RAFNA INDUSTRIES LIMITED - Rafna Industries – G & B Specialties
Contents
1. S133HA 4934 INOJ 17 SSIALSNGNI 9 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 11 APPENDIX U U C U U TT LEE S ddy ____ aj MS aw 24 er 0138430 TINA 9 ces JJdJoE ppp ua Grads LON XEnd 2015 mupani 16044 amp 157 157 7192 3158 33913 00661 111 5 5 T33HM T33HM 1 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 12 APPENDIX 01 9 8520 9AU L 1 1 37 25 ATW3S5SV SNILNNOW LNOMJ M3dVd NO 21 26 TIN LON 3LON 3ND Q3LIA 1 S3IHLSOQNI 001 Bi35N 8 9 B AD W E o e 2 X 1108 8 6 zi 2 x 2 1 g INN 33SN NOUN 9 27 72 2 59 X 108 8 1 2 1 s __ __2. 5133 LNO H3 N3HM AINO 133HM 9 539315 3301 Industries Limited Page 1012 A Global Railway Industries Company MO25RRG 0 MA04 MANUAL ADDENDUM MO25RRG 0 MA04 Date May 18 2003 Affected Manual Railgear Railgear Model R 250 Manual MO25RRG Rev 0 Affected Page s Additional Operating Procedure and Parts Drawing Addendum Information This addendum updates the Operation Parts and Service Manual to include the parts drawing of the GKN road wheels for 2003 GMC Suburban trucks Please add the following drawing to the Operating Service and Parts manual and refer to this drawing for quantities required for installation and part numbers when ordering spare parts Page 2012 imited Industries L 25 0 04 Global Railway Industries Company V6 9uHHScOW 13S S3HONI 2002 81 AVIN 31VG s Nvaunans 2 6002 A18W3SSV NOILVOISIGOW NOILdINOS3d 6 18 aiv 00661 1411 6 5 VNAVY lt 310IH3A 587 LH9I3M 12 S31ON 9NIHNLOYANNYN 4093 LNOYS 3H L NO 15 STASHM 1 NMOHS LON SH3N31SV3 S IH3HM
3. 100 8 oL O e 2091395 6 TO 80078 00 1 33HA 13315 020 8 2 z anO snos Qvi 10 9 2 9 99 5 6 1 M3HSv 0311055 708 Z LNN 0314075 v c 90 8 1 133599 0 9 z dvo 1 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 7 APPENDIX L UL 21 26 G3AOMHddV NAVMO 10 91 3Lva V e3sDvz Y 4 052 5 32 383334 5 93345 NO 31 26 TINS LON ALON QALINIT 531815 z 5 z Pod GS as 1 2 1 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 oo m Z owsszon 0 13994 gt 10 91 AW E E DSZ 184355 X201 T33HM 9 03315 3491410634 M3dVd 21926 LON AND 1V3HLNON 3 344165 4 2 25 2 lt Issued July 2001 9 01 509 X MIS 1 3135 01 ON z 1 35 NOUNS 11 11 3L
4. IWVHVHO IHVT1O 00861 14117 SSIYLSNGNI VNAVY NOISIA3H 310IH3A 587 LH9I3M QON k 57 Z S mon 1 S31ON LNOYS JHL NO V S STASHM ALIHV IO HOA NMOHS LON SH3N3LSVJ IVOLLNACI S 33HM HV3H 37709 9 WALI __ lt pp __ lt __ L 9 28 1j AT8IN3SSV ALO GanddAS LON 38156 6 WO3d sgrid 09 1nN 8 0100 5 8 195340 9 6 5 2 2 GNIS 9 15 133HM LNOYS s LAN 901 4 1 06 3908 4015 1 195330 2 1 d30VdS 133HM 1 4 2 143 9 561 NOILLdIHOS3G ON Lud 1611 81 VS10100 S Nid VNAVH Add 81 071 ANOYOL LNN T33HA S I33HM LNOYS 31995 WALI Industries Limited A Global Railway Industries Company MO25RRG 0 MA03 Page 1 of 3 MANUAL ADDENDUM MO25RRG 0 MAOS Rev 1 Date May 14 2003 Affected Manual Railgear Railgear Model 250 Manual MO25RRG Rev 0 Affected Page s Additional Operating Procedure and Parts Drawing Addendum Information This addendum updates the Operation Parts
5. INDUSTRIES LIMITED 19300 Clark Graham Baie d Urfe Quebec Tel 514 457 4373 or 1 888 525 3660 Fax 514 457 3567 MODEL R 250 HD CUSHION RIDE RAILGEAR OPERATING SERVICE AND PARTS MANUAL ROTATING FRONT ROTATING REAR READ THIS MANUAL BEFORE OPERATING RAILGEAR EQUIPPED VEHICLE Railgear Model CR 250HD 055 Application Models 2001 GMC 2500HD AII Models 25 HD Issued July 2001 Bulletin MO25RRG Issued July 2001 Bulletin MO25RRG 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 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG TABLE OF CONTENTS General Information Section 1 Safety Information 1 2 Description 1 3 Warranty 1 4 Serial Numbers 1 8 Specifications 1 9 Operation Section 2 Inspections Before Operation 2 2 Placing Vehicle On The Track 2 3 Travelling On Rail 2 7 Braking On Rail 2 7 Removing Vehicle From The Track 2 8 Service Section 3 Railgear Alignment 3 2 Rail Wheel Bearing Adjustment 3 7 Rail Wheel Load Adjustment 3 9 Routine Railgear Service 3 12 Hydraulic System Relief Valve Setting 3 17 Electrical System Trou
6. MAY 2 o c LL g 5 E OF VEHICLE Bulletin MO25RRG 5 3 MONTREAL QUE ROTATING FRONT RAILCEAR LOCK ASSEMBLY NOTE NOT FULL SCALE ON PAPER RAFNA INDUSTRIES LIMITED DESCRIPTION PART DESCRIPTION PARTS LIST 2 16 SAE LARGE OD WASHER PIN EXTENSION 3 8 LINE JAM NUT Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 30 1 19 4 30 19 4 TETEN ____5 AD ter NAVSO TOES ET SSS i 052 4 39N2R13339 5 uio vu uv 9NLVLOS NOILdRIOS3Q 0 LON Iv381NON TALINN 5 5 5 4 Bulletin MO25RRG APPENDIX Issued July 2001 804 LON ATGNSSSY dN X901 ONV 5 SH3NLSVJ WWOUNSO 2 12 3LON WQ TS 165 ANNI 3 5 1H 306 1898 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 5 5 p 9HUScON 30 39 4 21 06 Twas SNMVNO SSHONI 10 91 31VQ 8 1 4 LVN 5 dN 9901 ONUVLON 30 31 25 TINS LON 3LON 300 IV3HLNONW S3IMISPQONI Bulletin MO25RRG APPENDIX Issued J
7. 37705 9 WALI 10 56 6 79934 881 413 09 vstoloo s 8 195330 6 vezseu qnis 26041 9 5 508 s 1NN 4 1 06 82068 4015 NINYNL 1 4 135440 2 1 5 1 4 z TaSHM OX G6r soa NOILdIHOSAG LYVd 1HVd 151 51 151010055 Nid 87 1 07 ANOYOL LAN S IH3HM LNOYS 91495 S Wall WALI Industries Limited A Global Railway Industries Company Form MA 0 ADDENDUM TO OPERATING PARTS amp SERVICE MANUAL 25 0 November 9 2001 Affected Manual Railgear Railgear Model R 250HD VF RF RR Manual Affected Page s Addendum Information The Rafna Rubber covered wheel replaces the Rafna steel wheels Both the steel wheels and the rubber covered wheels can be used interchangeably on the railgear with minor work and an alignment Adjust wheel pressures in accordance with the following instructions Note Railwheel weights in excess of 700 Ibs will dramatically shorten the life of the rubber tread and will cause premature failure Railwheel weights less than 500 1 cause derailment Upper Lacknut Sprin
8. Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 6 FIGURE 2 5 GMC STEERING WHEEL LOCK OPERATION Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 7 3 0 TRAVELLING ON Before proceeding to travel the rail ensure that the railgear pump has been de energized that the railgear cylinders are fully extended that the front and rear mechanical locks are securely engaged and that the steering wheel lock has been installed with the front wheels pointing straight ahead WARNING Do not operate the vehicle in excess of 70 km hr 45 MPH on the track Railroad rules governing on rail travel must be observed at all times Do not operate vehicle on track if the vehicle load exceeds the maximum load rating of the railgear not operate the vehicle on track if the steering wheel lock is not engaged Do not operate the vehicle on track if the Railgear Pump is energized Do not operate the vehicle on track if the front or rear mechanical locks are not securely engaged The vehicle may now be driven as if on the highway at a reduced speed The steering wheel should not be touched it should be allowed to float in the steering wheel lock Note also that braking dis tance is increased while on the track 4 0
