENCE BULLETIN RAFNA RAILGEAR ISSUE DATE: 6/23/14 TRB NUMBER: TRB-062314 HAZARD / URGENCY RATING DANGER - Physical harm is possible if TSB is not observed or followed WARNING - Equipment damage is possible if TSB is not observed or followed CAUTION - Essential issue affecting operation, service, parts or installation INFORMATIONAL - Advisory which may be of interest APPLICABLE EQUIPMENT:...
Page 20 MIO-R290GM2011 Rev E TECHNICAL SERVICE BULLETIN RAFNA RAILGEAR ISSUE DATE: June 17, 2013 TSB NUMBER: TSB-190 HAZARD / URGENCY RATING DANGER - Physical harm is possible if TSB is not observed or followed WARNING - Equipment damage is possible if TSB is not observed or followed CAUTION - Essential issue affecting operation, service, parts or installation INFORMATIONAL - Advisory which may be of interest APPLICABLE EQUIPMENT:...
Page 21 MIO-R290GM2011 Rev E If Axle is out of specification replace with Axle R-2930. If Guide Tube Pin, P/N R-2949 has any wear replace with R290 Axle Repair Kit, P/N R990KIT- Attached to this TSB is a revised copy of G&B Specialties FRA Inspection for R290 Railgear. This revised FRA Inspection form is issued to ensure that the ( RAFNA) G&B Specialties R290 Railgear is inspected and serviced correctly.
Page 22 MIO-R290GM2011 Rev E AREA SUBJECT TO WEAR 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 -22-...
Page 23 MIO-R290GM2011 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 -23-...
Page 24 MIO-R290GM2011 Rev E TECHNICAL SERVICE BULLETIN RAFNA RAILGEAR ISSUE DATE: 6/23/14 TSB NUMBER: TSB-192 HAZARD / URGENCY RATING DANGER - Physical harm is possible if TSB is not observed or followed WARNING - Equipment damage is possible if TSB is not observed or followed CAUTION - Essential issue affecting operation, service, parts or installation INFORMATIONAL - Advisory which may be of interest...
Page 25 MIO-R290GM2011 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 -25-...
Page 26 MIO-R290GM2011 Rev E ALTERNATE INSPECTION METHOD 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: Wheel Kit & Tire Pressure Monitoring System
MIO-R290GM2011 Rev E 2.0 W & T HEEL RESSURE ONITORING YSTEM 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 ...
Page 28: Installation Of Aluminum Wheels, Tpms, Tire Stems, And Tires
MIO-R290GM2011 Rev E , TPMS, T NSTALLATION OF LUMINUM HEELS TEMS IRES The following procedure details the installation of the wheels, tires, and tire pressure sensors required for the vehicle’s tires to ride correctly on the rails and avoid contact with the vehicle.
Page 29 MIO-R290GM2011 Rev E Aluminum Wheel Installation 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-R290GM2011 Rev E REF: TPMS Installation 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-R290GM2011 Rev E Ref: TPMS Installation 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: Installation Of Steel Wheels And Tires
MIO-R290GM2011 Rev E NSTALLATION OF TEEL HEELS AND IRES The following procedure details the installation of the wheels and tires required for the vehicle’s tires to ride correctly on the rails and avoid contact with the vehicle. Wheel And Tire Installation Kit (for 4 or 5 wheel) Part Number Description R-21100...
Page 33 MIO-R290GM2011 Rev E 8. Due to the modified wheel track on the railgear equipped vehicle, both front and rear tire and wheel clearances must be checked. With the wheels and tires turning installed on the vehicle, ensure that the wheels, tires, and/or balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and/or any other component/obstruction throughout the entire range of motion of the steering and suspension.
Page 34 MIO-R290GM2011 Rev E Steel Wheel Installation 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: Installation Of 2011-2016 Tire Pressure Monitoring System
MIO-R290GM2011 Rev E 2011-2016 T NSTALLATION OF RESSURE ONITORING SYSTEM The following procedure details the installation of the tire pressure sensor on the 19.5” steel wheels provided with the RAFNA Railgear equipment. The hardware required for this installation for one sensor and one wheel is listed in table 1. Table 1: Tire Pressure Monitoring Sensor Installation kit Part Number Description...
Page 36: Tire Inflation
MIO-R290GM2011 Rev E Tire Inflation Tires should be inflated to a minimum pressure of 75psi to a maximum of 85psi. This will allow the replacement TPMS to operate within its designed pressure range of +/-15% of inflated pressure before alerting the driver with a pressure warning light. These are only recommended inflation pressures.
Page 37 MIO-R290GM2011 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 -37-...
