MODEL R-250 HD CUSHION-RIDE RAILGEAR INSTALLATION … · Issued July 2001 Bulletin MI25RRG INITIAL...

Issued July 2001 Bulletin MI25RRG

RAFNA 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

INSTALLATION MANUAL

"ROTATING FRONT - ROTATING REAR"

READ THIS MANUAL BEFORE INSTALLING RAILGEAR EQUIPMENT

Railgear Model: CR-250HD-055 Application Models: 2001 GMC 2500HD (All Models *25***HD)


Rafna Industries Ltd, 19300 Clark-Graham, Baie d’Urfe, Qc Tel: 1-888-525-3660 Fax: (514) 457 -3567

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.



TABLE OF CONTENTS Initial Preparation Section 1 Safety Precautions 1-2 Installation Procedure Overview 1-3 Preparations For Railgear Installation 1-4 Road Wheel and Tire Installation 1-5 Railgear Installation Section 2 Front Railgear Mounting Plate Installation 2-2 Front Railgear Installation 2-4 Front Rail Wheel & Rail Sweep Installation 2-5 Front Bumper Installation 2-7 Rear Railgear Mounting Plate Installation 2-8 Rear Railgear Installation 2-10 Rear Rail Wheel & Rail Sweep Installation 2-12 Auxiliary Installations Section 3 Steering Wheel Lock Installation 3-2 Hydraulic System Installation 3-4 Electrical System Installation 3-6 Preparations For Operation 3-9 Check List 3-10 Alignment Chart 3-12 Appendix Section 4

Issued July 2001 Bulletin MI25RRG INITIAL PREPARATION 1-1


SECTION 1: INITIAL PREPARATION SAFETY PRECAUTIONS 1-2 INSTALLATION PROCEDURE OVERVIEW 1-3 PREPARATIONS FOR RAILGEAR INSTALLATION 1-4 ROAD WHEEL AND TIRE INSTALLATION 1-5



1.0 SAFETY PRECAUTIONS

WARNING: § Installation instructions provided below only address the Rafna

Industries railgear equipment. Applicable railway company procedures and policies must be adhered to.

§ Always disconnect the vehicle’s battery when welding on the vehicle or

railgear in order to protect the vehicle’s electrical system. § Before performing any work under the vehicle or railgear, ensure the

engine is turned off and the parking brake is set. § Beware of all pinch points on the railgear and keep all parts of the body

clear. § With the installation of the special larger tires and rims, it may be

necessary to recalibrate the vehicle’s speedometer.

§ The following safety precautions should be taken before the vehicle is tested or operated:

ü Read the Operating, Service and Parts Manual ü Visually inspect the railgear for damaged parts ü Perform the Alignment Procedure ü Check for loose rail and road wheels and fasteners ü Check for leaking hydraulic lines and cylinders ü Check for proper lubrication

Failure to heed to any of the above mentioned warnings could result in severe bodily injury and/or equipment damage.

IF ANY INSTALLATION PROBLEMS ARE ENCOUNTERED, PLEASE CALL RAFNA INDUSTRIES LTD AT 1-888-525-3660 FOR TECHNICAL ASSISTANCE BEFORE CONTINUING WITH THE INSTALLATION PROCESS.



2.0 INSTALLATION PROCEDURE OVERVIEW This manual covers the installation of the Rafna Industries R-250 HD rotating front railgear and rotating rear railgear on the following vehicles:

§ 2001 GMC 2500 HD (All Models *25***HD) Please refer to the appendix for the latest additions that have not been included in this manual. The Rafna Industries R-250 HD railgear is a hydraulically operated system applicable to vehicles of up to 12,500 lbs G.V.W.R. Both front and rear units are hydraulically moved from rail to highway and highway to rail positions and are mounted to the vehicle frame. The hydraulic power is supplied through an auxiliary electrical hydraulic pump. The installation procedure consist of first installing special vehicle tires and rims, followed by installation of the front and rear railgear. The hydraulic and electrical installations follow and finally an adjustment of the equipment is performed. This manual uses the orientation convention for the vehicle as shown in figure 1-1.



3.0 PREPARATIONS FOR RAILGEAR INSTALLATION The following steps must be performed on all vehicles prior to installation of the railgear equipment: 1. Disconnect the negative battery terminal. 2. Remove the spare tire from under the vehicle’s cargo box if so equipped. 3. Remove the front bumper and all related mounting brackets. Retain all parts for re-

installation. 4. On Short Box Model (*257**HD) Trucks Only: Remove the rear bumper and all

related mounting brackets. Retain all parts for re-installation. 5. Remove the tail pipe section of the exhaust system. The tail pipe will have to be bent

and / or trimmed to fit following installation of the railgear.



4.0 ROAD WHEEL AND TIRE INSTALLATION In order for the vehicle’s tires to ride centered on the rails and avoid contact with the vehicle, it is necessary to install special 19.5” tires, offset rims and spacers. The following procedure details how to install the road wheel and tire modification assembly. The hardware required for this installation is listed in table 1-1.

Table 1-1: Road Wheel And Tire Installation Hardware Part Number Description Qty Goodyear G133 8R19.5” Tire (Not Supplied) 4 + 1 spare R-075 19.5” Offset Rim 4 + 1 spare R-2823 Wheel Spacer 4 R-2426 Turning Stop Block 2 R-078 90° Tapered Lug Nut 32 R-085 Replacement Front Wheel Stud 16 R-092 Replacement Rear Wheel Stud 16

IMPORTANT: § The special rims and tires must be installed before the railgear is installed in

order to obtain correct height measurements. § Do not hit the wheel spacers with any hard objects as this could dent the

spacer and cause vibrations when driving. If the spacers do not easily slide onto the hubs, lightly sand the hub and the inside of the spacer.

1. Jack up the vehicle and secure it on jack stands. 2. Remove the original front and rear wheels. 3. Mount and balance the special 19.5” tires on the offset rims. Rafna recommends the

use of Goodyear G-133 8R19.5 tires on all five rims, however equivalent tires with identical dimensions may be used at the installer’s discretion. When balancing the rims, install the balance weights on the exterior rim bead if possible. This will result in enabling a tighter turning radius when the turning stop blocks are installed.

4. Install the front and rear offset wheels: (refer to figure 1-2)

a) Replace the original front and rear wheel studs with the supplied long studs according to the vehicle manufacturer’s service manual. Note that the front wheel studs have a spacer on the head of the stud.

b) Place the wheel spacers (1) onto the hubs (2) over the new studs (3).



c) Mount the 19.5” offset wheels (4) on the hubs over the same new studs with the supplied 90° tapered lug nuts (5). Do not us e the original GMC nuts as they have a 60° taper and will fail to secure the rim to the hub.

d) Torque the 32 tapered lug nuts to 130-150 ft-lbs as per the sequence shown in figure 1-3.

5. Install the front wheel turning stop blocks:

a) Position the stop blocks on the back side of the lower suspension arms at the point where the original wheel stops on the hubs contact the suspension arms during full turn.

b) Tack weld the stop blocks to the lower suspension arms in this position. c) With the special offset wheels installed, jack up the vehicle by the frame so that

the front suspension is at maximum droop. d) Turn the steering wheel to each side until the new stop blocks contact the original

wheel stops on the hubs. Ensure that the offset rims and rim balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and / or any other obstruction. A 1/8” minimum clearance is required all around throughout the entire motion of the rim. It may be necessary to add or remove material from the turning stop blocks.

e) Fully weld the turning stop blocks to the lower suspension arms once their position and length is verified.

6. With the installation of the special larger tires and rims, it may be necessary to

recalibrate the vehicle’s speedometer.