9. 00011 R 250 HD BELECTRIC INSULATING BUSHING 1 f 19 S 201360 NNER BEARNG ST 1 1 1 D XI COTTER PN 3 6 2 3220230 5 WASHER O 3 4 16 UNF SLOTIED NUT 1 22 52050 SPINGLE NUT 1 ice ene wer Qi t 2875 Industries Limited A Global Railway Industries Company 92590565055 OV QG 2 Remove when greasing bearing LSR SISS BILL OF MATERIALS SE E garan i S 20000 197 SIEEVE FOR RUBBER WHEEL 1 VE NPT GREASE FITING Siobal Industries Company _ 2 5 201002 10 TREAD FOR RUBBER WHEEL 1 34 3 8 BOLT x 1 250 LONG 19300 e 599 3 5010 MB 2 VE x 4 5 200003 10 FLANGE FOR RUBBER WHEEL 1 3e 52055 smo O O O TL 8 10 Rubber Tread Wheel 5 R is83 SPINDLE HOUSNG ASSEMBLY 31 17 WEE NU C C T 5 sempe INSULATOR 1 s 201300 L 1 R 250 HD 7 Roa DELECTRIC INSULATNG 1 39520160 NNER BEARING Si 1 8 34 FLAT 1 zo
10. batt terminal The coil should shift in the housing producing a distinctive click With the shunt wire connected as in step c the voltage between the coil motor terminal and the coil base should be 12V If the coil does not click and or the voltage in step d is not 12V then the coil is inoperative and must be replaced Pump motor coil resistance test use Ohm Meter a b 9 Disconnect all wiring to the coil Connect an Ohm Meter to the coil switching terminal and to the coil base The resistance should be about 20 Ohms Connect an Ohm Meter to the coil motor erminal and to the coil switching terminal The resistance should be infinite open No resistance with this connection will indicate a shorted coil Connect an Ohm Meter to the coil batt terminal and to the coil switching terminal The resistance should be infinite open No resistance with this connection will indicate a shorted coil If the coil resistances are not within specifications the coil must be replaced Pump motor test a b 9 Disconnect pump motor wire from Ensure the pump base is properly grounded by running a ground strap from the motor base to the negative battery terminal Connect one end of a large shunt wire to the pump motor positive terminal and touch the other end to the battery positive terminal The pump motor should run upon touching the s
11. d e f Disengage the mechanical locking pin 2 by moving and holding the locking cable handle 3 to the left side of the vehicle It may be necessary to lower the railgear slightly in order to release the pressure on the locking pin Raise the railgear unit by selecting Raise on the rear control 1 Release the locking cable handle once the railgear has rotated past the rail locked position Continue raising the railgear unit until the mechanical locking pin clicks into the highway locked position the hydraulic cylinder will be completely retracted Release the hydraulic pressure in the cylinder by selecting Lower on the rear control The railgear should rest on the locking pin Ensure the mechanical locking pin is correctly engaged before proceeding 7 De energize the Railgear Pump by turning off the respective dash switch 8 Disengage the steering wheel lock refer to figure 2 3 a b Pull the steering lock 2 out of the lock retainer 3 Store the steering lock in a secure spot WARNING Before proceeding with highway travel ensure both the front and rear railgear units are securely seated in their respective mechanical locking systems Ensure that the railgear pump has been de energized 9 Carefully drive the vehicle off the track and onto the highway Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG
12. Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 02 46 N O gt 5 ea x 4 A Z Ay lt Issued July 2001 L 3 C T ID Z Z ___ ______ __ o t Kine 000 8 0 1344 2 7 ONTIDS j LE ZEE 2 id 21 01 INA 91 196 5 _ _ ___2 j s t C ATBAGSSY wana L NS3N38 1 21 1905 M3dvd NO TNA JUN zi __ IND 63 6 12 503 NMOHS LON SYINLSV4 IWOUNJOI la 6190 8 13404 8 190 85 8 2 190 3 9 ws 5190 4 c 190 3 1 BSNaviB 2 140 8 2 HOION 1 190 8 4511 51494 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Industries Limited A Global Railway Industries Company MANUAL ADDENDUM Form MA 01 MA MO25RRG 0 MA02 Rev 1 Date May 22 2
13. 9939 iva INDAJ E 1 L ONNdNDD 106 0 1 3SOH 254 gt 70 253 ONAVYOAH 90 20 05 858 SNULIJ 40 90 53 598 YILIN MOTI adm Aquassy ang warsut dous G easy dous D dus 5 E SEN Tara NOLIdINISIO 13478 4511 S4HVd Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 15 APPENDIX erm one T 30 i i335 TT 370998 S3HJNI 10 wsxmouwem prie a NAN un nomas aves 9 A 38913 00661 7031409 BAWA INOM 038 411 5 15 bos JAWA 14084 9 IG 334405 YIMOd WIE 3002 30700 lt gt gt lt m 0 HO1 AS 1081995 233 LNNAOW ava va ANTS HALAS 1041802 14233 LNODW SUNT 00183105 LN IDN 29397198 11083 NO 4404 LNODH
14. Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 4 3 0 WARRANTY RAFNA INDUSTRIES LTD LIMITED WARRANTY Rafna Industries warranty covers a period of TWELVE 12 months after the date of the rail gear s entry into service The warranty asserts that each new rail gear sold will be free from defects in material and workmanship under normal use and service Rafna s obligation under this warranty is limited to repairing or replacing at its factory or other locations as designated by the company Any defective part or parts must be returned within 30 days of the date of failure or notice of defect for factory inspection or as designated by Rafna Industries Ltd Equipment or parts not manufactured by Rafna Industries but which are furnished in connection with Rafna products are covered directly and solely by the warranty of the original equipment manufacturer supplying them The obligation of Rafna Industries under this warranty is limited to the replacement of parts that appear to be defective after review and inspection by our firm or designated representative This warranty does not oblige Rafna Industries to bear the customer s cost of labor or transportation charges concerning the return of defective parts However if found to be defective the outbound direct ground freight on the part will be prepaid to locations within continental U
15. TRUCK WHEEL MODIFICATION ASSEMBLY 4 10 FRONT RAILGEAR MOUNTING ASSEMBLY 411 REAR RAILGEAR MOUNTING ASSEMBLY 4 12 RAILGEAR HYDRAULIC ASSEMBLY 4 13 RAILGEAR ELECTRICAL ASSEMBLY 4 14 RAILGEAR PUMP ASSEMBLY 4 15 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG APPENDIX 51 SECTION 5 APPENDIX Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 52 APPENDIX szo ow AVAS S3HONI 101 848 Y j j ONT U w eramr 6897 4 QN Dvd D z A 22 wd ind Sec S v 2 A18A3SSV Em 14053 ONILVLOSN 2 INXS Nisi JNO 1V3HLNON 12 22 x 4 356 IKV 48 S3IMLSNONI VNIVY _ v d33MS 305 t JIMS IVY aT 1331 UN3SSV TJ3HM 0 3OJ NMOHS LON AIGW3SSV df 5 SM NISV4 WOLN3DI 2 19 ILON Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 APPENDIX Ke
16. refer to figure 2 4 a Firmly grasp one side of the hook portion Item 1 of the Hook and Loop steering wheel lock and peel the strip over itself to remove b Store the hook strip on the hook strip holder located in the cab Note Take care when removing the hook strip Due to certain plasticizers in the steering wheel and steering wheel column along with the vehicle s operating environment the adhesive on the strips may give way and be removed If the strip is removed replace it at the earliest convenience 3013 ted A Global Railway Industries Company Imi Industries L MO25RRG 0 MAO0S3 59 A 18IW3SSV 3901 SNId331S ANY auau SUE ereg 0061 seusnpu Aemey V G4ALINIT 31915 lt gt _ 5 5 ___ s 1 201 315 0701005 ETE 1y2WE 59 MENS Tee X M YIA 15 21 50s010o s _ e AVE 59 CV MENG Tee X YII 15 1 0060 00 5 pre 2 WOVE NAUM 1 2 7 5010025 z 2 8 SASS 5904 lt 420 0501005 AT8W3SSV ALO 1uVd 1HVd Wall 1SI1SldVd 01 12