Page 38 MIO-R290GM2011 Rev E THIS PAGE INTENTIONALLY LEFT BLANK 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-R290GM2011 Rev E Vehicle Capacity Weight & Tire Info Label Part Number Vehicle(s) Language(s) Size (mm) English/French/ 15261447 All GM < 10,000 lbs Spanish/Arabic/ 105 x 43 Chinese •Requirements – FMVSS/CMVSS 110 BEST PRACTICE LINK GS 48/SSA 1438 Tire Pressure Label 109604 NOM-12-SCT2 TREAD Act Example Label...
Page 40: Installation Of 2017, 2018-19 Tire Pressure Monitoring System (Steel Rims)
MIO-R290GM2011 Rev E 2017, 2018-19 T NSTALLATION OF RESSURE ONITORING YSTEM TEEL The following procedure details the installation of the tire pressure sensor on the 19.5” steel wheels provided with the RAFNA Railgear equipment. The hardware required for this installation for one sensor and one wheel is listed in table 1. Table 1: Tire Pressure Monitoring Sensor Installation Kit Part Number Description...
Page 41: Spare Tire
MIO-R290GM2011 Rev E Spare Tire The OEM spare tire does not contain a tire pressure sensor. An extra OEM sensor will be shipped with this kit if ordered. The same installation process should be followed as in the previous section. Tire Inflation Tires should be inflated to a minimum pressure of 75psi to a maximum of 85psi.
Page 42 MIO-R290GM2011 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 -42-...
Page 43 MIO-R290GM2011 Rev E Figure 2 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 -43-...
Page 44 MIO-R290GM2011 Rev E Figure 3 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 -44-...
Page 45 MIO-R290GM2011 Rev E Figure 4 TORQUE TO 12 IN-LBS Figure 5 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 -45-...
Page 46 MIO-R290GM2011 Rev E Figure 6 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 -46-...
Page 47 MIO-R290GM2011 Rev E Vehicle Capacity Weight & Tire Info Label Part Number Vehicle(s) Language(s) Size (mm) English/French/ 15261447 All GM < 10,000 lbs Spanish/Arabic/ 105 x 43 Chinese •Requirements – FMVSS/CMVSS 110 BEST PRACTICE LINK GS 48/SSA 1438 Tire Pressure Label 109604 NOM-12-SCT2 TREAD Act Example Label...
Page 48: Operation Safety Precautions
MIO-R290GM2011 Rev E 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 49: Operation Of Wheel Kit
MIO-R290GM2011 Rev E PERATION OF HEEL With the wheels and tires installed on this vehicle, it may be operated as normal, however caution must be used as the vehicle now has an increased turning. 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 50 MIO-R290GM2011 Rev E THIS PAGE INTENTIONALLY LEFT BLANK 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 -50-...
Page 51: Front & Rear Mounting Kit
MIO-R290GM2011 Rev E 3.0 F & R RONT OUNTING KIT NSTALLATION AFETY RECAUTIONS If any installation problems are encountered, please call G&B Specialties 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 52: Installation Of Front Mounting Kit
MIO-R290GM2011 Rev E NSTALLATION OF RONT OUNTING The following procedure details the installation of the front mounting kit. The hardware required for this installation is listed in table 1. Table 1: Front Mounting Kit Installation Parts Part Number Description R-21090D Front Mounting Bracket, Drivers Side R-21090P Front Mounting Bracket, Passengers Side...
Page 53 MIO-R290GM2011 Rev E 7. Ensure the front mounting plates are tight against the inner side of the frame and the underside of the front frame cross member and that the mounting plate lower surfaces are 0° to the horizontal. Torque the rear and lower 1/2” fasteners, as shown. Do not over torque.
Page 54 MIO-R290GM2011 Rev E FOR 2011-2014 GM HD TRUCKS SHIPPED PRIOR TO 3/01/2014 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 -54-...
Page 55 MIO-R290GM2011 Rev E FOR 2011-2014 GM HD TRUCKS SHIPPED AFTER 3/01/2014 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 -55-...
Page 56 MIO-R290GM2011 Rev E FOR 2015-2019 GM HD TRUCKS 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 -56-...
Page 57 MIO-R290GM2011 Rev E ALL GM HD TRUCKS 2011-2019 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 -57-...
Page 58 MIO-R290GM2011 Rev E FOR 2011-2014 GM HD TRUCKS SHIPPED PRIOR TO 3/01/2014 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 -58-...
Page 59 MIO-R290GM2011 Rev E FOR 2011-2014 GM HD TRUCKS SHIPPED AFTER TO 3/01/2014 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 -59-...
