Rafna Industries Hy-Rail Mo45rrfot 450-0T

RAFNA INDUSTRIES LIMITED
19300 Clark Graham, Baie d’Urfé, Québec

Tel: (514) 457-4373 or 1-888-525-3660
Fax: (514) 457-3567
MODEL R-450 OT
"CUSHION-RIDE" RAILGEAR
OPERATING, SERVICE AND
PARTS MANUAL
ON TRACK - ROTATING FRONT – ROTATING REAR

R-060, R-062, PTO PUMP
READ AND UNDERSTAND THIS MANUAL

BEFORE OPERATING
RAILGEAR EQUIPPED VEHICLE
Application Models: 1999 – 2003 Ford F-450 (All Models)

1999 – 2003 Ford F-550 (All Models)
Issued April 2002 (Rev A) Bulletin MO45RRFOT

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Rafna Industries Ltd., 19300 Clark Graham, Baie d’Urfé, QC Tel: 1-888-525-3660 Fax: (514) 457-3567
i
CHANGES AND ADDITIONS TO THE MANUAL
This section includes the latest changes and additions to the installation, operation, parts
and service of the railgear not included in the current revision of this manual. Please
refer to this section prior to installing and operating the railgear.
Rafna will update this section as changes become available.
ii
iii
WARNINGS AND CAUTIONS
Throughout this manual potential dangers are identified as Warnings and Cautions.
Following these recommendations will ensure a safe installation, operation, and service
of the Rafna Industries Ltd. railgear.
Warnings and Cautions are defined and formatted as presented below.
• Describes a potential hazard or a procedure that, if not performed

! correctly, can result in equipment damage or failure, personal injury
or death.
iv
v
TABLE OF CONTENTS
Changes and Additions to the Manual ........................................................................... i
Warnings and Cautions ................................................................................................ iii
Table of Contents .......................................................................................................... v
List of Figures ............................................................................................................. vii
Section 1.0 General Information .............................................................. 1-1

1.1 Safety information ........................................................................................... 1-3
1.2 Description ...................................................................................................... 1-4
1.3 Pump Identification ......................................................................................... 1-5
1.4 Warranty .......................................................................................................... 1-6
1.5 Warranty Claim Form ..................................................................................... 1-9
1.6 Serial Numbers .............................................................................................. 1-10
1.7 Specifications ................................................................................................ 1-11
Section 2.0 Operation............................................................................... 2-1

2.1 Inspections Before Operation .......................................................................... 2-3
2.2 Placing The Vehicle On Rail ........................................................................... 2-4
2.3 Travelling On Rail ........................................................................................... 2-9
2.4 Braking On Rail .............................................................................................. 2-9
2.5 Removing The Vehicle From Rail ................................................................ 2-10
Section 3.0 Service................................................................................... 3-1

3.1 Rail Wheel Bearing Adjustment ..................................................................... 3-3
3.2 Rail Wheel Load Adjustment .......................................................................... 3-5
3.3 Railgear Alignment ....................................................................................... 3-10
3.4 Rear Railgear Lock-up System Adjustment .................................................. 3-16
3.5 Optional Rail Wheel Hydraulic Brakes Adjustment ..................................... 3-18
3.6 Routine Railgear Service ............................................................................... 3-20
3.7 Hydraulic System Relief Valve Setting ........................................................ 3-26
3.8 Electrical System Troubleshooting ............................................................... 3-28
vi
Section 4.0 Parts....................................................................................... 4-1