17. the railgear pump should not run yet The railgear pump is an intermittent duty pump which will only run while activating the front or rear push button controls 3 Note that in order to align the front railgear guide wheels directly over the rails the rear railgear must le deployed first then the vehicle is reversed until the front is aligned 4 The direction of hydraulic flow to the front and rear railgear is selected by pushing the respective control box Raise or Lower push buttons This energizes the front or rear hydraulic solenoid valve and starts the pump motor 5 Lower the rear railgear unit refer to figure 2 1 a Raise the railgear out of the mechanical locking system by selecting Raise on the rear control 1 b Disengage the mechanical locking pin 2 by pulling the locking cable handle 3 c While holding the locking cable handle in this position lower the railgear by selecting Lower the rear control d Release the locking cable handle once the railgear has rotated below the highway locked position e Note that while the railgear is taking some of the vehicle s load the railgear suspension 4 should be observed compressing With the vehicle unloaded the nuts above the springs should be about 1 above the spring plate once the railgear is fully deployed If this is not the case check for adequate lubrication If the inner tubes are not free to move the spring suspension will not work correctl
18. SERVICE 3 1 SECTION 3 SERVICE RAILGEAR ALIGNMENT 3 2 RAIL WHEEL BEARING ADJUSTMENT 3 7 RAIL WHEEL LOAD ADJUSTMENT 3 9 ROUTINE RAILGEAR SERVICE 3 12 HYDRAULIC SYSTEM RELIEF VALVE SETTING 3 17 ELECTRICAL SYSTEM TROUBLESHOOTING 3 18 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 2 1 0 RAILGEAR ALIGNMENT This railgear equipment must be correctly aligned in order to perform properly and avoid excessive wear on the equipment four rail wheels may be independently aligned while lateral adjustment of the front and rear railgear is accomplished through adjusting the railgear on the mounting plates A parallel line system and the following procedure should be used to perform the railgear alignment Rafna Industries also supply a special alignment tool kit Order 2 x R 066AD and 2 x R 066AP with which separate instructions are supplied WARNING vehicle tires should have been aligned following installation of the railgear and prior to performing the railgear alignment This procedure should be done with the vehicle parked on straight level track with the front tires pointing straight ahead in order to achieve correct alignment Before any maintenance or adjustments are performed under the vehicle or railgear ensure the engine is turned off and the parking brake is set 1 Ensure the vehicle tires have been align
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20. the equipment If misalignment of the railgear equipment is indicated promptly perform the alignment procedure Do not operate the railgear equipped vehicle at speeds in excess of 70 km h 45 MPH on rail Rail travel speed should always be in conformance with rail company regulations and should be reduce during inclement weather passing through road crossings switches frogs bridges and curves of more than 2 degrees Curves of greater than 20 degrees should be negotiated with extreme caution Operation of this vehicle at unsafe speeds could result in derailment Ensure that the railgear mechanical lock ups on both the front and rear units are engaged positively before initiating highway or rail travel The railgear equipped vehicle has an increased turning radius Exercise caution when operating as sharp corners may be difficult to negotiate The following safety precautions should be taken before vehicle is operated Visually inspect the railgear prior to use for damaged or worn parts Check for loose wheels and fasteners Check for leaking hydraulic lines and cylinders Check for proper lubrication Failure to heed to any of the above mentioned warnings could result in severe bodily injury and equipment damage Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 3 2 0 DESCRIPTION This manual covers the operat
21. 003 AFFECTED MANUAL RAILGEAR Railgear Model R 250 GMC Vehicles Manual MO25RRG Affected Page s Section 4 Parts page 4 9 Addendum Information This addendum updates the Operation Parts and Service Manual to include parts drawings for OTR and GKN road wheels fitted to the vehicle Replace the part drawing in the manual with attached parts drawings 6 SduS ON L dO 133HS aariadns LON LAN HAdVL OWS 9 S3HONI WIG 100 Sarid veros 594 NMVHG 4015 E 1 JHL NO HLO dad NLS STH3HM 810 2 T83HM 9 X 561 1 s _________ man S I33HM 910 A18IW3SSV Su3Nalsv4 TVOLLN3GI ALO 54 ON 19 Wall T33HM QVOH HON3H3H3H Page 2 of 4 S IH3HM HV3H 297 719 oagano Siva VS10100 S Nid WVHVHO IHV TO 00661 1411 6 5 871 07 ANOYOL LAN TH3HM ted MO25RRG 0 MAO2 Rev 1 A Global Railway Industries Company S IH3HM LNOH4 Imi 310IH3A 587 1 SALON Industries L V6
22. 5 Proceed to adjust side to side location of alignment until distance between each vehicle front rim and each string line is equal dimensions E and F equal and the distance between each vehicle rear rim and each string line is equal dimensions G H equal Note that dimensions E and F may not equal dimensions G and H FIGURE 3 1 RAILGEAR ALIGNMENT MEASUREMENTS C E M N zz EC D 6 Railgear wheel alignment refer to figure 3 1 and 3 2 a b c d e 9 Secure 18 long straightedge to the backside each railgear wheel Measure the distance between the front most and rear most points of each straightedee and the parallel lines dimensions I J K and L in the front and M N O and P the With a tolerance of 1 16 dimensions I and J should be equal dimensions K and 1 should be equal dimensions M and N should be equal and dimensions O and P should be equal If this is not the case proceed to adjust the rail wheel alignment Otherwise proceed to step 7 Loosen the four bolts and nuts 1 securing each railgear wheel spindle housing 2 to the railgear axles 3 such that the wheels are free to rotate on the horizontal plane yet snug enough to stay in place Adjust each wheel to the centered position dimension I amp J equal K amp L
23. BRAKING ON RAIL This railgear equipment allows the vehicles tire contact with the rail to provide the braking action identically as if on the highway However it is important to apply the brakes gradually in order to avoid locking up the vehicle tires Note also that stopping distance while on the track is greater than when on the highway and braking ability can be adversely effected during inclement weather Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 8 5 0 REMOVING VEHICLE FROM THE TRACK WARNING Operating instruction provided below only address 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 Understand equipment operation before operating equipment 1 Approach a level crossing or other suitable location and prepare to remove the vehicle from the track by placing the automatic transmission in PARK manual transmission in NEUTRAL and applying the parking brake 2 Energize the Railgear Pump by turning on the respective dash switch The dash switch light should come on at this point but the railgear pump should not run yet The railgear pump is an intermittent duty pump which will only run while activating the front or rear push button
24. Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 2 1 0 INSPECTIONS BEFORE OPERATION 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 Y Check for proper lubrication at specified intervals Also the operator should ensure that the vehicle is in good operating condition by following the vehicle manufacturer s operating guide WARNING Following the first eight 8 hours of rail travel an initial wheel bearing inspection and verification of sufficient wheel bearing grease should be performed During this time period the wheel bearings will have seated themselves and may require adjustment of end play If the end play is not in accordance with specifications of 0 005 bearing failure could occur and would not be covered under the Rafna Industries Warranty Refer to the Service section of this manual for wheel bearing adjustment procedures Following the first 1000 km 625 Miles of highway and rail travel the vehicle offset rim and wheel spacer retaining nuts should be re torqued Refer to the Service section of this manual for re torquing procedures On newly applied railgear equipment ensure that the railgear and guide wheel alignment procedure is performed before operation of the equip
25. OuHScOW L dO I 133HS 84114406 LON 96 HORNO 591 14 on 2 3993 LNOH4 NO QU SHHHMUNOHA 208 93415 5133 4 9 SENI NMOHS LON SIM NAD SEAS SY SH3N31SV43 WOLLNAGI 2 HON3H3H3H Page 3 of 4 810100 5 Nid 1 uv3u 297 719 o3gano 81 00861 ANDYOL TH3HM 7411 5 5 MO25RRG 0 MA02 Rev 1 ted A Global Railway Industries Company S IH3HM 1 4 Imi 37495 Baon sa 2134 9 WALI NOILVOlTddV 3 T10IH3A 587 31 95 S WALI S31ON Industries L 4014 imited Industries L MO25RRG 0 MA02 Rev 1 A Global Railway Industries Company 86 OHHScOW 12014465 mnvos 2002 8 ava NV Nvaunans OWS 6002 HON3H3H3H A18A3SSV NOILVOISIGOW TARM NOlLdlHOS3d 297 719 Sagano
26. V ANIYE 42142 4 ol U3NIVL3H 07 PT THM ATHASSSV ALO NOLIdINOSJQ LUV ON WALI 4517 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 9 APPENDIX 1 lt IQ 10 91 FON 1avd 058 4 JUN3H233J 55 XYINIYY 1ND34 WdVd NO 21 26 LON 3LDN IV3HLNON Q3LINI1 53 15 VNIVY 1AN 3901 1435 NOUN 8 HO Z L 8 149 2 1 2 0 rl L z M3OVdS NidWnB INA 8892 8 Z lt INANI 281 vz sz s 1 L A IGW3SSY 4254 LEVI 4 4511 SLUVd 313IH3A 40 1NO34 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 10 APPENDIX r an rus T T U C U T TJ u j j Has lt 004 33H o ss sow NOL ipsi AWGSSV 1 2 2 a aaa osa 1594
27. YLINDER ROD PIVOT HAND TIGHT NOT TORQUE Table 3 3 Standard Bolt Torque Values Bolt Detail Bolt Torque Value ft lbs ume UNC Gr 8 Fasteners 175 5 8 UNC Gr 8 Fasteners UNC Gr 8 Fasteners 3 8 UNC Gr 8 Fasteners 4 UNC Gr Fasteners Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 17 5 0 HYDRAULIC SYSTEM RELIEF VALVE SETTING This system is equipped with one relief valve located on the railgear hydraulic 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 13 throughout the following adjustment procedure 1 Locate the hydraulic hose 1 that supplies the rod end of the front railgear hydraulic cylinder 2 from the hydraulic pump pressure port 3 and disconnect it at the pump Install a test gauge 4 up to 3000 PSI between the disconnected hydraulic hose and the pump pressure port The pressure gauge will indicate the relief valve 5 setting when the pump is loaded Raise the front railgear completely Select the Raise position on the front control so that the hydraulic cylinder creates a load on the pump by trying to The hydraulic pump should start and the pressure reading on the test gauge should climb to 1800 PSI If the pressure is not correct re
28. _ 8 vo u 1 3015 LH3B 31 19 SNILNMOW 4 290 8 1 X 835 1431 QL vZ H gt osoz ATHWS3SST AID NUIJdIH2S3U LUVA ON 13494 AJJI LSIT SLUVd SFISIHIA 49 1 0 81 50 1 Al18 13 904 2015 3 140 NO NAOHS LON JAV SAANLSV4 1VOIL83A NV 3491 330N3SSVd NO NADHS LON 39 SAYANLSV4 2 1 WINDZISDH 3LDN Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 13 APPENDIX 10 91 Amr 1599 32 353335 55 ONILNDON M3dVd NO JWOS TINS LON and W3MINOW ALINTI 53 15 __ O L 9 8 740 2 9 S9NO1 Z X 1108 8 INN Z L LASIN ONILNAOW 1431 SNILNDON 41 ALB 4511 54 4 319IHJ3A 30 MV3M SOMVMOL L 402686 8 2 80280 3 1 Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Bulletin MO25RRG Issued July 2001 5 14 APPENDIX SdN d 190 35 1090 BgD H 1 4355 315539 i3dvd 55 1144 LON 3LON IND WAYLNOW Q3LIAT 5 5
29. an inspection of the railgear units has been carried out before any track testing is performed 1 Place the vehicle on a level section of rail with the railgear deployed to the rail position 2 Ensure that the vehicle tires are not in contact with any obstructions except the rails and that they are inflated to the correct air pressure 3 Check each rail wheel load as follows refer to figure 3 6 a Place the jack 1 on a solid railway tie 2 beneath the rail wheel spindle housing 3 and jack the rail wheel off the rail b Insert a piece of paper 4 between the rail and the rail wheel and lower the jack until the rail wheel squeezes the paper so that it cannot be pulled out c Slowly jack up the rail wheel while pulling on the paper When the paper can be pulled out stop jacking d Record the weight reading on the jack and compare to the minimum required load in Table 3 1 Table 3 1 Minimum Required Rail Wheel Load Front Rail Wheel Load 700 800 Ibs Rear Rail Wheel Load 450 500 Ibs Note Different size jacks will show different hydraulic pressure readings while lifting identical weights This manual therefore specifies railwheel load in terms of weight not pressure Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 10 4 If the load on the rail wheels are not within the specifi
30. and Service Manual to include the operation of and the parts drawing of the Hook and Loop style steering wheel lock The enabling and disabling procedures need to be added to the manual along with a parts drawing This steering wheel lock is an option and does not replace the existing steering wheel lock Also attached to this addendum 15 a new parts drawing for the Hook and Loop steering wheel lock Refer to the attached parts drawing for parts and quantities required for installation The following procedures should be added to the Operation Section of the Operating Parts and Service Manual 2 0 PLACING THE VEHICLE ON THE TRACK 8a Engage the steering wheel lock system For vehicles fitted with the Hook and Loop steering wheel lock system refer to figure 2 4 a Tum the steering wheel Item 1 until the front tires point straight ahead b Position the hook portion Item 2 of the Hook and Loop steering wheel lock onto the loop strips Item 3 affixed to the steering wheel and steering wheel column cover Item 4 The hooks should mate with the loops Press firmly into place Industries Limited A Global Railway Industries Company MO25RRG 0 MA03 Page 2of 3 Figure 2 4 Steering Wheel Lock Operation Hook and Loop 5 0 REMOVING THE VEHICLE FROM THE TRACK 8a Disengage the steering wheel lock system For vehicles fitted with the Hook and Loop steering wheel lock system