Issued July 2001 Bulletin MI25RRG RAILGEAR INSTALLATION 2-1


SECTION 2: RAILGEAR INSTALLATION FRONT RAILGEAR MOUNTING PLATE INSTALLATION 2-2 FRONT RAILGEAR INSTALLATION 2-4 FRONT RAIL WHEEL & RAIL SWEEP INSTALLATION 2-5 FRONT BUMPER INSTALLATION 2-7 REAR RAILGEAR MOUNTING PLATE INSTALLATION 2-8 REAR RAILGEAR INSTALLATION 2-10 REAR RAIL WHEEL & RAIL SWEEP INSTALLATION 2-12



1.0 FRONT RAILGEAR MOUNTING PLATE INSTALLATION This section covers the installation of the R-250 HD front railgear mounting plates. The hardware required for this installation is listed in table 2-1.

Table 2-1: Front Railgear Mounting Hardware Part Number Description Qty R-2477D Front Mounting Plate (Left Side) 1 R-2477P Front Mounting Plate (Right Side) 1 R-2650 Front Mounting Angle 2 R-2438 Washer Plate 2 ½” UNC Gr. 8 Bolt x 4 ½” Long 4 ½” UNC Gr. 8 Bolt x 2” Long 2 ½” Gr. 8 Washer 12 ½” UNC Gr. 8 Nylon Insert Lock Nut 6 ¾” UNC Gr. 8 Bolt x 2 ½” Long 4 ¾” Gr. 8 Washer 8 ¾” UNC Gr. 8 Nylon Insert Lock Nut 4 The following procedure details the mounting plate installation (refer to figure 2-1): 1. There are two “thru” holes in the sides of the mounting plates and one hole in the

bottom of the mounting plates. Take note of the location of these holes. Insert the front mounting plates (1) into the frame channels (2) as shown.

2. The lower “thru” hole in each mounting plate should line up with existing holes in the

sides of the frame. Use ½” x 4 ½” long bolts (3) to secure the mounting plates at these locations.

3. The bottom hole in each mounting plate should line up with a large hole in the bottom

of the frame. Place the washer plates (4) on the outside of the frame and use ½” x 2” long bolts (5) to secure the mounting plates at these locations. The washer plates prevent the bolt heads from pulling through the holes in the frame.

4. Drill the frame 9/16” to match the location of the upper “thru” holes in the mounting

plates. Use ½” x 4 ½” long bolts (6) to secure the mount plates at these locations. 5. Ensure both plates align with each other and torque the ½” bolts to 100 ft-lbs. 6. Attach the front mounting angles (7) to each mounting plate with two ¾” x 2 ½” long

bolts (8) per side. 7. Ensure the mounting angles are at 90° to the ground and torque the four ¾” bolts to

175 ft-lbs. Tack weld the mounting angles in this position to maintain alignment.



8. Re-install the front bumper in its original position. Note that the bumper will have to be trimmed around the mounting plates.



2.0 FRONT RAILGEAR INSTALLATION This section covers the installation of the R-250HD rotating front railgear. The hardware required for this installation is listed in table 2-2.

Table 2-2: Front Railgear Installation Hardware Part Number Description Qty R-2689F Rotating Front Railgear 1 ¾” UNC Gr. 8 Bolt x 2 ½” Long 4 ¾” Gr. 8 Washer 8 ¾” UNC Gr. 8 Nylon Insert Lock Nut 4 The following procedure details the front railgear installation (refer to figure 2-2): 1. Position the railgear (1) in front of the vehicle with the railgear mounting brackets (2)

facing the mounting hardware (3) already installed on the vehicle. 2. The railgear has eight mounting holes on each side to fit a wide variety of vehicle

heights. Raise the railgear to the vehicle. Align the mounting holes such that the center of the railgear pivot point is 17-18” from the ground. Use four ¾” x 2 ½” long bolts (4) to secure the railgear to the mounting hardware.

3. Tighten but do not torque the four ¾” bolts securing the railgear to the mounting

hardware. These bolts will be torqued following the alignment procedure.



3.0 FRONT RAIL WHEEL & RAIL SWEEP INSTALLATION This section covers the installation of the front rail wheels and rail sweeps. The hardware required for this installation is listed in table 2-3.

Table 2-3: Front Rail Wheel & Rail Sweep Installation Hardware Part Number Description Qty R-1600 10” Wheel Assembly 2 R-2409R Rail Sweep (Right Side) 1 R-2409L Rail Sweep (Left Side) 1 ½” UNC Gr. 8 Bolt x 2” Long 8 ½” Gr. 8 Washer 16 ½” UNC Gr. 8 Nylon Insert Lock Nut 8 The following procedure details the rail wheel and rail sweep installation (refer to figure 2-3): 1. Place the front rail wheels (1) below the mounting tables (2) on the railgear axle (3). 2. Place the rail sweeps (4) in front of each wheel and on top of the mounting tables. 3. Bolt the rail wheels and rail sweeps to the mounting table with eight ½” x 2” long

bolts (5). 4. Tighten but do not torque the eight ½” bolts. These bolts will be torqued following

the rail wheel alignment. 5. Slowly raise the railgear manually to the highway position and check clearances. The

front bumper may have to be trimmed to clear the rail wheels and rail sweeps. 6. With the railgear in the fully raised position and the offset wheels installed, the rail

wheel flange must be a minimum of 7 ½” above the ground. If necessary adjust the railgear to the next set of mounting holes to compensate the height.



4.0 RAILGEAR FRONT BUMPER INSTALLATION This section covers the installation of the railgear front bumper after installing the R-250 HD front railgear. The hardware required for this installation is listed in table 2-4.

Table 2-4: Railgear Front Bumper Installation Hardware Part Number Description Qty R-2687AL Railgear Front Bumper 1 R-2688 Front Bumper Spacer 2 R-051 Side Wand Set With Fasteners 1 ½” UNC Gr. 8 Bolt x 4” Long 4 ½” Gr. 8 Washer 8 ½” UNC Gr. 8 Nylon Insert Lock Nut 4 The following procedure details the railgear front bumper installation (refer to figure 2-4) 1. Fasten the front bumper (1) and front bumper spacers (2) to the railgear bumper

brackets (3) with four ½” x 4” long bolts (4). 2. Align the bumper and tighten the four ½” bolts. 3. Drill a ¼” hole (5) in the top flange of each end of the bumper. 4. Fasten the side wands (6) to each end of the front bumper with the supplied fasteners

through the holes drilled in step 3.



5.0 REAR RAILGEAR MOUNTING PLATE INSTALLATION This section covers the installation of the R-250 HD rear railgear mounting plates. The hardware required for this installation is listed in table 2-5.

Table 2-5: Rear Railgear Mounting Plate Hardware Part Number Description Qty R-2820D Rear Mounting Plate (Left Side) 1 R-2820P Rear Mounting Plate (Right Side) 1 ½” UNC Gr. 8 Bolt x 2” Long 8 ½” GR. 8 Washer 16 ½” UNC Gr. 8 Nylon Insert Lock Nut 8 The following procedure details the mounting plate installation (refer to figure 2-5): 1. If the truck is equipped with rear over-load springs, remove the rear over-load bump

stops from the frame as they will interfere with the mounting plates. Retain all parts for re-installation.

2. The rear mounting plates (1) are supplied with no holes drilled in them. Six holes

must be drilled in each mounting plate; two holes (2) forward of the spring hanger (3), two holes (4) rearward of the spring hanger and two holes (5) to clear the rivet heads on the frame (6).