Page 60 MIO-R290GM2011 Rev E FOR 2015-2019 GM HD TRUCKS 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 -60-...
Page 61: Installation Of Rear Mounting Kit
MIO-R290GM2011 Rev E NSTALLATION OF OUNTING The following procedure details the installation of the rear mounting kit. The hardware required for this installation is listed in table 1 for a long bed application, gas or diesel. Use Table 2 for short bed application, gas only. Table 1: Rear Mounting Kit (Long Bed –...
Page 62 MIO-R290GM2011 Rev E Table 2: Rear Mounting Kit (Short Bed – Gas Only) Installation Parts Part Number Description R-21140D Rear Mounting Bracket, Drivers Side R-21140P Rear Mounting Bracket, Passengers Side R-2960 Railgear Mounting Shim – ½” Thick R-2960A Railgear Mounting Shim – 1” Thick R-2631 Railgear Mounting Shim –...
Page 63 MIO-R290GM2011 Rev E 9. Using the supplied M14, M16 & M18 metric hardware, install the tow hitch as shown. The bolts will go thru/attach to the vehicle frame, railgear mounting brackets, OEM bumper bracket and tow hitch. The railgear mounting brackets have slots/holes to allow the mounting bolts to pass thru the brackets and allow the use of the OEM tow hitch mounting locations.
Page 64 MIO-R290GM2011 Rev E Long Bed Application 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 -64-...
Page 65 MIO-R290GM2011 Rev E Long Bed Application 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 -65-...
Page 66 MIO-R290GM2011 Rev E Long Bed Application 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 -66-...
Page 67 MIO-R290GM2011 Rev E Long Bed Application 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 -67-...
Page 68 MIO-R290GM2011 Rev E Long Bed Application 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 -68-...
Page 69 MIO-R290GM2011 Rev E Long Bed Application 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 -69-...
Page 70 MIO-R290GM2011 Rev E Long Bed Application 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 -70-...
Page 71 MIO-R290GM2011 Rev E Short Bed Application 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 -71-...
Page 72 MIO-R290GM2011 Rev E Short Bed Application 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 -72-...
Page 73 MIO-R290GM2011 Rev E Short Bed Application 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 -73-...
Page 74 MIO-R290GM2011 Rev E Short Bed Application 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 -74-...
Page 75: Operation Safety Precautions
MIO-R290GM2011 Rev E 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 76: Operation Of Front/Rear Mounting Kit
MIO-R290GM2011 Rev E PERATION OF RONT OUNTING With the front mounting kit installed on this vehicle, it may be operated as normal, however the front bumper is located further forward than standard. Side wands are located on the front bumper to aid in determining the length and width of the vehicle. Caution must be used when operating the vehicle.
Page 77: Front & Rear Railgear Kit
MIO-R290GM2011 Rev E 4.0 F & R RONT AILGEAR KIT 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 ...
Page 78: Railgear Kits
MIO-R290GM2011 Rev E AILGEAR The following procedure details the installation of the railgear kit. The procedure is identical for both front and rear applications. Table 1: Railgear Kit Installation Parts Part Number Description R-2900A Railgear Assembly (Standard/In-Cab) R-2900B Railgear Assembly (Full In-Cab) R-1600 Rail Wheel Assembly R-21102D...
Page 79: Installation Of Railgear Kit
MIO-R290GM2011 Rev E NSTALLATION OF AILGEAR 1. Ensure that the respective (front or rear) mounting kit has been installed on the vehicle prior to installing the railgear kit. 2. To install the railgear at the correct height, ensure that the road wheels and tires kit has been installed on the vehicle and that the vehicle is resting on its four properly inflated tires.
Page 80 MIO-R290GM2011 Rev E 10. Re-install the vehicle bumper and other components as required. 11. Manually rotate the railgear up to the road position. Take note of if and where the railgear, rail wheels, and/or rail sweeps contact the vehicle bumper and or exhaust. Trim and reinforce the bumper as required.
Page 81 MIO-R290GM2011 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 -81-...
Page 82 MIO-R290GM2011 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 -82-...
Page 83: Installation Of Front Railgear Lever Lock Kit
MIO-R290GM2011 Rev E NSTALLATION OF RONT AILGEAR EVER The following procedure details the installation of the front railgear kit as it pertains to the Front Railgear Lever Actuated Lock. The hardware required for one front installation is listed in table 1. Table 1: Railgear Kit Installation Parts Part Number Description...
Page 84: Operation Of Front Railgear Lever Lock Kit
MIO-R290GM2011 Rev E PERATION OF RONT AILGEAR EVER The front railgear lever lock is designed to automatically lock when the railgear unit is raised to the road position. It is important to ensure the lever lock is adjusted properly and in good working condition.