31. ar railgear wheel bearings will need to be adjusted if the wheel end play exceeds 0 005 Recommended end play range is from 0 003 to 0 004 If the bearings are not adjusted bearing failure could occur and this would not be covered under the Rafna Industries Warranty If the end play is not in conformance with this specification adjust the wheel bearings as follows refer to figure 3 5 WARNING Before any maintenance or adjustments are performed under the vehicle or railgear ensure the engine is turned off and the parking brake is set 1 Perform this procedure with the railgear in the highway position and with the railgear wheels free to turn 2 Access the wheel bearings Remove the wheel hub cap 1 and gasket 2 by unbolting the three hub cap retaining bolts 3 3 Adjust the wheel bearing a Remove spindle nut cotter pin 4 b While rotating the wheel forward torque the wheel spindle nut 5 to 20 ft lbs c Loosen the spindle nut slightly until it is just loose d Re torque the spindle nut to 6 ft lbs e Install a new cotter pin through the spindle nut and spindle If the cotter pin holes do not line up tighten the spindle nut until the holes align Do not tighten more than flat of the nut f Ensure there is sufficient grease in the wheel bearing cavity g Re install the gasket and hub cap Torque the hub cap retaining bolts to specifications If a torque wrench is not available the foll
32. arts not manufactured by Rafna Industries Ltd will be covered by the Original Equipment Manufactures warranty Based on the OEM s investigation of the warranty claim against their manufactured component their decision will stand Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 7 WARRANTY CLAIM FORM This form must be completed prior to starting any warranty work Warranty War01 XXXX Railgear S N mw w 7 1 e Uwe Shipping instructions Standard Special Standard Select Expedition Express Ground Air 5 day 3 2 3 da 2 Shipper Way Bill QUANTITY DESCRIPTION ____ _______ Eo 0 0 73 Ho 1 PROBLEM DESCRIPTION Required Documentation from the Customer or issuing Credit Description of Rafna Parts Ordered or Used Total Claimed US CAD RAFNA INDUSTRIES approved by DATE CUSTOMER S REPRESENTATIVE DATE For Internal Use only 5825 Shipping 5826 Outside Supplier 5821 1 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 8 4 0 SERIAL NUMBERS Following receip
33. authorized prior to any repairs modifications or adjustments being started Warranty information and authorization can be obtained from Rafna Industries Vice President Engineering or Customer Service Manager who can be contacted at 1 888 525 3660 Rafna s warranty will not apply if the Railgear or any of its components have been modified or replaced without the written consent of the company Additional Billing Installers amp Customers If during installation it is found that incorrect parts have been shipped Rafna will cover all costs involved in replacing these parts and return of incorrectly shipped parts All warranty claims concerning short incorrect shipment of parts or accessories must be made within 30 days of delivery In order to maintain control over extra or additional billing due to incorrect shipments only the Vice President Engineering or Customer Service Manager can issue a Purchase Order authorizing replacement parts shipping or work to be performed by an outside source Warranty Claim information and requirements Rafna Industries will require the following information at time of claim as well as the a properly filled out Warranty Claim Form form reference war 1 03 00 Information Required 1 Customer Purchase Order number 2 Rafna railgear serial number 3 Vehicle unit number 4 Vehicle VIN number 5 Purchaser of Rafna railgear 6 Date of purchase 7 Name of end user 8 Company r
34. bleshooting 3 18 Parts Section 4 Rotating Front Railgear Assembly 4 2 Rotating Front Railgear Lock Up Assembly 4 3 Rotating Rear Railgear Assembly 4 4 Rotating Rear Railgear Lock Up Assembly 4 5 Wheel Assembly 4 6 4 7 Steering Wheel Lock Assembly 4 8 Front Railgear Bumper Assembly 4 9 Truck Wheel Modification Assembly 4 10 Front Railgear Mounting Assembly 4 11 Rear Railgear Mounting Assembly 4 12 Railgear Hydraulic Assembly 4 13 Railgear Electrical Assembly 4 14 Railgear Pump Assembly 4 15 Appendix Section 5 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 1 SECTION 1 GENERAL INFORMATION SAFETY INFORMATION 1 2 DESCRIPTION 1 3 WARRANTY 1 4 SERIAL NUMBERS 1 8 SPECIFICATIONS 1 9 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 2 1 0 SAFETY INFORMATION 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 Ensure that positions and functions of all railgear controls are known before attempting operation Ensure all body parts and loose clothing are clear of any moving parts of
35. cations listed in Table 31 adjust as follows refer to figure 3 7 a b 9 f 8 h i Raise the railgear until the rail wheels are unloaded Loosen the jam nuts 1 under each lower spring plate 2 and the upper lock nuts 3 above each upper spring plate Adjust the lower spring plates and upper lock nuts up to increase the load or down to decrease the load on the rail wheels Each side should be moved the same amount The acceptable range of adjustment on the lower spring plates is 1 2 3 from bottom of lower spring plate to the top of axle If the correct loads cannot be obtained within this range adjust the height of the railgear in the mounting plate holes Lower the railgear and recheck each rail wheel load Re adjust if necessary Tighten the jam nuts against the lower spring plates Raise the railgear and tighten the upper lock nuts until the rubber springs just start to compress Do not pre compress the rubber springs Lower the railgear to the rail position The upper lock nut should be about 34 1 above the upper spring plate Raise the railgear to the highway position Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 11 WARNING The wheels must be a minimum of 7 1 2 above the ground when the highway position If this minimum distance cannot met with the cor
36. controls 3 Note that the vehicle is removed from the track by first raising the front railgear and then raising the rear railgear Finally the steering wheel lock is removed 4 The direction of hydraulic flow to the front and rear railgear is selected by pushing the respective control box Raise or Lower push button This energizes the front or rear hydraulic solenoid valve and starts the pump motor 5 Raise the front railgear unit refer to figure 2 2 a Disengage the mechanical locking pin 2 by moving and holding the locking handle 3 to the left side of the vehicle It may be necessary to lower the railgear slightly in order to release the pressure on the locking pin b Raise the railgear unit by selecting Raise on the front control 1 c Release the locking handle once the railgear has rotated past the rail locked position d Continue raising the railgear unit until the mechanical locking pin clicks into the highway locked position the hydraulic cylinder will be retracted e Release the hydraulic pressure in the cylinder by selecting Lower on the front control The railgear should rest on the locking pin f Ensure the mechanical locking pin is correctly engaged before proceeding Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 9 6 Raise the rear railgear unit refer to figure 2 1 a b