3. Place the mounting plates on the outside of the frame around the spring hangers.

Position the mounting plates so that the railgear mounting surface is horizontal and 22” from the ground. The mounting plates should be aligned with each other front to back. Clamp the mounting plates in this position.

4. Mark each mounting plate as follows: two marks over the rivet heads, two marks

through the existing holes in the frame where the over-load bump stop is mounted, and two marks rearward of the spring hanger. On short box model trucks, the two last marks should be where the bumper mounts to the frame. On long box model trucks, the frame will have to be drilled also at these two last marks.

5. Remove the mounting plates from the frame and drill each mounting plate with ¾”

holes over the rivet heads and ½” holes for the four mounting bolts. On long box model trucks, also drill the frame to match the two rear-most holes.

6. Re-position the mounting plates on the frame. 7. Use two ½” x 2” long bolts (7) to secure each mounting plate to the frame through the

two forward holes. (Note: If the truck was equipped with rear over-load springs, replace the rear over-load bump stops over the mounting plates and use longer bolts – not supplied. Also the third and fourth bump stop mounting holes will need to be drilled through the mounting plates.)



8. On short box model trucks: Use two ½” x 2” bolts (8) to secure each mounting

plate and the original rear bumper brackets to the frame through the original holes in the frame.

9. On long box model trucks: Use two ½” x 2” bolts (8) to secure each mounting plate

to the frame through the rear most holes in the mounting plates. 10. Ensure that the distance from the bottom of the mounting plates to the ground is about

22” and that the railgear mounting surface is parallel to the ground. Torque the ½” bolts to 100 ft-lbs.



6.0 REAR RAILGEAR INSTALLATION This section covers the installation of the rear railgear. The hardware required for this installation is listed in table 2-6.

Table 2-6: Rear Railgear Installation Hardware Part Number Description Qty R-2818B Rotating Rear Railgear w/ In-Cab Controls/Cable Lock 1 “Pull To Unlock” Cable Decal Plate 1 5/8” UNC Gr. 8 Bolt x 2” Long 4 5/8” Gr. 8 Washer 8 5/8” UNC Gr. 8 Nylon Insert Lock Nut 4 The following procedure details the rear railgear installation (refer to figure 2-6): 1. Position the railgear (1) below the mounting plates (2) with the hydraulic cylinder

free end (3) facing to the front. 2. Raise the railgear to the mounting plates and align the mounting holes in the railgear

with the slots in the mounting plates. Note that the mounting plates have multiple mounting slots. Position the railgear as far forward as possible while ensuring that the free end of the cylinder is clear of the differential cover.

3. Fasten the railgear in place with four 5/8” x 2” long bolts (4). 4. Tighten but do not torque the four 5/8” bolts securing the railgear to the mounting

plates. These bolts will be torqued following the alignment procedure. 5. Fabricate and install a bracket to secure the railgear locking cable handle (5) in a

convenient location near to where the rear railgear control will be installed. Ensure the “Pull To Unlock” Decal Plate is visible on the locking cable’s bulkhead fitting.

6. On Short Box Model Trucks Only: Re-install the bumper in it’s original position.



7.0 REAR RAIL WHEEL & RAIL SWEEP INSTALLATION This section covers the installation of the rear rail wheels and rail sweeps. The hardware required for this installation is listed in table 2-7.

Table 2-7: Rear Rail Wheel & Rail Sweep Installation Hardware Part Number Description Qty R-1600 10” Wheel Assembly 2 R-2409L Rail Sweep (Right Side) 1 R-2409R Rail Sweep (Left Side) 1 ½” UNC Gr. 8 Bolt x 2” Long 8 ½” Gr. 8 Washer 16 ½” UNC Gr. 8 Nylon Insert Lock Nut 8 The following procedure details the rear rail wheel and rail sweep installation (refer to figure 2-7): 1. Place the rear rail wheels (1) below the mounting tables (2) on the railgear axle (3). 2. Place the rail sweeps (4) to the rear of each wheel and on top of the mounting tables. 3. Bolt the rail wheels and rail sweeps to the mounting table with eight ½” x 2” long

bolts (5). 4. Tighten but do not torque the eight ½” bolts. These bolts will be torqued following

the rail wheel alignment. 5. Re-install the tail pipe. The tail pipe may require bending and / or trimming to clear

the railgear. 6. Slowly raise the railgear manually to the highway position and check clearances. The

rear bumper and rear quarter panels may have to be trimmed to clear the rail wheels and rail sweeps.

Issued July 2001 Bulletin MI25RRG AUXILIARY INSTALLATIONS 3-1


SECTION 3: AUXILIARY INSTALLATIONS STEERING WHEEL LOCK INSTALLATION 3-2 HYDRAULIC SYSTEM INSTALLATION 3-4 ELECTRICAL SYSTEM INSTALLATION 3-6 PREPARATIONS FOR OPERATION 3-9 CHECK LIST 3-10



1.0 STEERING WHEEL LOCK INSTALLATION This section covers the installation of the steering wheel lock. The hardware required for this installation is listed in table 3-1.

Table 3-1: Steering Wheel Lock Installation Hardware Part Number Description Qty R-2481 Steering Wheel Lock 1 R-2425 Backing Plate 1 R-2423 Lock Retainer 1 R-2466 Steering Column Side Plate 2 Steering Wheel Lock Decal 1 No. 10 Self Tapping Screw x ½” long 4 ¼” UNC Sunk Head Bolt x 1 ½” Long 2 ¼” SAE Washer 2 ¼” UNC Gr. 3 Nylon Insert Lock Nut 2 The following procedure details the steering wheel lock installation (refer to figure 3-1):

1. Insert the steering wheel lock (1) into the lock retainer (2) and position them on the

steering column top cover (3). Note that it may be necessary to slightly bend the steering wheel lock to get a snug fit on top of the steering wheel.

WARNING: § Ensure that the air bag cover in the steering wheel is not obstructed by

the installation of the steering wheel lock. 2. Ensure the position will enable complete locking of the steering wheel (4) while not

covering the air bag and mark the location of the holes required to bolt the lock retainer to the steering column top cover.

3. Remove the steering column top cover and drill two 5/16” holes where marked in step

2. Note that it may be necessary to remove the steering wheel to access the steering column top cover retainers.

4. Place the backing plate (5) on the inside of the steering column top cover and the lock

retainer on the outside of the cover, then fasten in place with two ¼” x 1 ½” long bolts (6).

5. Install the steering column top cover and store the steering wheel lock in the cab.



6. Place each steering column side plate (7) against each side of the steering column over the join between the top and bottom steering column covers. Using two self-tapping screws (8), secure each side plate in place to hold the top and bottom covers together.

7. Locate and stick the Steering Wheel Lock decal in a highly visible spot on the dash.



2.0 HYDRAULIC SYSTEM INSTALLATION This section covers the installation of the hydraulic pump, hoses and operating controls. The hardware required for this installation is listed in table 3-2.

Table 3-2: Hydraulic System Installation Hardware Part Number Description Qty R-060 Hydraulic Pump w/ Coil and Electric Operating Valves 1 ¼” Hose 35” Long w/ straight end & 90° end 2 ¼” Hose 300” Long w/ straight end & 90° end 2 3/8” Male O-Ring Boss to ¼” Male JIC Fitting 4 3/8” UNC Gr. 8 Bolt x 1.25” Long 4 3/8” SAE Washer 8 3/8” UNC Gr. 3 Nylon Insert Lock Nut 4 The following procedure details the hydraulic system installation (refer to figure 3-2 or refer to the Operating, Service and Parts manual for more detailed hydraulic schematics):

IMPORTANT: § When routing hydraulic hoses, ensure that the hoses do not contact any

sharp edges or hot surfaces. § When connecting hydraulic hoses, refer to the orientation convention shown

in figure 1-1 as figure 3-2 shows only schematics, not orientation. 1. Install the hydraulic pump onto the mounting bracket on the right side of the front

railgear. Ensure that the pump does not block the vehicle lights. The pump should be oriented with the hydraulic manifold and valves on top and the plastic tank towards the center of the railgear. Use 3/8” x 1.25” bolts to secure the pump to the mounting bracket. (Note: If the pump is to be installed in an alternate location, take note of the pump suction pipe location in the tank. It must always be oriented downwards.)