Page 85: Removing The Vehicle From Rail - To Raise The Railgear
MIO-R290GM2011 Rev E Removing the Vehicle from Rail – To Raise the Railgear: 1. Disengage the lock pin by pulling on the lock lever. Do not force. If the lock pin cannot be disengaged, lower the railgear slightly. (Some railgear models have a lock cam converter installed to prevent the lock pin from engaging in the rail position in which case the lock pin does not need to be disengaged.) 2.
Page 86: Parts Of Front Railgear Lever Lock Kit
MIO-R290GM2011 Rev E ARTS OF RONT AILGEAR EVER 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 -86-...
Page 87 MIO-R290GM2011 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 -87-...
Page 88 MIO-R290GM2011 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 -88-...
Page 89 MIO-R290GM2011 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 -89-...
Page 90: Installation Of Rear Railgear Rod Lock Kit
MIO-R290GM2011 Rev E NSTALLATION OF AILGEAR The following procedure details the installation of the rear railgear kit as it pertains to the Rear Railgear Rod Actuated Lock. The hardware required for one front installation is listed in table 1. Table 1: Railgear Kit Installation Parts Part Number Description R-2900LR...
Page 91: Operation Of Rear Railgear Rod Lock Kit
MIO-R290GM2011 Rev E PERATION OF AILGEAR The rear railgear rod lock is designed to automatically lock when the railgear unit is raised to the road position. It is important to ensure the rod lock is adjusted properly and in good working condition.
Page 92: Parts Of Rear Railgear Rod Kit
MIO-R290GM2011 Rev E ARTS OF 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 -92-...
Page 93 MIO-R290GM2011 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 -93-...
Page 94 MIO-R290GM2011 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 -94-...
Page 95 MIO-R290GM2011 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 -95-...
Page 96: Operation Safety Precautions
MIO-R290GM2011 Rev E 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. Read and understand this manual completely before attempting operation of ...
Page 97: Operation Of Railgear Kit (Standard/In-Cab Controls)
MIO-R290GM2011 Rev E PERATION OF AILGEAR TANDARD ONTROLS 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 98: Operation Of Railgear Kit (Full In-Cab Controls)
MIO-R290GM2011 Rev E PERATION OF AILGEAR ONTROLS 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 99: Service Of Railgear Kit
MIO-R290GM2011 Rev E ERVICE OF AILGEAR The railgear kit must be serviced regularly to avoid damage to the equipment. Table 1 below provides the Recommended Service Schedule and the detailed service procedures follow. Non-standard fastener torque values relative to this railgear are shown in Figure 1. Table 2 provides all other Standard Fastener Torque Values.
Page 100 MIO-R290GM2011 Rev E Figure 1: Non-Standard Fastener Torque Values Figure 2: 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 -100-...
Page 101: Railgear Over-Center Adjustment
MIO-R290GM2011 Rev E AILGEAR ENTER DJUSTMENT The railgear is designed to rotate slightly past vertical into the rail position to provide a secondary safety feature in the event of a hydraulic and / or lock pin failure. With this additional rotation, the railgear would have to lift the vehicle before it could rotate out of the rail position.
Page 102: Rail Wheel Bearing Adjustment
MIO-R290GM2011 Rev E HEEL EARING DJUSTMENT The rail wheel bearings require periodic adjustment to keep the end-play within specification. If the rail wheel bearings are not correctly adjusted, failure may occur and 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 103: Rail Wheel Load Adjustment
MIO-R290GM2011 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 to avoid derailment. Likewise, a minimum amount of load must be maintained on the vehicle wheels to provide traction for acceleration and braking, this load at installation must be a minimum of 450 lbs and a maximum of 750 lbs and is checked as described below using a bottle jack equipped with a gauge.
Page 104: Adjust Each Rail Wheel Load As Follows
MIO-R290GM2011 Rev E Table 3: 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 105 MIO-R290GM2011 Rev E Adjust each rail wheel load as follows: There are two rubber springs on the railgear located between the railgear lower cross frame and each adjustment rod. The adjustment rods are threaded into the railgear axle. The rubber springs support the load between the lower cross frame and the axle while a ¾” Nylock nut on top of each guide tube prevents the axle from separating from the lower cross frame.