4.1 Railgear Assembly - Rotating Front................................................................ 4-2
4.2 Railgear Lock-up Assembly - Rotating Front ................................................. 4-3
4.3 Railgear Lower Assembly - Rotating Rear ..................................................... 4-4
4.4 Railgear Upper Assembly - Rotating Rear ...................................................... 4-5
4.5 Railgear Lock-up Assembly - Rotating Rear .................................................. 4-6
4.6 Railgear Mounting Assembly - Front.............................................................. 4-7
4.7 Steel Rail Wheel Assembly ............................................................................. 4-8
4.8 Rail Sweep Assembly - Front.......................................................................... 4-9
4.9 Rail Sweep Assembly - Rear ......................................................................... 4-10
4.10 Steering Wheel Lock Assembly - R-2879..................................................... 4-11
4.11 Steering Wheel Lock Assembly - ‘Hook and Loop’ ..................................... 4-12
4.12 22.5” Wheel & Tire Modification ................................................................. 4-13
4.13 Pump Mounting - R-060 ............................................................................... 4-14
4.14 Pump Mounting - R-062 ............................................................................... 4-15
4.15 Front Bumper Assembly ............................................................................... 4-16
4.16 Pump Assembly - R-060 ............................................................................... 4-17
4.17 Pump Assembly - R-062 ............................................................................... 4-18
4.18 Hydraulic Assembly - R-060......................................................................... 4-19
4.20 Hydraulic Assembly - PTO ........................................................................... 4-21
4.21 Electrical Schematic - R-060......................................................................... 4-22
4.22 Electrical Schematic - R-062........................................................................ 4-23
4.23 Optional Brake Assembly - Front ................................................................. 4-24
4.24 Optional Brake Assembly - Rear .................................................................. 4-25
4.25 Optional Brake Pump Assembly .................................................................. 4-26
4.26 Optional Brake Electrical Schematic ............................................................ 4-27
Section 5.0 Appendix ............................................................................... 5-1
vii
LIST OF FIGURES
Figure 1-1: Orientation Convention ............................................................................. 1-4
Figure 1-2: Pump Identification ................................................................................... 1-5
Figure 1-3: Identification Plate .................................................................................. 1-10
Figure 2-1: Rear Railgear Operation ............................................................................ 2-5

Figure 2-2: Rotating Front Railgear Operation ............................................................ 2-7
Figure 2-3: Steering Lock Operation - R-2879 ............................................................ 2-8
Figure 2-4: Steering Lock Operation - ‘Hook and Loop’ ............................................ 2-8
Figure 3-1: Rail Wheel Bearing Adjustment................................................................ 3-4

Figure 3-2: Rail Wheel Pressure Measurement............................................................ 3-6
Figure 3-3: Rail Wheel Load Adjustment - Front ........................................................ 3-9
Figure 3-4: Rail Wheel Load Adjustment - Rear ......................................................... 3-9
Figure 3-5: Railgear Alignment Bars ......................................................................... 3-11
Figure 3-6: Railgear Alignment Measurements ......................................................... 3-12
Figure 3-7: Rail Wheel Alignment ............................................................................. 3-13
Figure 3-8: Railgear Lateral Adjustment - Front ....................................................... 3-14
Figure 3-9: Rear Railgear Lateral Alignment ............................................................ 3-15
Figure 3-10: Rear Railgear Lock-up Adjustment ......................................................... 3-16
Figure 3-11: Rear Railgear Lock-up Detail.................................................................. 3-17
Figure 3-12: Optional Rail Wheel Brake Shoe Adjustment ......................................... 3-19
Figure 3-13: Railgear Lubrication Points - Front ......................................................... 3-22
Figure 3-14: Railgear Lubrication Points - Rear .......................................................... 3-22
Figure 3-15: 8 Stud Vehicle Lug Nut Torques ............................................................. 3-23
Figure 3-16: 10 Stud Vehicle Lug Nut Torques ........................................................... 3-23
Figure 3-17: Railgear Non-Standard Bolt Torques - Front .......................................... 3-24
Figure 3-18: Railgear Non-Standard Bolt Torques - Rear ........................................... 3-24
Figure 3-19: Hydraulic System Relief Valve Setting - R-060 ..................................... 3-27
Figure 3-20: Hydraulic System Relief Valve Setting - R-062 ..................................... 3-27
Figure 3-21: Electrical System Schematic - R-060 ...................................................... 3-29
Figure 3-22: Electrical System Schematic - R-062 ...................................................... 3-29
viii
GENERAL INFORMATION 1-1
Section 1.0 GENERAL INFORMATION