2. Remove the solenoid from the hydraulic pump and fasten it under the hood in a

suitable location near to the vehicle’s battery. Ensure that the solenoid base is properly grounded. Re-install the solenoid retaining screws on the pump to prevent moisture from entering the pump motor.

3. Install a 3/8” male O-Ring Boss to ¼” male JIC hydraulic fitting on each of the four

pressure ports on the hydraulic pump valves. 4. Determine which pump mounted hydraulic valve is operated by the control box on

the short length of wire. Connect a 35” long hydraulic hose (straight & 90° ends) from each pressure port of this valve to each port on the front railgear hydraulic cylinder. The 90° hose ends should be at the pump pressure ports.



5. Connect a 300” long hydraulic hose (straight & 90° ends) from each pressure port of

the second pump mounted hydraulic valve to each rear railgear hydraulic cylinder port. The 90° hose ends should be installed at the pump pressure ports. Route the two long hoses along the left side of the frame to the rear of the vehicle and tie-wrap in place.

6. Ensure all hydraulic hoses and fittings have been correctly installed as per figure 3-2,

then tighten all fittings. 7. Tie-wrap all hoses securely so they do not rub.



3.0 ELECTRICAL SYSTEM INSTALLATION This section covers the installation of the electrical system. The hardware required for this installation is listed in table 3-3.

Table 3-3: Electrical System Installation Hardware Part Number Description Qty R-1567 Illuminated Dash Switch 1 R-1577 5A In-Line Fuse 1 Not Supplied 14 Gauge Stranded Coppe r Wire As Req’d Not Supplied 4 Gauge Copper Wire, Neoprene Jacketed (SAE J1127-

type SRG) As Req’d

Not Supplied Cable Loom As Req’d The following procedure details the electrical system installation (refer to figure 3-3): (Refer to the Operating, Service and Parts manual for more detailed electrical schematics)

IMPORTANT: § When routing electrical wires, ensure that the wires do not contact any sharp

edges or hot surfaces. § All wire connections are to be soldered and heat shrink sealed to prevent

future corrosion related problems. § All wires must be covered with protective cable loom.

1. Install the illuminated dash switch in a convenient location under the dashboard. 2. Install the 5 Amp in-line fuse under the hood near the railgear pump solenoid. 3. Using suitable 4 gauge wire, cable loom, connectors, solder and heat shrink tubing:

a) Connect one wire from the vehicle’s battery to the “Batt” terminal on the railgear pump solenoid mounted under the hood.

b) Connect another wire from the “Motor” terminal on the solenoid to the terminal on the pump motor.

c) Apply a small amount of silicon sealant to the pump motor terminal to protect it from shorting out or rusting.

4. Ensure that the pump motor base is properly grounded to the vehicle chassis. Using

suitable 4 gauge wire, cable loom, connectors, solder and heat shrink tubing: a) Connect one wire from the railgear pump motor base to a suitable ground

location. The railgear may not be grounded due to paint on the mounting plates and tar on the frame.



5. Using suitable 14 gauge wire, cable loom, connectors, solder and heat shrink tubing: a) Connect a wire from the “Batt” terminal on the railgear pump solenoid to the 5

Amp in-line fuse. b) Connect a wire from the 5 Amp in-line fuse through the firewall to the illuminated

dash switch supply terminal. c) Connect a wire from the illuminated dash switch load terminal through the

firewall. Splice, at this point, with the black wire coming out of the pump motor. d) Connect a wire from the illuminated dash switch ground terminal to a suitable

ground. e) Connect the white wire coming out of the pump motor to the switching terminal

on the railgear pump solenoid. 6. The wiring to and from the control boxes and the hydraulic valves are pre-wired from

the factory. The installer may lengthen or shorten these wires as required. 7. Position and secure the control box with the short length of wire on the bracket on the

left side of the front railgear. It is possible to disconnect the control box wiring in order to facilitate routing of the wire harness. Ensure that the wires are reconnected correctly.

8. Position and secure the control box with the long length of wire in a convenient

location near the rear railgear lock-up cable handle. It is possible to disconnect the control box wiring in order to facilitate routing of the wire harness. Ensure that the wires are reconnected correctly.

9. Ensure all wires are enclosed in cable loom, soldered and secured with tie-wraps. 10. If during testing the front railgear moves when the rear controls are used (or vice-

versa), interchange the hydraulic hoses from the upper to the lower hydraulic valves on the pump.

11. If during testing the railgear goes down when the “Raise” button is pushed on the

control box, interchange the two hydraulic hoses at the respective hydraulic valve on the pump.



4.0 PREPARATIONS FOR OPERATION This section covers the preparation of the vehicle before having it put in service. 1. Fill the hydraulic system and bleed the air out:

a) Fill the hydraulic pump tank with ESSO Univis N-22 (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 Operating, Service and Parts Manual for operating instructions)

c) Refill the hydraulic pump tank and repeat step b) until all air is removed from the front hydraulic system. (the fluid level will be constant)

d) Operate the rear railgear up and down briefly to circulate the fluid and bleed the system of air. (refer to the Operating, Service and Parts Manual for operating instructions)

e) Refill the hydraulic pump tank and repeat step d) until all air is removed from the rear hydraulic system. (the fluid level will be constant)

2. Perform the Hydraulic Relief Valve Setting Adjustment Procedure detailed in the

Operating, Service and Parts Manual. 3. Perform the Rail Wheel Pressure Adjustment Procedure detailed in the Operating,

Service and Parts Manual. 4. Perform the Railgear and Rail Wheel Alignment Procedure detailed in the Operating,

Service and Parts Manual. Be sure to torque the railgear mounting bolts and the rail wheel mounting bolts following the alignment procedure.

5. Check for lubrication at all lubrication points detailed in the Operating, Service and

Parts Manual. 6. Check for correct bolt torque values as detailed in the Operating, Service, and Parts

Manual. 7. Adjust all rail sweeps have 1/8” clearance from the track. 8. Ensure the vehicle rims and tires clear throughout their full range of motion. 9. Complete the Installation Check List in the following section to make sure nothing

has been forgotten. 10. Read the entire Operating, Service, and Parts Manual before attempting operation of

the railgear equipped vehicle.