37. d 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 14 FIGURE 5 8 FRONT RAILGEAR LUBRICATION POINTS GREASE LOCK SYSTEM MONTHLY GREASE GUIDE TUBES MONTHLY GREASE CYLINDER ENDS MONTHLY GREASE GUIDE TUBES MONTHLY GREASE INNER TUBE PIVOTS MONTHLY GREASE RAIL WHEELS EVERY 3 MONTHS OR 3000 RAIL KM FIGURE 3 9 REAR RAILGEAR LUBRICATION POINTS GREASE CYLINDER ENDS MONTHLY GREASE GUIDE GREASE LOCK TUBES MONTHLY SYSTEM MONTHLY GREASE GUIDE TUBES MONTHLY GREASE INNER TUBE PIVOTS MONTHLY GREASE RAIL WHEELS EVERY 3 MONTHS OR 3000 RAIL KM Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 15 FIGURE 5 10 TRUCK RIM NUT TORQUE SEQUENCE FIGURE 5 11 FRONT RAILGEAR NON STANDARD BOLT TORQUES UPPER SUSPENSION NUT HAND TIGHT DO NOT PRECOMPRESS SPRING BEARING CAP 40 FT LBS INNER TUBE PIVOT amp CYLINDER ROD PIVOT HAND TIGHT DO NOT TORQUE Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 16 FIGURE 5 12 REAR RAILGEAR NON STANDARD BOLT TORQUES UPPER SUSPENSION NUT HAND TIGHT DO NOT BEARING CAPS PRECOMPRESS SPRING z 40 FT LBS INNER TUBE PIVOTS amp C
38. e highway locked position Note that while the railgear is taking some of the vehicle s load the railgear suspension 4 should be observed compressing With the vehicle unloaded the nuts above the springs should be about 1 above the spring plate once the railgear Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG b 1 J OPERATION 2 5 is fully deployed If this is not the case check for adequate lubrication If the inner tubes are not free to move the spring suspension will not work correctly The railgear moves down into position on the rails until the hydraulic cylinder 5 is fully extended and the mechanical locking pin clicks the into rail locked position In this position the railgear should be about vertical Release the front control Ensure that the railgear is securely locked in position and correctly contacts the rails before proceeding FIGURE 2 2 ROTATING FRONT RAILGEAR OPERATION 7 De energize the Railgear Pump by turning off the respective dash switch 8 Engage the steering wheel lock system refer to figure 2 3 a b Turn steering wheel 1 until the front tires point straight ahead Pass the steering lock 2 over the horn cover and into the steering column lock retainer 3 Ensure the steering lock secures the steering wheel and does not interfere with the driver s air bag cover
39. easing the bearing remove the dust grease cap to prevent damage to the grease seal Adjust bearing endplay in accordance with the Operating Maintenance and Parts Manual To replace the rubber sleeve A Unbolt the wheel from the hub item 17 then unbolt the flange from the wheel item 14 B With a suitable press press off the sleeve C Press on a new sleeve D Ensure the sleeve is flush with the flange edge of the wheel Reinstall flange with new hardware item 14 15 tighten to 40 ft lbs Reinstall wheel to hub tightening bolts item 17 to 100 ft lbs Verify bolt torque every 625 rail miles 1000 kms Industries Limited A Global Railway Industries Company S Q9 9 Remove when greasing bearing lt 05 0022092222 2277 27 255 5594 2 BILL MATERIALS Paar wo DESCRIPTION OF ITEM FART UANTIFY Pant DESCRIPTION ITEM RAF NA INDUSTRIES LIMITED TOR RUBBER WEE xu MEM 7 5 200002 197 TREAD FOR RUBBER WHEEL 1 14 3 8 UNC 688807 1280 LONG 8 USE WEG i I e 10 Rubber Tread Wheel smo HOUSNG ASSEMBLY 1 17 520160 wernt C U T 5 ERI EE
40. ed following the installation of the railgear and prior to performing the railgear alignment 2 Lower the front and rear railgear units to the rail position on a straight level section of track 3 Ensure the vehicle front tires are pointing straight ahead and engage the steering lock 4 Set up a parallel string line system about 6 inches above the head of the rail as follows refer to figure 3 1 a Fabricate two metal alignment bars with 1 2 diameter posts on each end about 7 tall and about 9 apart Create a circumferencial groove in each post about 1 from the top to hold the string lines Ensure that the two alignment bars are fabricated identical to within 1 32 tolerance The location of the posts on the alignment bars will ensure that dimensions A and B are equal b 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 The location of the alignment bar posts will ensure that dimensions C and D are equal c Run a string line from the front alignment bar post to the rear alignment bar post on each side of the vehicle using the grooves cut in the posts d Ensure that dimensions A and B are equal and dimensions C and D are equal Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 3
41. equal M amp N equal and O amp P equal Note that dimensions I amp J may not equal K amp L and M amp N may not equal O amp P at this point Re torque the rail wheel fasteners to specifications Remove the straightedges Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 4 FIGURE 5 2 RAIL WHEEL ALIGNMENT ALIGNMENT WARNING When adjusting the lateral alignment of the front and rear railgear do not use any force against the suspension guide tube assemblies that may cause damage which would restrict the suspension movement of the railgear 7 Front railgear lateral alignment refer to figure 3 1 and 3 3 a b c d e f g Secure a straightedge to the backside of each front rail wheel flange Measure distance from the front most and rear most points of the two straightedges to the parallel lines dimensions I J K and L If these measurements are within 1 8 tolerance proceed to step 8 Otherwise continue to step 7 d Raise the railgear off the track and loosen the four bolts 1 that secure the railgear unit 2 to the front mounting plates 3 Move the railgear unit laterally until dimensions I J K and L are equal to within 1 8 tolerance Re torque the four mounting bolts to specifications Remove the two straightedges and lower the railgear to rail position Rafna Industr
42. equesting warranty claim 9 Ship to Address 10 Bill to Address Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 6 On approval of warranty claim 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 Rafna will in turn ship all required parts pre paid ground direct to the Installer or Customer On receipt of claimed warranty parts Rafna or their sub supplier will inspect defective parts and if deemed warranty a credit will be issued to the Installer or Customer If claimed warranty parts are not received within 30 days a credit will not be issued Labor Warranty and or additional labor charges Labor or additional labor charges such as travel are not covered by either the Rafna Warranty or any of Rafna s sub suppliers Faulty Railgear Installations If a warranty claim arises due to incorrect installation by an installer who has not followed the written instructions as out lined in our manual or as trained by either Rafna Customer Service or Sales Department warranty claims will not be honored Parts Warranty Rafna manufactured parts will be warranted and replaced if found to be defective due to poor materials or workmanship for up to one year from date of the railgear s entry into service P
43. g height ROAD POSITION Spring heights in RAIL POSITION Industries Limited A Global Railway Industries Company Weight on railwheel Lbs A With the railgear in on road position adjust the upper locknut so the overall spring height is 3 9 16 This will allow the railgear to have maximum spring travel B When orrrail loosen the jam nut and adjust the spring height so it does not exceed 700lbs 2 5 8 Ideally with the truck unloaded set the weight to 500 Ibs this will allow for increased railwheel loads as the truck is loaded with gear or as the truck s spring age Do not exceed the recommended 700 Ib Load C Ensure the distance B between the underside of the spring plate and the top of the lower axle is between 2 1 4 and 3 If this distance cannot be attained the railgear will have to be repositioned D Retighten the jam nut E When going back onroad ensure the spring is only slightly compressed i e the original nominal height of 3 9 16 is not exceeded If the spring is loose the original nominal height is greater than 3 9 16 tighten the upper locknut F Recheck and repeat for other wheels G This procedure MUST be repeated whenever the load is changed in the vehicle MAINTENANCE 1 A grease fitting is provided on the back of the wheel Time interval for greasing OL should be in accordance with the Operating Maintenance and Parts Manual When gr