1.1 Safety information ........................................................................................... 1-3
1.2 Description ...................................................................................................... 1-4
1.3 Pump Identification ......................................................................................... 1-5
1.4 Warranty .......................................................................................................... 1-6
1.5 Warranty Claim Form ..................................................................................... 1-9
1.6 Serial Numbers .............................................................................................. 1-10
1.7 Specifications ................................................................................................ 1-11
1.1 SAFETY INFORMATION

Note: Refer to the Changes and Additions section and/or the
Appendix of this manual for any addition, corrections,
and/or changes for the following procedure.
• Read and understand 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 clothing are clear of any moving parts.
• If misalignment of the railgear equipment is indicated, promptly
perform the alignment procedure.
• Rail travel speed should always be in conformance with railway
company regulations and should be reduce during inclement weather,
passing through road crossings, switches, frogs, bridges and curves.
Curves of greater than 20 degrees should be negotiated with extreme
caution. Operation of this vehicle at unsafe speeds could result in
derailment.
• For safety, the railgear is locked in both the road and rail positions.
All railgear models are locked in the road position with a mechanical
locking pin to avoid being deployed accidentally. The railgear is
locked in the rail position to prevent the railgear from retracting
while on rail. Certain models use a safety lock out valve on the
hydraulic cylinders while others use the same mechanical locking
mechanism to secure the railgear in the road position.
• The railgear equipped vehicle has an increased turning radius.
Exercise caution when operating, as sharp corners may be difficult to
negotiate.
• This vehicle will not operate crossing signals. Use caution when
approaching and traversing level crossings.
• The following safety precautions should be taken before the vehicle is
operated:
9 Visually inspect the railgear prior to use for damaged or worn
parts
9 Check for loose wheels and fasteners
9 Check for leaking hydraulic lines and cylinders
9 Check for proper lubrication
• Failure to heed to any of the above mentioned warnings could result
in severe bodily injury and/or equipment damage.
1.2 DESCRIPTION
This manual covers the operation, service and parts of the Rafna Industries R-450
rotating front, and rotating rear ‘On Track’ railgear as applicable to multiple vehicles. If
necessary, any difference in operation, service or parts for specific vehicle and/or railgear
models is clearly detailed by separate instructions for each. Otherwise, the operation,
service and parts instructions are the same for all models. Please refer to the front of this
manual for the latest changes and additions that have not been included in this manual at
time of printing.
The Rafna Industries R-450 OT railgear is a hydraulically operated road-to-rail

conversion system applicable to vehicles of up to 19,000 lbs Gross Vehicle Weight
Rating (GVWR). The front and rear railgear are frame mounted systems, which are
hydraulically raised and lowered. The hydraulic power is supplied by either a 12 VDC
electrical /hydraulic pump or a PTO pump system. During road travel, the front and rear
railgear are mechanically locked in position. During rail travel, the front and rear railgear
are locked in the rail position through a hydraulic check valve on the railgear. A steering
wheel lock system keeps the vehicle’s front wheels straight during rail travel. The
propulsion on rail is provided by the vehicle’s rear inner dual tires’ contact with the rail.
Braking on rail is accomplished through the vehicle’s original braking system, as well as
through an optional independent rail wheel braking system.
This manual uses the orientation convention for the vehicle as shown in figure 1-1.
Figure 1-1: Orientation Convention
RIGHT
FRONT REAR
LEFT
1.3 PUMP IDENTIFICATION

This manual details the operation, service and parts of several hydraulic pump types and
associated electrical controls. In the figure 1-2 below, various pumps are depicted and
key features identified. This page will help identify which procedure to follow when
operating, servicing, and ordering parts for the hydraulic pump and electrical controls.
Figure 1-2: Pump Identification