RAFNA R-250 HD PREDELIVERY CHECK LIST

Railgear Serial #: Vehicle Year: Model: Vehicle Make:

Date Received: Vehicle Model: Date Completed: Vehicle V.I.N. :

Installation By: Inspection By: Check List Item Approved/Value Remarks

Hydraulic pump attached properly Hydraulic system bled of air Railgear pump relief set at 1800psi Split loom used on all exposed hyd. hoses Hyd. hoses clear of heat & sharp edges Hydraulic system free of leaks Hyd. pump grounded Electrical connections soldered and sealed Split loom uses on all exposed wires Wires clear of heat & sharp edges Rail sweeps installed Front railgear pivot 17” - 18” from ground Rear mounting plates 22” from ground Rear mounting plates parallel to ground Rail wheel pressures adjusted Check tire air press

Front left Front right

Rear left Rear right

Railgear alignment completed Distance between rail wheel flanges 53-7/16” to 53-½”

Front rail wheels Rear rail wheels

Distance between tire centers Front tires 62” to 63” Rear tires 59-¼” to 61-½”

Rail sweeps adjusted 1/8” above track Front railgear is 90 ±1° on track Rear railgear is 90 ±1° on track Rail wheel bearings end-play adjusted Distance front rail wheel flange to ground Min 7-½” Distance rear rail wheel flange to ground Min 12-½” Front and rear lock systems engage easily



RAFNA R-250 HD PREDELIVERY CHECK LIST

Railgear Serial #: Vehicle Year: Model: Vehicle Make:

Date Received: Vehicle Model: Date Completed: Vehicle V.I.N. :

Installation By: Inspection By: Check List Item Approved/Value Remarks

Steering wheel lock system installed Bumpers installed and trimmed Side wands installed on front bumper Rims/tires clear thru full range of motion Tail pipe clear of tire and railgear Truck rims / tires clear all obstructions Truck wheel spacers installed Steering lock decal installed on dash Railgear lubricated All bolts torqued as per specifications See O.P.S. Manual Vehicle track tested Operating, Service & Parts Manual in truck



Front

D

K

L

C B

A

Rear

H

GP

O

E

MF

N

AB

JI

The front and rear dimensions between the string lines should be equal.The dimensions from front to rear should also be equal.

FRONT

REAR

Truck Model Truck Number

Hi-Rail S/N

Rail wheel Load (lbs)

Left Front Right FrontRight RearLeft Rear

Rear

Front

Rail wheel Flange To Gound

Rail wheels Flange To Flange 53 7/16" to 53 9/16"

RearFront Front Rear Rear

Front

A,B,C,D Must be Equal. E,F,G,H Must be Equal.(A,B,C,D May not be Equal to E,F,G,H).

I and J Must be Equal within 1/16"K and L Must be Equal within 1/16"M and N Must be Equal within 1/16"O and P Must be Equal within 1/16"

P and M Must be Equal within 1/8"O and N Must be Equal within 1/8"

L and J Must be Equal within 1/8"K and I Must be Equal within 1/8"

MONTREAL, QUE.

APPROVED:

REFERENCE:

DESCRIPTION: ALIGNMENT MEASUREMENTS

NOTE: NOT FULL SCALE ON PAPER

DATE: JAN 07/02

DRAWING NO.:

DRAWING SCALE:

DRAWN: S.R.

DIM:

PART NO.:

PAGE OF

MAT'L:

RAFNA INDUSTRIES LIMITED

ALIGNMENT MEASUREMENTS

I

J

Q

Q'

Q Q'

Issued July 2001 Bulletin MI25RRG APPENDIX 4-1


SECTION 4: APPENDIX

Rafna Industries Limited A Global Railway Industries Company

Form MA-01

ADDENDUM TO INSTALLATION MANUAL

MA #: MI25RRG-0-MA01 Date: May 24, 2002

Affected Manual / Railgear

Railgear Model: R-250HD Manual #: MI25RRG (Rev 0)

Affected Page(s): 2-2 & 2-3 Addendum Information: This addendum updates the Installation Manual to include 2003 GMC / Chevy 2500HD vehicles. For these trucks, the front mounting plates are part number R-2477AD and R-2477AP. Additionally, the former Front Mounting Angles (part number R-2650) have been replaced with new Front Mounting Angles (part number R-2698) for all 2001-2003 GMC / Chevy 2500HD vehicles. This change affects the contents of table 2-1, the installation step 3 and figure 2-1. Refer to new table 2-1 below for updated part numbers and quantities required for installation.

Table 2-1: Front Railgear Mounting Hardware Part Number Description Qty R-2477D Front Mounting Plate (LHS) 2001-2002 Vehicles R-2477AD Front Mounting Plate (LHS) 2003 Vehicles

1

R-2477P Front Mounting Plate (RHS) 2001-2002 Vehicles R-2477AP Front Mounting Plate (RHS) 2003 Vehicles

1

R-2698 Front Mounting Angle 2 R-2438 Washer Plate 2 ½” UNC Gr. 8 Bolt x 4-½” Long 4 ½” UNC Gr. 8 Bolt x 2” Long 2 ½” Gr. 8 Washer - 2001-2002 Vehicles 12 ½” Gr. 8 Washer - 2003 Vehicles 10 ½” UNC Gr. 8 Nylon Insert Lock Nut - 2001-2002 6 ½” UNC Gr. 8 Nylon Insert Lock Nut - 2003 4 ¾” UNC Gr. 8 Bolt x 2-½” Long 4 ¾” Gr. 8 Washer 8 ¾” UNC Gr. 8 Nylon Insert Lock Nut 4


Refer to new installation step 3 below for updated installation instructions. 3. The bottom hole in each mounting plate should line up with a large hole in the

bottom of the frame. Place the washer plates (Item 4) on the outside of the frame and use ½” x 2” long bolts (Item 5) to secure the mounting plates at these locations. The washer plates prevent the bolt heads from pulling through the holes in the frame. On 2003 vehicles the nuts for the ½” bolts are welded to the mounting plates. On 2001-2002 vehicles these nuts and washers must be installed by hand.

Refer to new figure 2-1 below for updated installation instruction sketches.

FIGURE 2-1: FRONT MOUNTING PLATE INSTALLATION

1

3

2

4

56

78IDENTICAL FASTENERS

NOT SHOWN FOR CLARITY

Rafna Industries Limited

A Global Railway Industries Company

MANUAL ADDENDUM

MA #: MI25RRG-0-MA02 Rev. 1 Date: May 20, 2003


Railgear Model: R-250 (GMC Vehicles) Manual #: MI25RRG

Affected Page(s): Section 1-4 (page 1-5)

Addendum Information: This addendum updates the Installation Manual to include the installation of both OTR and GKN road wheels on the vehicle, as well as the installation of GKN wheels as applicable to 2003 GMC Suburban trucks. The Road Wheel and Tire Installation procedure is now divided into three sub-sections. Each part describes the installation procedure for the specific road wheel. OTR road wheels can be identified by “OTR 10813” stamped on the wheel face, and are gray in color. GKN road wheels are stamped with “GKNUSA” on the wheel face, and are ivory in color. Follow the procedure for the particular type of road wheel. Replace Section 1, sub-section 4.0 in the installation manual with the attached sub-sections:

Rafna Industries Limited Page 2 of 10

A Global Railway Industries Company MI25RRG-0-MA02 Rev. 1

4.0 Road Wheel and Tire Installation – OTR Wheels This section covers the installation of the OTR road wheels and tires required for the vehicle’s tires to ride correctly on the rails and avoid contact with the vehicle. The hardware required for this installation is listed in table 1-1.

Note: The road wheels and tires must be installed before the railgear is installed in order to obtain correct height measurements.

• Do not hit the wheel spacers with any hard objects as this could dent the


The following procedure details how to install the OTR road wheels and tires: 1. Jack up the vehicle and secure it on jack stands. 2. Remove the original front and rear wheels. 3. Based on rail contact area and load carrying capacity, Rafna Industries Ltd. suggests the use

of Goodyear G124 - 225/70R19.5 or Goodyear G133 - 8R19.5 tires on all wheels on the railgear equipped vehicle. However, at the installer's and/or railroad's discretion, an equivalently sized and rated tire may be used. Mount and balance the tires on the wheels.