44. hunt wire If the pump does not run the pump motor is defective Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 19 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 1 Check the front and rear control switches for sticking or shorting out 2 Disconnect the wire from the coil switching terminal If the pump continues to run then the coil is defective FIGURE 3 14 ELECTRIC SYSTEM SCHEMATIC PUMP ON OFF REAR CONTROL BOX FRONT CONTROL BOX gt lt gt PUMP SWITCH CONFIGURATIONS VIEWED FROM REAR OF SWITCH WIRE COLOR Coe NEUTRAL LOWER ON BLACK 19e vDC SUPPLY h d G GREEN FRONT REAR VALVE CONTROL pou R RED FRONT REAR VALVE CONTROL hod WHITE SOLENOID SWITCHING POWER bod Rafna Industries Ltd 19300 Clark Graham Baie d Urfe 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG PARTS 4 1 SECTION 4 ROTATING FRONT RAILGEAR ASSEMBLY 42 ROTATING FRONT RAILGEAR LOCK UP ASSEMBLY 4 3 ROTATING REAR RAILGEAR ASSEMBLY 4 4 ROTATING REAR RAILGEAR LOCK ASSEMBLY 4 5 RAIL WHEEL ASSEMBLY 46 RAIL SWEEP ASSEMBLY 4 7 STEERING WHEEL LOCK ASSEMBLY 48 FRONT RAILGEAR BUMPER ASSEMBLY 49
45. ies Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 5 FIGURE 5 5 FRONT RAILGEAR LATERAL ALIGNMENT ALIGNMENT 8 Rear railgear lateral alignment refer to figure 3 1 and 3 4 a b 9 f g Secure a straightedge to the back side of each rear rail wheel flange Measure distance from the front most and rear most points of the two straightedges to the parallel lines dimensions If these measurements are within 1 8 tolerance proceed to step 9 Otherwise continue to step 8 d Raise the railgear off the track and loosen the four bolts 1 that secure the railgear unit 2 to the rear mounting plates 3 Move the railgear unit laterally until dimensions are equal to within 1 8 tolerance Re torque the four mounting bolts to specifications Remove the two straightedges and lower the railgear to the rail position 9 Remove the parallel line system 10 Remove the vehicle from the rails Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 6 FIGURE 3 4 REAR RAILGEAR LATERAL ALIGNMENT ALIGNMENT Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 7 20 RAIL WHEEL BEARING ADJUSTMENT The front and re
46. ion parts and service of the Rafna Industries rotating frmt and rotating rear R 250 HD railgear units as applicable to multiple vehicles If necessary any difference in operation parts or service for specific vehicle and or railgear models is clearly detailed by separate instructions for each Otherwise the operation parts and service instructions are the same for all models Please refer to the appendix for the latest additions that have not been included in this manual The Industries R 250 HD railgear is a hydraulically operated roadto rail conversion system applicable to vehicles of up to 12 500 65 G V W R The front and rear railgear units are frame mounted systems which are hydraulically raised and lowered The hydraulic power is supplied by a 12VDC electrical hydraulic pump During highway and rail travel the front and rear railgear units are mechanically locked in position A steering wheel lock system keeps the vehicle s front wheels straight during rail travel The railgear s spring suspension system ensures constant wheel to rail contact and a comfortable ride Onrail propulsion is provided by the vehicle s rear tires contact with the rail Onrail braking is accomplished through the vehicle s original braking system This manual uses the orientation convention for the vehicle as shown in figure 1 1 FIGURE 1 1 ORIENTATION CONVENTION RIGHT REAR
47. lease the front control and adjust the external relief valve on the pump accordingly Once the correct pressure on the pump relief valve is obtained release the pressure in the system and remove the test gauge Re connect all hydraulic lines FIGURE 3 13 HYDRAULIC RELIEF VALVE PRESSURE ADJUSTMENT REAR HYDRAULIC CYLINDER FRONT HYDRAULIC CYLINDER Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 18 6 0 ELECTRICAL SYSTEM TROUBLESHOOTING The following basic tests can be performed to check the integrity of the railgear electrical system Refer to the electrical schematic in figure 3 14 Should the hydraulic pump fail to operate all wiring should be checked for shorts the fuse should be checked and the following tests should be performed 1 Pump motor coil shift test and voltage test use Volt Meter mode a b 9 Disconnect the wire from the coil motor terminal to the hydraulic pump motor Ensure the coil batt terminal is connected to the positive terminal of the battery and the coil base is properly grounded There should be 12V between the coil batt terminal and the coil base and OV between the coil motor terminal and the coil base Connect one end of a short shunt wire to the coil switching terminal and touch the other end to the coil
48. ment Note that excessively worn guide wheels vehicle pulling to one side while on the rail and vibrations through the vehicle while on the rail are indicators of misaligned railgear or guide wheels If any of these situations are encountered proceed to perform the alignment procedure as described in the Service section of this manual as soon as possible to avoid damage to the equipment and vehicle Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 3 2 00 PLACING VEHICLE ON THE TRACK WARNING Operating instruction 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 Understand equipment operation before operating equipment 1 At a suitable location drive the vehicle past the rail crossing and reverse onto and parallel to the rails while aligning the rear railgear unit guide wheels directly over the rails At this point the front railgear unit guide wheels should be somewhat aligned over the rails 2 Place the vehicle automatic transmission in PARK manual transmission in NEUTRAL and apply the parking brake Energize the Railgear Pump by turning on the respective dash switch The dash switch light should come on at this point but
49. nited States and Canada by Rafna Industries Ltd The warranty does not cover responsibility for customer s claims arising from abuse misuse neglect or alteration of the rail gear All claims ae subject to inspection of said parts by our firm This warranty is in lieu of other warranties expressed or implied including any implied warranties of merchantability or fitness for a particular purpose and any liability for special or consequential damages PRODUCT IMPROVEMENT LIABILITY DISCLAIMER Rafna Industries Ltd reserves the right to make any changes in or improvements on its products without incurring any liability or obligation whatever and without being required to make any corresponding changes or improvements in products previously manufactured or sold IMPORTANT NOTICE This warranty will be considered void if Rafna Industries Installation instructions or Service and Maintenance schedule is not followed according to the detailed instructions contained in both our Installation Manual and our Operation and Service Manual Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG GENERAL INFORMATION 1 5 WARRANTY PoLICIES AND PROCEDURES FoR INSTALLERS AND CUSTOMERS Installers amp Customer Warranty To prevent unnecessary delays or misunderstandings in handlin g Installers or Customers warranty claims it is required that all warranty requests be