CONTROL BOX
VALVES
MOTOR
PUMP BRACKET TANK
R-060 PUMP
MOTOR
CONTROL BOX
U-BOLT CLAMP
VALVES
PUMP BRACKET
TANK
R-062 PUMP
1.4 WARRANTY
Rafna Industries Ltd.,
Limited Warranty
Rafna Industries’ warranty covers a period of TWELVE (12) months after the date
of the railgear’s entry into service. The warranty asserts that each new railgear
sold will be free from defects in material and workmanship under normal use and
service. 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 United States and Canada by Rafna Industries Ltd. The warranty does
not cover normal wear parts such as rail wheels, guide tubes, bearings, seals, rail
sweeps or responsibility for customer’s claims arising from abuse, misuse,
neglect, or alteration of the railgear. All claims are 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.
Rev. date: 21/09/01
Warranty Policies And Procedures For

Installers And Customers
Installers & Customer Warranty:
To prevent unnecessary delays or misunderstandings in handling Installers’ or

Customers’ warranty claims, it is required that all warranty requests be authorized prior
to any repairs, modifications or adjustments being started.
Warranty information and authorization can be obtained from Rafna Industries -

Engineering Manager or Customer Service Manager who can be contacted at
1-888-525-3660.
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 & 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 Engineering Manager 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
“Warranty Form v#2 04/01”
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 requesting warranty claim.
9) Ship to Address.
10) Bill to Address.
On approval of warranty claim, and where return of parts is requested by Rafna, the
Installer or Customer will issue a Purchase Order to Rafna Industries Ltd. to cover the
defective parts and out bound freight for part values exceeding $50.00 US and $75.00
CDN. 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:
Either the Rafna Warranty or any of Rafna’s sub-suppliers does not cover labor or
additional labor charges such as travel.
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. Parts 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.
1.5 WARRANTY CLAIM FORM
This form must be completed prior to starting any warranty work Warranty #
Customer Date
Tel/Fax Railgear S/N
Vehicle No. Vehicle VIN
End User Date of Purchase
P.O. Number Ref #
Inv. Address Ship to Address
Shipping instructions: Standard Special Standard Select Expedition Express

Ground Air 5 day + 3 day 2-3 day 2 day
Shipper: Way Bill #
PART No. QUANTITY DESCRIPTION
PROBLEM DESCRIPTION
Required Documentation from the Customer (For issuing Credit)
Description of Rafna Parts (Ordered or Used) Invoice # Total Claimed $ US/CAD
RAFNA INDUSTRIES approved by: DATE:
CUSTOMER’S REPRESENTATIVE: DATE:
For Internal Use only:

Engineering 5825 Shipping 5826 Outside Supplier 5821
Manufacturing 5820 Service 5822 Installation 5824
5823
1.6 SERIAL NUMBERS

Following receipt of this manual, the serial numbers, model numbers and date of
manufacture for both the front and rear railgear should be recorded below for future
reference. This information is located on the identification plate (figure 1-2) mounted on
each railgear.
Front Railgear:
Serial Number: __________________
Model Number: __________________
Date of Manufacture: __________________
Rear Railgear:
Serial Number: __________________
Model Number: __________________
Date of Manufacture: __________________
Figure 1-3: Identification Plate

MONTREAL, QUEBEC
(514) 457-4373
ROAD-TO-RAIL CONVERSION UNIT
MODEL SERIAL BUILT
1.7 SPECIFICATIONS
Item Metric Imperial

Maximum Applicable GVWR * 8619 Kg 19000 lbs
Maximum Applicable GAWR.F ** 2718 Kg 6000 lbs
Maximum Applicable GAWR.R *** 6124 Kg 13500 lbs
Front Approximate Installed Weight 157 Kg 345 lbs
Rear Approximate Installed Weight 280 Kg 617 lbs
Optional Railgear Brakes Kit, Front 35 Kg 76 lbs
Optional Railgear Brakes Kit, Rear 35 Kg 76 lbs
Track Gauge 1435 mm 56-½ inch
Wheel Diameter 254 mm 10 inch
* Gross Vehicle Weight Rating