4. Install the front wheels (refer to figure 1-2):

a) Where fitted, remove all clips installed on the wheel studs. These clips will prevent the wheel spacer from seating properly.

b) Place the front wheel spacers (Item 1) on the front hubs (Item 2) over the original wheel studs (Item 3).

c) Mount the front wheels (Item 4) on the front hubs over the spacers with the original wheel lug nuts (Item 5).

d) Torque the 16 lug nuts to 140 ft-lbs as per sequence in figure 1-3.

Table 1-1: Road Wheel And Tire Installation Hardware – OTR Wheels Part Number Description Qty 19.5” Tire (Not Supplied) 4 + 1 spare R-002 19.5” Wheel 4 + 1 spare R-2402 Front Wheel Spacer 2 R-2699 Front Turning Stop Block 2

!



5. Install the rear wheels: a) Mount the wheels on the hubs with the original lug nuts. No spacers are required on the

rear wheels. b) Torque the 16 lug nuts to 140 ft-lbs as per sequence in figure 1-3.


a) Position the turning stop blocks over the original turning stops on the back side of the lower suspension arms. To verify their position is correct, fully turn the steering wheel until the front hub contacts the suspension arm. The boss on the hub should contact the turning stop block squarely on. Repeat for the other side.

b) Tack weld the stop blocks to the lower suspension arms in this position. c) With the special offset wheels installed, jack up the vehicle by the frame so that the front

suspension is at maximum droop. d) Turn the steering wheel to each side until the new stop blocks contact the original wheel

stops on the hubs. Ensure that the offset rims and/or rim balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and / or any other obstruction. A 1/8” minimum clearance is required all around throughout the entire motion of the rim. It may be necessary to add or remove material from the turning stop blocks.


7. 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, tires, supplied spacers, and supplied turning stop blocks 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. It may be necessary to add or remove material from the turning stop blocks and/or to relocate brake lines, ABS lines, and/or other equipment in order to gain adequate clearances. Ensure that any vehicle modifications are done in accordance with the vehicle manufacturer's or their representative's approval.

8. With the installation of the special larger tires and rims, it may be necessary to recalibrate the

vehicle’s speedometer. 9. A new location must be found for the spare wheel and the necessary brackets fabricated. It

cannot be mounted under the cargo box due to interference with the rear railgear.



Figure 1-2: Front Road Wheel and Tire Installation – OTR Wheels

IDENTICAL FASTENERS NOT SHOWN FOR CLARITY

Figure 1-3: Lug Nut Torque Sequence



4.1 Road Wheel and Tire Installation – GKN Wheels This section covers the installation of the GKN road wheels and tires required for the vehicle’s tires to ride correctly on the rails and avoid contact with the vehicle. Note, for 2003 GMC Suburban trucks refer to the ROAD WHEEL AND TIRE INSTALLATION – GKN WHEELS (2003 GMC-SUBURBAN) section of this addendum. The hardware required for this installation is listed in table 1-2.

Table 1-2: Road Wheel And Tire Installation Hardware – GKN Wheels Part Number Description Qty

19.5” Tire (Not Supplied) 4 + 1 spare R-075 19.5” Wheel 4 + 1 spare R-2823 Wheel Spacer 4 R-2426 Front Turning Stop Block 2 R-078 90° Taper Lug Nut 32 R-085 Front Wheel Stud 16 R-092 Rear Wheel Stud 16

Note: The road wheels and tires must be installed before the railgear is

installed in order to obtain correct height measurements.

• Do not hit the wheel spacers with any hard objects as this could dent the spacer and cause vibrations when driving. If the spacers do not easily slide onto the hubs, lightly sand the hub and the inside of the spacer.

The following procedure details how to install the GKN road wheels and tires: 1. Jack up the vehicle and secure it on jack stands. 2. Remove the original front and rear wheels. 3. Following the vehicle manufacturer’s recommended procedures, remove the original front

wheel studs and install the supplied front wheel studs. Note the supplied front wheel studs have a machined head and a collar on the shank. Refer to figure 1-4.

4. Following the vehicle manufacturer’s recommended procedures, remove the original rear

wheel studs and install the supplied rear wheel studs. Note the supplied rear wheel studs do not have a machined head and a collar on the shank. Refer to figure 1-4.

5. Based on rail contact area and load carrying capacity, Rafna Industries Ltd. suggests the use


!



6. Install the wheels (refer to figure 1-5): a) Where removed, do not reinstall the retaining clips mounted on the wheel stud. These

will prevent the wheel spacer from seating properly on the hub face. b) Place the wheel spacers (Item 1) on the hubs (Item 2) over the newly installed wheel

studs (Item 3). c) Mount the wheels (Item 4) on the hubs over the spacers with the supplied wheel lug nuts

(Item 5). Do not use the original GMC nuts as they have a 60° tape r and will fail to secure the rim to the hub.

d) Torque the 32 lug nuts to 140 ft-lbs as per sequence in figure 1-3.

• Do not re-use the original GMC lug nuts as they have a different taper and will fail to secure the wheels to the hubs.


a) Position the turning stop blocks over the original turning stops on the back side of the lower suspension arms. To verify their position is correct, fully turn the steering wheel until the front hub contacts the suspension arm. The boss on the hub should contact the turning stop block squarely on. Repeat for the other side.



stops on the hubs. Ensure that the offset rims and/or rim balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and / or any other obstruction. A 1/8” minimum clearance is required all around throughout the entire motion of the rim. It may be necessary to add or remove material from the turning stop blocks.



wheel clearances must be checked. With the wheels, tires, supplied spacers, and supplied turning stop blocks 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. It may be necessary to add or remove material from the turning stop blocks and/or to relocate brake lines, ABS lines, and/or other equipment in order to gain adequate clearances. Ensure that any vehicle modifications are done in accordance with the vehicle manufacturer's or their representative's approval.


vehicle’s speedometer.

!



10. A new location must be found for the spare wheel and the necessary brackets fabricated. It cannot be mounted under the cargo box due to interference with the rear railgear.

Figure 1-4: Stud Installation – GKN Wheels

FRONTR-085 STUD INSTALLATION

REARR-092 STUD INSTALLATION

COLLAR

Figure 1-5: Road Wheel and Tire Installation – GKN Wheels

1

3

2

4

5IDENTICAL FASTENERSNOT SHOWN FOR CLARITY



4.2 Road Wheel And Tire Installation – GKN Wheels (2003 GMC-Suburban)

This section covers the installation of the GKN road wheels and tires required for the vehicle’s tires to ride correctly on the rails and avoid contact with the vehicle. This section is applicable to 2003 GMC Suburban trucks. The hardware required for this installation is listed in table 1-3.

Table 1-3: Road Wheel And Tire Installation Hardware Part Number Description Qty Goodyear G133 8R19.5” Tire (Not Supplied) 4 + 1 spare R-075 19.5” Offset Rim 4 + 1 spare R-2823 Front Wheel Spacer (½” offset) 2 R-2823A Rear Wheel Spacer (¾” offset) 2 R-2426 Turning Stop Block 2 R-078 90° Tapered Lug Nut 32 R-085 Replacement Front Wheel Stud 16 R-092 Replacement Rear Wheel Stud 16

Note: The road wheels and tires must be installed before the railgear is installed in order to obtain correct height measurements.

• Do not hit the wheel spacers with any hard objects as this could dent the


The following procedure details how to install the GKN road wheels and tires: 1. Jack up the vehicle and secure it on jack stands. 2. Remove the original front and rear wheels. 3. Following the vehicle manufacturer’s recommended procedures, remove the original front

wheel studs and install the supplied front wheel studs. Note the supplied front wheel studs have a machined head and a collar on the shank. Refer to figure 1-4.