50. owing procedure may be substituted for steps 3 b through 3 d above a Tighten the spindle nut until the wheel cannot be turned by hand b Loosen the spindle nut until the wheel can be turned by hand and the cotter pin can be installed c Re adjust when torque wrench is available Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 8 FIGURE 3 5 RAIL WHEEL BEARING ADJUSTMENT Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 9 30 WHEEL LOAD ADJUSTMENT The percentage of the vehicle load carried by the railgear wheels must be properly adjusted to ensure sufficient traction and guidance and to avoid overloading of the railgear equipment The load on the rail wheels is an indicator of the amount of load carried by the railgear and is adjusted as described below with a hydraulic bottle jack This adjustment is done at installation and only requires re adjustment if the railgear is moved or vehicle equipment is changed The load need not be adjusted with every minor load change in the vehicle WARNING Before any maintenance or adjustments are performed under the vehicle or railgear ensure the engine is turned off and the parking brake is set The vehicle should not be carrying any load during this procedure Ensure
51. put back into service Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 13 Table 3 2 Recommended Service Schedule Service Required 1 Visually inspect the railgear prior to use for damaged worn parts 2 Check for loose rail wheels and fasteners Y 3 Ensure the rail gear locking mechanism is functioning properly in both the road and rail positions 4 Check and adjust truck tire pressure as Y vehicle specifications 5 Ensure the vehicle is in good operating condition based on the vehicle operating and maintenance instructions Initial 8hr Check and adjust rail wheel end play 0 005 max Inspect railgear wheel flanges for wear Use the Rafna Wheel Flange Indicator for measurement Inspect all hydraulic fittings and hoses for leaks wear Inspect rail sweeps for close proximity to v rail head 11 Grease hydraulic cylinder pivot points 12 Grease inner tube lower pivot points a 14 Grease locking mechanism 5 Check fluid level in hydraulic reservoir Top off with appropriate filtered fluid 16 Grease rail wheel bearings 3 months or 3 000 rail kms 1 900 rail miles whichever is less 17 and repack wheel bearings 8 Perform rail wheel load check and railgear alignment procedures Rafna Industries Lt
52. rect rail wheel loads and the holes available in the mounting plates contact Rafna Industries FIGURE 5 7 RAIL WHEEL LOAD ADJUSTMENT 3 0 73 17 RAIL 0 HIGHWAY DECREASE LOAD INCREASE LOAD Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG SERVICE 3 12 4 0 ROUTINE RAILGEAR SERVICE The front and rear railgear must be serviced to ensure proper operation and avoid damage to the equipment Refer to table 3 2 for the Recommended Service Schedule Grease fittings are provided at all lubrication points on Industries railgear and are located in figures 38 and 39 The recommended lubricant for this equipment is 55 LONAX EP2 GREASE or equivalent operating range 30 to 135 C for all lubrication points In cold weather areas and or winter seasons use low temperature grease such as SHELL DARINA XL 102 Torque truck rim lug nuts to 125 165 ft lbs as per sequence shown in figure 3 10 Should any loose nuts and bolts be encountered on the railgear during the inspections or during maintenance of the railgear units first refer to figures 3 11 amp 3 12 for non standard bolt torques and then to table 3 3 for standard bolt torques WARNING If the vehicle should derail a thorough inspection of the complete railgear assemblies for damaged parts should be carried out before the units are
53. t of this manual the serial numbers model numbers and date of manufacture for both the front and rear railgear units should be recarded below for future reference This information is located on the identification plates figure 12 mounted on the railgear main frames Front Railgear Unit Serial Number Model Number Date of Manufacture Rear Railgear Unit Serial Number Model Number Date of Manufacture FIGURE 1 2 IDENTIFICATION PLATE RAFNA INDUSTRIES LIMITED MONTREAL QUEBEC 514 457 4373 ROAD TO RAIL CONVERSION UNIT d Ld MODEL SERIAL BUILT Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 GENERAL INFORMATION 5 0 SPECIFICATIONS Item Metric Installed 281 Kg Maximum Vehicle Load 5680 Kg Track Gauges ee dana eiae 1435 mm Wheel Diameter Pepe dead dd 245 mm Bulletin MO25RRG 1 9 SAE 630 15 12 500 Ibs 56 in 10 in Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG OPERATION 2 1 SECTION 2 OPERATION INSPECTIONS BEFORE OPERATION 2 2 PLACING VEHICLE ON THE TRACK 2 3 TRAVELLING ON RAIL 2 7 BRAKING ON RAIL 2 7 REMOVING VEHICLE FROM THE TRACK 2 8 Rafna Industries Ltd 19300 Clark
54. uly 2001 R 2 7 2 Wall INN L B 5 2 00000000 27 6 gz o 007 g e 8 Z2 SND1 E X 108 9 18404405 WOT 5082 4 s 001 2102 8 Tava arera 5 1 ATEN3SST 118 NOILdINJSS4UQ 4571 SLUVd 4 2 Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Tel 1 888 525 3660 Fax 514 457 3567 5 088 2 0 L 3 1 359 awos U 10 91 009 ON luvd 062 30 33333 5 6 Bulletin MO25RRG 65 T33HM IVY 3301449530 M3dVd NO JWS LON ALON jnO WAYLNOW 54181604 APPENDIX Issued July 2001 TI 2 39 gz 1 NOT ZX Nd 23100 ZL jo ONUL 18 8 5 Swo1 cZ0 x Nn 4 1 lt PT 357350 120 8 BNiHSng ANLVINSNI 500 8 L 0 DONS 666 21 I 310 65 co9i u Lot
55. y Rafna Industries Ltd 19300 Clark Graham Baie d Urfe Qc Tel 1 888 525 3660 Fax 514 457 3567 Issued July 2001 Bulletin MO25RRG 5 2 h OPERATION 2 4 Continue lowering the railgear until the hydraulic cylinder 5 is fully extended and the mechanical locking pin clicks into the rail locked position In this position the railgear should be about vertical Release the rear control Ensure that the rear railgear is securely locked in position and correctly contacts the rails before proceeding FIGURE 2 1 ROTATING REAR RAILGEAR OPERATION 6 Lower front railgear unit refer to figure 2 2 a b c d e f 9 With railgear unit correctly deployed onto the rails reverse vehicle until the front railgear guide wheels are directly over the rails Place the vehicle s automatic transmission in PARK manual transmission in NEUTRAL apply the parking brake and re energize the Railgear Pump if required by turning on the respective dash switch Raise the railgear out of the mechanical locking system by selecting Raise on the front control 1 Release the mechanical locking pin 2 from the highway locked position by moving the locking handle 3 towards the left side of the vehicle Hold the locking handle in this position Lower the railgear by selecting Lower on the front control Release the locking handle once the railgear has rotated below th
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