Page 106: Railgear Alignment
MIO-R290GM2011 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 107: Wheel Wear Standards And Recommendations
MIO-R290GM2011 Rev E HEEL TANDARDS AND ECOMMENDATIONS At the present time, G&B produces 8”, 10”, 12”, 14”, and 16” steel wheels. Each size has a different flange and tread thickness, which dictates the allowable wear. Although the following numbers are recommended limits, risk of failure is increased when not followed. Rail gauge can be supplied by G&B Specialties for 8”, 10”, 12”, 14”, and 16”...
Page 108: Railgear - Pre-Delivery Check List
MIO-R290GM2011 Rev E R-290 R – P AILGEAR ELIVERY HECK This checklist is provided to help ensure that the railgear is properly installed and adjusted prior to the vehicle being put in service. To register this railgear installation, please fax a completed copy of both this form and the railgear alignment sheet to G&B Specialties, Inc.
Page 109 MIO-R290GM2011 Rev E Electrical Checks Pump and manifold ground wire installed All connections soldered and heat shrink sealed (no crimps) Split loom used to protect all exposed wiring All wires clear of hot / sharp edges and tied back Miscellaneous Checks All welded / heated / bare metal painted Exterior railgear controls operate railgear correctly In-Cab controls operate railgear correctly (ICC and FCC only)
Page 110 MIO-R290GM2011 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 -110-...
Page 111 MIO-R290GM2011 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 -111-...
Page 112: Parts Of Railgear Kit
MIO-R290GM2011 Rev E ARTS OF AILGEAR R-2900A (STD/ICC) 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 -112-...
Page 113 MIO-R290GM2011 Rev E R-2900A (STD/ICC) 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 -113-...
Page 114 MIO-R290GM2011 Rev E R-2900A (STD/ICC) 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 -114-...
Page 115 MIO-R290GM2011 Rev E R-2900D (STD/ICC WITH BRONZE BUSHINGS) 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 -115-...
Page 116 MIO-R290GM2011 Rev E R-2900D (STD/ICC WITH BRONZE BUSHINGS) 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 -116-...
Page 117 MIO-R290GM2011 Rev E R-2900D (STD/ICC WITH BRONZE BUSHINGS) 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 -117-...
Page 118 MIO-R290GM2011 Rev E R-2900B (FICC) 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 -118-...
Page 119 MIO-R290GM2011 Rev E R-2900B (FICC) 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 -119-...
Page 120 MIO-R290GM2011 Rev E R-2900B (FICC) 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 -120-...
Page 121 MIO-R290GM2011 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 -121-...
Page 122 MIO-R290GM2011 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 -122-...
Page 123 MIO-R290GM2011 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 -123-...
Page 124 MIO-R290GM2011 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 -124-...
Page 125 MIO-R290GM2011 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 -125-...
Page 126 MIO-R290GM2011 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 -126-...
Page 127 MIO-R290GM2011 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 -127-...
Page 128 MIO-R290GM2011 Rev E THIS PAGE INTENTIONALLY LEFT BLANK 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 -128-...
Page 129: Hydraulic Kit (Std, Icc, & Manual Valve Controls)
MIO-R290GM2011 Rev E 5.0 H (STD, ICC, & M YDRAULIC ANUAL ALVE ONTROLS NSTALLATION AFETY RECAUTION If any installation problems are encountered, please call G&B Specialties 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 130 MIO-R290GM2011 Rev E  If the emergency hand pump has been used to raise or lower the railgear, ensure the manifold directional valve manual over-rides are in the closed and locked position before starting road or rail travel.  Ensure the hydraulic pump has been de-energized before starting road or rail travel.
Page 131: Installation Of Hydraulic Manifold Steel Box W/ Insulator
MIO-R290GM2011 Rev E NSTALLATION OF YDRAULIC ANIFOLD TEEL OX W NSULATOR The following procedure details the installation of the hydraulic manifold steel box w/insulator spacer. Table 1: Hydraulic Kit Installation Parts Part Number Description R-13124 Pump Manifold Box R-13127 Top Plate R-10540 Manifold Insulator Plate ¼”...
Page 132 MIO-R290GM2011 Rev E 12. Remove the pump assembly with the mounting bracket still attached to the pump. 13. Remove the four bolts on the bottom of the mounting bracket and slide the pump out from the bracket. 14. Remove the remaining four bolts that attach the manifold and the mounting bracket. (Item 6, Fig 5) 15.
Page 133 MIO-R290GM2011 Rev E MANIFOLD HYDRAULIC PUMP HYDRAULIC PUMP & MANIFOLD ARE MOUNTED UNDER THE HOOD IN THE SPARE BATTERY TRAY USING SUPPLIED BRACKETS. Fig 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;...
Page 134 MIO-R290GM2011 Rev E Fig 2 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 -134-...
Page 135 MIO-R290GM2011 Rev E Fig 3 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 -135-...