4. Following the vehicle manufacturer’s recommended procedures, remove the original rear

wheel studs and install the supplied rear wheel studs. Note the supplied rear wheel studs do not have a machined head and a collar on the shank Refer to figure 1-4.

5. Based on rail contact area and load carrying capacity, Rafna Industries Ltd. suggests the use


!



6. Install the front offset wheels: (refer to figure 1-6) a) Where removed, do not reinstall the retaining clip mounted on the stud. These will

prevent the wheel spacer from seating properly on the hub face. b) Place the front wheel spacers (½” offset) (Item 1) onto the front hubs (Item 2) over the

new studs (Item 3). c) Mount the 19.5” offset wheels (Item 4) on the hubs over the same new studs with the

supplied 90° tapered lug nuts (Item 5). Do not use the original GMC nuts as they have a 60° taper and will fail to secure the rim to the hub.

d) Torque the 16 tapered lug nuts to 140 ft-lbs as per the sequence shown in figure 1-3.


7. Install the rear offset wheels: (refer to figure 1-4)

a) Where used, do not reinstall the retaining clip mounted on the stud. These will prevent the wheel spacer from seating properly on the hub face.

b) Place the rear wheel spacers (¾” offset) (Item 6) onto the rear hubs (Item 7) over the new studs (Item 8).

c) Mount the 19.5” offset wheels (Item 4) on the hubs over the same new studs with the supplied 90° tapered lug nuts (Item 5). Do not use the original GMC nuts as they have a 60° taper and will fail to secure the rim to the hub.

d) Torque the 16 tapered lug nuts to 140 ft-lbs as per the sequence shown in figure 1-3.



a) Position the turning stop blocks (Item 9) over the original turning stops on the back side of the lower suspension arms. To verify their position is correct, fully turn the steering wheel until the front hub contacts the suspension arm. The boss on the hub should contact the turning stop block squarely on. Repeat for the other side.



stops on the hubs. Ensure that the offset rims and/or rim balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and / or any other obstruction. A 1/8” minimum clea rance is required all around throughout the entire

!

!



motion of the rim. It may be necessary to add or remove material from the turning stop blocks.



wheel clearances must be checked. With the wheels, tires, supplied spacers, and supplied turning stop blocks 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. It may be necessary to add or remove material from the turning stop blocks and/or to relocate brake lines, ABS lines, and/or other equipment in order to gain adequate clearances. Ensure that any vehicle modifications are done in accordance with the vehicle manufacturer's or the ir representative's approval.


vehicle’s speedometer. 11. A new location must be found for the spare wheel and the necessary brackets fabricated. It

cannot be mounted under the cargo box due to interference with the rear railgear.

Figure 1-6: Road Wheel and Tire Installation – GKN Wheels 2003 GMC Suburban

1

5

4

FRONT WHEELS4

5

REAR WHEELS

6

8

(SCALE 3:1)

3

FRONT STUDS WITH SPACERS

REAR STUDS WITHOUT SPACERS(SCALE 3:1)

2

7

9


A Global Railway Industries Company MI25RRG-0-MA03

MANUAL ADDENDUM

MA #: MI25RRG-0-MA03 Rev. 1 Date: May 14, 2003


Railgear Model: R-250 Manual #: MI25RRG Rev. 0

Affected Page(s): Additional Procedure Addendum Information: This addendum updates the Installation Manua l to include the ‘Hook and Loop’ style steering wheel lock. This procedure is only to be used if the vehicle is to be fitted with the ‘Hook and Loop’ style steering wheel lock. This addendum does not replace the existing steering wheel lock installation procedure, but is an addition to section 3 in the manual.

1.1 Steering Wheel Lock Installation - ‘Hook and Loop’ This section covers the installation of the ‘Hook and Loop’ style steering wheel lock. The hardware required for this installation is listed in table 3-1A.

Table 3-1A: Steering Wheel Lock Installation Hardware - ‘Hook and Loop’ Part Number Description Qty S-001050 Steering Wheel Lock (‘loop’ strip with adhesive backing) S-001050B Steering Wheel Lock (‘loop’ strip with adhesive backing)

2

S-001050C Steering Wheel Lock (‘loop’ strip with adhesive backing) S-001050G Hook Strip Holder (‘loop’ strip with adhesive backing)

1

S-001050A Steering Wheel Lock (‘hook’ strip) 1 S-001040 Steering Wheel Lock Decal 1


A Global Railway Industries Company MI25RRG-0-MA03 The following procedure details the ‘Hook and Loop’ steering wheel lock installation (refer to figure 3-1A):

• Ensure the areas where the ‘loop’ strips will be affixed are clean, and free of

dirt and grease. Do not touch these areas, as well as the adhesive on the back of the ‘loop’ strips.

• Wait a minimum of 24 hours for the self-adhesive on the back of the ‘loop’

strips to fully cure. 1. Ensure the front wheels are pointing straight ahead and the steering wheel is centered before

installation. 2. Without removing the protective backing, position the ‘loop’ strips (Item 1) on top of the

steering column cover (Item 2), and the steering wheel (Item 3). Ensure the ‘loop’ strips do not interfere with any devices, such as the hazard light button, on the steering wheel column cover. Modify the ‘loop’ strips as required to clear any obstructions. Mark their locations on the steering wheel column cover and the steering wheel.

3. Without removing the protective backing, position the Hook Strip Holder (1-½” wide x 2”

long) in a convenient place in the cab (i.e., the top of the dash, or other similar smooth surface that does not interfere with the view and/or operation of the vehicle). This will be the ‘hook strip holder’ when the steering lock is disengaged. Mark the location.

4. Scuff the areas previously marked with medium / fine sand paper or a ‘3M Scotch Brite’, or

equivalent, abrasive pad. 5. The areas should be free of dust, dirt, and any oily residue. Thoroughly clean the areas with

denatured alcohol or a similar non-oil based degreaser that will not react with the plastic. Let dry.

6. Take care when placing the ‘loop’ strips; once they are applied, they should not be removed.

Do not touch the adhesive with your fingers. Removing the ‘loop’ strips once installed, or touching the adhesive may cause poor adhesion. Peel off the protective backing from the ‘loop’ strips. Position, and firmly press them into place. Do not disturb the ‘loop’ strips for 24 to 30 hours to allow the adhesive to fully cure.

7. Store the steering wheel lock ‘hook’ strip on the ‘Hook Strip Holder’ located in the cab. 8. Stick the “Steering Wheel Lock” decal in a highly visible spot on the dashboard.

!



Figure 3-1A: Steering Wheel Lock Installation - ‘Hook and Loop’

3

1

2

4



MANUAL ADDENDUM

MA #: MI25RRG-0-MA04 Date: May 18, 2003


Railgear Model: R-250 Manual #: MI25RRG Rev. 0

Affected Page(s): Additional Procedure Addendum Information: This addendum updates the Installation Manual to include the “Road Wheel and Tire Installation” section as applicable to GMC Suburban 2003 year models. This addendum does not replace the existing “Road Wheel and Tire Installation” procedure, but is an addition to section 1 in the manual.


A Global Railway Industries Company MI25RRG-0-MA04 4.1 Road Wheel And Tire Installation (2003 GMC-Suburban) In order for the vehicle’s tires to ride centered on the rails and avoid contact with the vehicle, it is necessary to install special 19.5” tires, offset rims and spacers. The following procedure details how to install the road wheel and tire modification assembly. The hardware required for this installation is listed in table 1-2.