Page 136 MIO-R290GM2011 Rev E Fig 4 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 -136-...
Page 137 MIO-R290GM2011 Rev E Fig 5 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 -137-...
Page 138 MIO-R290GM2011 Rev E Fig 6 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 -138-...
Page 139: Pump/Manifold Install/Modification Instructions
MIO-R290GM2011 Rev E ANIFOLD NSTALL ODIFICATION NSTRUCTIONS 1. Remove spare battery tray from vehicle. The spare battery tray is located at the front corner of the engine compartment on the driver’s side. Trim battery tray mounting flange as shown. Figure 1 (for 2015 gm only) 2.
Page 140 MIO-R290GM2011 Rev E REMOVE FLANGE AT BEND AS SHOWN Figure 1 (2015-2019 MODEL YEAR) 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 -140-...
Page 141 MIO-R290GM2011 Rev E Figure 2 (2011 TO 2014 MODEL YEAR) 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 -141-...
Page 142 MIO-R290GM2011 Rev E Figure 2A (2015 TO 2019 MODEL YEAR) 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 -142-...
Page 143 MIO-R290GM2011 Rev E Figure 3 (2011 TO 2014 MODEL YEAR) 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 -143-...
Page 144 MIO-R290GM2011 Rev E Figure 3A (2015 TO 2019 MODEL YEAR) 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 -144-...
Page 145 MIO-R290GM2011 Rev E Figure 4 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 -145-...
Page 146 MIO-R290GM2011 Rev E Figure 5 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 -146-...
Page 147 MIO-R290GM2011 Rev E Figure 6 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 -147-...
Page 148 MIO-R290GM2011 Rev E HYDRAULIC PUMP & MANIFOLD MANIFOLD P/N S-003042 HYDRAULIC PUMP P/N S-003041 HYDRAULIC PUMP & MANIFOLD ARE MOUNTED UNDER THE HOOD IN TO THE SPARE BATTERY BOX USING SUPPLIED BRACKETS. 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;...
Page 149: Installation Of Hydraulic Kit
MIO-R290GM2011 Rev E NSTALLATION OF YDRAULIC Installation of Hydraulic Kit (STD) Table 1: Hydraulic Kit Installation Parts Part Number Description R-048B Hydraulic Pump and Manifold CO-106 Dash Switch R-1577 In-Line Fuse Connector R-1577-1 In-Line 5 Amp Fuse R-2965D Pump Shim Plate CO-130G “Railgear Pump”...
Page 150 MIO-R290GM2011 Rev E 1. The pump is shipped with a manifold, a hand pump handle, a solenoid, and a rubber terminal boot. 2. Locate and install the solenoid in a convenient location under the hood near the vehicle’s battery using installer supplied hardware. Ensure that the solenoid’s body is electrically grounded.
Page 151 MIO-R290GM2011 Rev E 17. The pump manifold has two wire harnesses and two wires connected to it: One 4’ wire harness for the front railgear with a control box on the end. b) One 36’ wire harness for the rear railgear with a control box on the end. One white and one black wire each with ring terminals on the ends.
Page 152 MIO-R290GM2011 Rev E 24. Ensure all wires and terminals are soldered, heat shrink sealed, enclosed in protective cable loom and secured with tie-wraps. 25. Ensure all holes in the firewall are sealed and protected with a grommet. 26. Fill the hydraulic system and bleed the air out: Fill the pump tank with DEXRON III (or equivalent) hydraulic fluid.
Page 153 MIO-R290GM2011 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 -153-...
Page 154 MIO-R290GM2011 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 -154-...
Page 155: Installation Of Hydraulic Kit (Icc Controls)
MIO-R290GM2011 Rev E (ICC C NSTALLATION OF YDRAULIC ONTROLS Table 1: Hydraulic Kit Installation Parts Part Number Description R-048 Hydraulic Pump And Manifold R-700 In-Cab Control Panel CO-071 10 Amp Circuit Breaker CO-130N “Front Gear Up” Decal CO-130O “Rear Gear Up” Decal CO-130P “Front Gear Down”...
Page 156 MIO-R290GM2011 Rev E 1. If not already done, install the lock cam converters. Manually rotate both the front and rear railgear until the rail position lock cams are accessible. Position the lock cam converters on the rail position lock cams and weld them in place. Grind the cams smooth. The lock cam converters should prevent the front and rear lock pins from engaging in the rail position.
Page 157 MIO-R290GM2011 Rev E 15. Connect the end of the 360” long hydraulic hose marked “D2” to the D2 port on the rear railgear cylinder check valve. 16. Ensure that none of the hoses contact any sharp edges or hot surfaces. Tie-wrap all hoses securely leaving enough slack for the railgear to function.
Page 158 MIO-R290GM2011 Rev E 23. Route the 36’ wire harness from the pump along the frame to the rear of the vehicle and secure in place with tie-wraps. If necessary, the control box can be removed from and reinstalled on the wire harness to facilitate routing. Fabricate a bracket and mount the rear railgear control box with installer-supplied hardware in a protected vertical position in a suitable location.
Page 159 MIO-R290GM2011 Rev E 33. Lower both front and rear railgear to rail position and ensure the lock cam converters previously installed prevent the lock pins from engaging the lock cams. 34. Locate and store the hand pump handle and the locking cable holding collar in a secure location in the vehicle cab.
Page 160 MIO-R290GM2011 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 -160-...
Page 161 MIO-R290GM2011 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 -161-...
Page 162 MIO-R290GM2011 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 -162-...
Page 163 MIO-R290GM2011 Rev E Lock Cam Converter Install (ICC Controls) 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 -163-...
Page 164: Installation Of Hydraulic Kit (Ficc Controls)
MIO-R290GM2011 Rev E (FICC C NSTALLATION OF YDRAULIC ONTROLS Table 1: Hydraulic Kit Installation Parts Part Number Description R-048 Hydraulic Pump R-2965 Rear Pump Mounting Bracket R-2965B Front Pump Mounting Plate R-2965C Front Manifold Mounting Bracket R-2965D Shim Plate for Hydraulic Pump R-700 In-Cab Control Panel CO-071...
Page 165 MIO-R290GM2011 Rev E 1. The pump is shipped with a manifold, a hand pump handle, a solenoid, and a rubber terminal boot. 2. Locate and install the solenoid in a convenient location under the hood near the vehicle’s battery using installer supplied hardware. Ensure that the solenoid’s body is electrically grounded.
Page 166 MIO-R290GM2011 Rev E 16. Ensure that none of the hoses contact any sharp edges or hot surfaces. Tie-wrap all hoses securely leaving enough slack for the railgear to function. 17. Install the In-Cab Control panel in the cab in a convenient location under the dash. 18.
Page 167 MIO-R290GM2011 Rev E 23. Route the 4’ wire harness from the pump to the front or rear of the vehicle and secure in place with tie-wraps. If necessary, the control box can be removed from and reinstalled on the wire harness to facilitate routing. Fabricate a bracket and mount the front or rear railgear control box with installer-supplied hardware in a protected vertical position in a suitable location.
Page 168 MIO-R290GM2011 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 -168-...
Page 169 MIO-R290GM2011 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 -169-...
Page 170 MIO-R290GM2011 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 -170-...
Page 171: Installation Of Hydraulic Kit With Manual Valves
MIO-R290GM2011 Rev E NSTALLATION OF YDRAULIC IT WITH ANUAL ALVES K-H29RRXS004270 Hydraulic Kit See Pages 178-180 for Parts Part Number Description R-2965B Plate Pump Mounting S-003041 Hydraulic Pump R-31595 Manual Control Valve R-31596 #8 JIC Hydraulic Plug R-31597 Plug, Male Adaptor R-2965 Rear Pump Mounting Bracket CO-106...
Page 172 MIO-R290GM2011 Rev E K-H29RRXS003041 Hydraulic Kit See Pages 175-177 for Parts Part Number Description R-2965B Plate Pump Mounting S-003041 Hydraulic Pump R-2965 Rear Pump Mounting Bracket R-31592 Manual Control Valve R-31590 Toggle Switch R-31591 Boot, Toggle Switch CO-106 Dash Switch R-1577 In-Line Fuse 5 Amp CO-130G...
Page 173 MIO-R290GM2011 Rev E 1. The pump is shipped with a hand pump handle, a solenoid, and a rubber terminal boot. 2. Locate and install the solenoid in a convenient location under the hood near the vehicle’s battery. Ensure that the solenoid’s body is electrically grounded. 3.
Page 174 MIO-R290GM2011 Rev E 14. Fill the hydraulic system and bleed the air out: Fill the pump tank with DEXRON III (or equivalent) hydraulic fluid. b) Operate the front railgear up and down briefly to circulate the fluid and bleed the system of air (refer to the Railgear Kit and Hydraulic Kit Operation, Service, and Parts manuals for operation instructions).
Page 175 MIO-R290GM2011 Rev E Rear Mounted Pump Install – Swap Front Labels with Rear for Front Mounted Pump Install. 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 -175-...
Page 176 MIO-R290GM2011 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 -176-...