Table 1-2: Road Wheel And Tire Installation Hardware Part Number Description Qty Goodyear G133 8R19.5” Tire (Not Supplied) 4 + 1 spare R-075 19.5” Offset Rim 4 + 1 spare R-2823 Front Wheel Spacer (½” offset) 2 R-2823A Rear Wheel Spacer (¾” offset) 2 R-2426 Turning Stop Block 2 R-078 90° Tapered Lug Nut 32 R-085 Replacement Front Wheel Stud 16 R-092 Replacement Rear Wheel Stud 16

IMPORTANT:

§ The special rims and tires must be installed before the railgear is installed in order to obtain correct height measurements.

§ Do not hit the wheel spacers with any hard objects as this could dent the spacer and cause vibrations when driving. If the spacers do not easily slide onto the hubs, lightly sand the hub and the inside of the spacer.

1. Jack up the vehicle and secure it on jack stands. 2. Remove the original front and rear wheels. 3. Mount and balance the special 19.5” tires on the offset rims. Rafna recommends the use of

Goodyear G-133 8R19.5 tires on all five rims, however equivalent tires with identical dimensions may be used at the installer’s discretion. When balancing the rims, install the balance weights on the exterior rim bead if possible. This will result in enabling a tighter turning radius when the turning stop blocks are installed.


A Global Railway Industries Company MI25RRG-0-MA04 4. Install the front offset wheels: (refer to figure 1-4)

a) Replace the original front wheel studs with the supplied long studs according to the vehicle manufacturer’s service manual. Note that the front wheel studs have a spacer on the head of the stud.

b) Where used, do not reinstall the retaining clip mounted on the stud. This will prevent the wheel spacer from seating properly on the hub face.

c) Place the front wheel spacers (½” offset) (1) onto the front hubs (2) over the new studs (3).

d) Mount the 19.5” offset wheels (4) on the hubs over the same new studs with the supplied 90° tapered lug nuts (5). Do not use the original GMC nuts as they have a 60° taper and will fail to secure the rim to the hub.

e) Torque the 16 tapered lug nuts to 140 ft-lbs as per the sequence shown in figure 1-3.

5. Install the rear offset wheels: (refer to figure 1-4) a) Replace the original rear wheel studs with the supplied long studs according to the

vehicle manufacturer’s service manual. Note that the rear wheel studs do not have a spacer on the head of the stud.

b) Where used, do not reinstall the retaining clip mounted on the stud. This will prevent the wheel spacer from seating properly on the hub face.

c) Place the rear wheel spacers (¾” offset) (6) onto the rear hubs (7) over the new studs (8). d) Mount the 19.5” offset wheels (4) on the hubs over the same new studs with the supplied

90° tapered lug nuts (5). Do not use the original GMC nuts as they have a 60° taper and will fail to secure the rim to the hub.

e) Torque the 16 tapered lug nuts to 140 ft-lbs as per the sequence shown in figure 1-3.


a) Position the stop blocks (9) on the back side of the lower suspension arms at the point where the original wheel stops on the hubs contact the suspension arms during full turn.



stops on the hubs. Ensure that the offset rims and rim balance weights do not contact the vehicle suspension or steering components, the brake lines, the ABS lines and / or any other obstruction. A 1/8” minimum clearance is required all around throughout the entire motion of the rim. It may be necessary to add or remove material from the turning stop blocks.



vehicle’s speedometer.



FIGURE 1-4: TRUCK WHEEL MODIFICATION ASSEMBLY

REAR WHEELS

6

8

(SCALE 3:1)

3

FRONT STUDS WITH SPACERS

REAR STUDS WITHOUT SPACERS(SCALE 3:1)

2003 GMC - Suburban

2

7

9

1

5

4

FRONT WHEELS4

5


Form MA-0

ADDENDUM TO INSTALLATION MANUAL

MA #: MI25XX -0-MA03 Date: November 27, 2001


Railgear Model: R-250HD VF/RF/RR Manual #: Assorted

Affected Page(s): Addendum Information: The following procedure describes the retrofit installation of the rubber tread wheels to the Rafna R-250HD railgear. This retrofit conversion includes 4 wheel assemblies, including the spindle, wheel tables, etc. as well as new hardware. The existing railsweeps will be reused. SAFETY INFORMATION: 1. Always follow safe shop practices. 2. Ensure the vehicle engine is turned off and the parking brake is set. RETROFIT INSTRUCTIONS : 1. Remove the complete steel wheel assembly from the railgear, saving the railsweeps

and discarding the hardware. 2. Reinstall the rubber tread wheels along with the railsweep and new hardware. 3. Realign the railgear as detailed in the “Operating, Maintenance and Parts Manual”. 4. Adjust wheel pressures in accordance with the following instructions:

Note: Railwheel weights in excess of 700 lbs. will dramatically shorten the life of the rubber tread, and will cause premature failure.

Railwheel weights less than 500 lbs. may cause derailment.


Weight on railwheel

(Lbs.) A

(inch)

500 2 7/8

550 2 13/16

600 2 3/4

650 2 11/16

700 2 5/8

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 “on-rail” 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 lbs. 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 lb. 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 “on-road” 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 proc edure MUST be repeated whenever the load is changed in the vehicle.

A

B



Form MA-01

MANUAL ADDENDUM

MA #: MICOMF-0-MA01 Date: June 4, 2002


Railgear Model: R250 & R450 Ford Vehicles only Manual #: Assorted (Ford Vehicles Only)

Affected Page(s): Section 3 Addendum Information: This addendum updates the installation manual to include a redesigned steering wheel lock for F-250, F-350, F-450, and F-550 Ford vehicles. The old steering wheel lock (part numbers R-2400, R-2401A/R-2425 and R-241B/R-2423) can be replaced with assembly part number R-2879. This change affects the installation procedure 3.1, the contents of table 3-1, and figure 3-1 of the installation manual.

Refer to new Table 3-1 below for updated part numbers, and quantities required for installation. Also, refer to new figure 3-1.

Table 3-1: Ford Steering Wheel Lock Installation Hardware Part Number Description Qty R-2879 Steering Wheel Lock kit 1

The following procedure details the steering wheel lock installation: (refer to figure 3-1)

Ensure the front wheels are pointing straight ahead, and the steering wheel in centered before assembly.

1. Mount the latch assembly (Item 1) to the steering column (Item 2). Center the latch assembly on the steering column, keeping clear of the hazard light button. The front edge of the latch assembly should be flush with the front edge of the steering column cover. The mounting ears of the latch assembly may have to be bent slightly to fit the curvature of the steering column. Mark the two hole locations, and drill two #20 (0.166”) holes where marked. Do not drill too deep; drill only the cover. Fasten in place with two rivets (Item 3) supplied.

2. With the steering wheel straight, mount the latch support (item 4) on the top rear portion of the steering wheel airbag/horn cover (Item 5). The rear edge of the latch support should be flush with the rear edge of the steering wheel airbag/horn cover. Ensure the



latch will engage, and is centered with the latch support. Mark the location of the two holes, and drill two #20 holes where marked. Do not drill too deep; drill only the cover. Fasten in place with two rivets supplied.

3. Stick the ‘Steering wheel lock” decal to a highly visible spot on the dashboard.

FIGURE 3-1: STEERING WHEEL LOCK INSTALLATION

5

3

1

2

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MODEL R-250 HD CUSHION-RIDE RAILGEAR INSTALLATION … · Issued July 2001 Bulletin MI25RRG INITIAL...

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Transcript of MODEL R-250 HD CUSHION-RIDE RAILGEAR INSTALLATION … · Issued July 2001 Bulletin MI25RRG INITIAL...