Page 177 MIO-R290GM2011 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 -177-...
Page 178 MIO-R290GM2011 Rev E Front Mounted Pump Install – Swap Front Labels with Rear for Rear Mounted Pump Install. 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 -178-...
Page 179 MIO-R290GM2011 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 -179-...
Page 180 MIO-R290GM2011 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 -180-...
Page 181: Operation Safety Precautions
MIO-R290GM2011 Rev E PERATION AFETY RECAUTIONS If any operating, service 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 182: Operation Of Hydraulic Kit
MIO-R290GM2011 Rev E PERATION OF YDRAULIC With the hydraulic kit installed on this vehicle, it may be operated as normal. 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 Railgear Kit Operation, Service and Parts manual for information on the mechanical operation, service and parts of the railgear.
Page 183: Operation Of The Emergency Hand Pump (Locking Manual Valve Only)
MIO-R290GM2011 Rev E 3. Select and open the manual over-ride for the respective railgear and desired direction of movement. 4. Remove the locking cable holding collar from storage. It can be slipped in between the locking cable handle and the locking cable bulkhead fitting to hold the locking cable in the disengaged position.
Page 184: Service Of Hydraulic Kit
MIO-R290GM2011 Rev E ERVICE OF YDRAULIC The hydraulic kit must be serviced regularly to avoid damage to the equipment. The recommended oil for the railgear hydraulic system is DEXRON III or equivalent. In extremely cold weather areas/seasons, Tellus S4 VX32 or equivalent may be used. Table 1: Recommended Service Schedule Service Required Inspect hydraulic kit fasteners (re-torque if required)
Page 185: Electrical System Troubleshooting
MIO-R290GM2011 Rev E Electrical System Troubleshooting The following basic test can be performed to check the integrity of the railgear electrical system. Should the railgear pump fail to operate, first check the fuse or the circuit breaker and all wiring for shorts. Then the following test can be performed to verify the integrity of the pump motor and pump solenoid.
Page 186 MIO-R290GM2011 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 -186-...
Page 187 MIO-R290GM2011 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 -187-...
Page 188 MIO-R290GM2011 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 -188-...
Page 189 MIO-R290GM2011 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 -189-...
Page 190 MIO-R290GM2011 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 -190-...
Page 191 MIO-R290GM2011 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 -191-...
Page 192 MIO-R290GM2011 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 -192-...
Page 193: Steering Wheel Lock Kit
MIO-R290GM2011 Rev E 6.0 S TEERING HEEL 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 ...
Page 194: Installation Of Steering Wheel Lock
MIO-R290GM2011 Rev E NSTALLATION OF TEERING HEEL Steering Wheel Lock Kit Components Part Number Description S-001050 Steering Wheel Lock S-001040 Steering Wheel Lock Decal R-21163 Speed Decal 1. Ensure the front wheels are pointing straight ahead and the steering wheel is centered before installation.
Page 195 MIO-R290GM2011 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 -195-...
Page 196 MIO-R290GM2011 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 -196-...
Page 197: Operation Safety Precautions
MIO-R290GM2011 Rev E 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 198: Operating Of Steering Wheel Lock
MIO-R290GM2011 Rev E PERATING OF TEERING HEEL The following procedure details the steering wheel lock operation. Placing the Vehicle on The Track: Engage the steering wheel lock after both the front and rear railgear are fully deployed and prior to rail travel. b) Turn the steering wheel until the front tires point straight ahead.
Page 199: Railgear Kits/Parts Lists
MIO-R290GM2011 Rev E 7.0 R AILGEAR ARTS ISTS 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 -199-...
Page 200 MIO-R290GM2011 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 -200-...
Page 201 MIO-R290GM2011 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 -201-...
Page 202 MIO-R290GM2011 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 -202-...
Page 203 MIO-R290GM2011 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 -203-...
Page 204 MIO-R290GM2011 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 -204-...
Page 205 MIO-R290GM2011 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 -205-...
Page 206 MIO-R290GM2011 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 -206-...
Page 207 MIO-R290GM2011 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 -207-...
Page 208 MIO-R290GM2011 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 -208-...
Page 209 MIO-R290GM2011 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 -209-...
Page 210 MIO-R290GM2011 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 -210-...
Page 211 MIO-R290GM2011 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 -211-...
Page 212 MIO-R290GM2011 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 -212-...
Page 213 MIO-R290GM2011 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 -213-...
Page 214 MIO-R290GM2011 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 -214-...
Page 215 MIO-R290GM2011 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 -215-...
Page 216 MIO-R290GM2011 Rev E NOTES 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 -216-...

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