** Gross Axle Weight Rating - Front
*** Gross Axle Weight Rating - Rear
Issued April 2003 (Rev 0) Bulletin MO45RRFOT
OPERATION 2-1
Section 2.0 OPERATION

OPERATION 2-2
OPERATION 2-3
2.1 INSPECTIONS BEFORE OPERATION

Prior to each use of the railgear equipment, the following items should be inspected:
9 Check for damaged or worn parts

9 Check for loose wheels and/or fasteners
9 Check for leaking or damaged hydraulic lines, fittings, and cylinders
9 Check for proper lubrication at specified intervals
9 Check for proper rail wheel brake operation where equipped
Also, the operator should ensure that the vehicle is in good operating condition by
following the vehicle manufacturer’s operating guide.
• 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 endplay. If the
endplay is not in accordance with specifications, bearing failure could
occur and would not be covered under the Rafna Industries
Warranty. Refer to the Rail Wheel Bearing Adjustment procedure in
the Service section of this manual.
• Following the first 1000 km (625 Miles) of road and rail travel, the
vehicle 22.5” wheel lug nuts should be re-torqued. Refer to the
Routine Railgear Service procedure in the Service section of this
manual.
• On newly installed railgear equipment, ensure that the Railgear

Alignment procedure is performed before operation of the equipment.
Note that excessively worn rail wheels, vehicle pulling to one side
while on rail, and vibrations through the vehicle while on rail are
indicators of mis-aligned railgear. If any of these situations are
encountered, perform the Railgear Alignment procedure as described
in the Service section of this manual as soon as possible to avoid
damage to the equipment, vehicle and/or possible personal injury.
OPERATION 2-4
2.2 PLACING THE VEHICLE ON RAIL

• Operating instructions provided below only address the Rafna
! Industries railgear equipment. Applicable railway company

procedures and policies must be adhered to.
• At level rail crossings, ensure that no other vehicles are approaching

and flag the crossing to ensure safety. This vehicle will not activate
crossing signals.
• 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 rail wheels directly over the rails. At this
point the front rail wheels should be somewhat aligned over the rails.
2. Place the vehicle’s 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
the pump should not run yet. The pump is an intermittent duty pump, which will only
run while activating the railgear controls. Some vehicles may utilize a PTO driven
hydraulic pump in which case, the PTO must be engaged. Follow the manufacturer’s
recommendations when engaging the PTO.
3. Note that in order to align the front rail wheels directly over the rails, the rear railgear
must be deployed first, and 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 “Up” or “Down” button on the respective control box. This switches the
respective hydraulic solenoid valve and starts the pump motor.
5. On vehicles equipped with a PTO pump, the hydraulic flow is selected by actuating
the lever on the respective railgear operating valve.
OPERATION 2-5
6. Lower the rear railgear: (refer to figure 2-1)

a) Raise the railgear off the lock pins by selecting “Up” on the rear control box
(Item 1) or by actuating the hydraulic operating valve. Disengage the lock pins
by pulling the locking cable handle (Item 2). Do not force the locking cable
handle. If the pins cannot be disengaged, raise the railgear further by selecting
“Up” on the rear control box or the operating valve. Hold the locking cable
handle in the disengaged position.
b) Lower the railgear by selecting “Down” on the rear control box or the operating
valve.
c) Release the locking cable handle once the railgear has rotated below the road
locked position.
d) Continue lowering the railgear until the hydraulic cylinders are fully extended. In
this position, the railgear should be near vertical.
e) Ensure that the rear railgear is properly deployed before proceeding.
• While the railgear is taking some of the vehicle’s load, the railgear
suspension (Item 5) should be observed compressing. With the vehicle
! unloaded, the nuts (Item 6) should be about 1” above the spring plates
(Item 7) once the railgear is fully deployed. If this is not the case,
check for adequate guide tube lubrication and proper rail wheel load
setting. If the guide tubes are not free to move or if the rail wheel load
is incorrect, the spring suspension will not work correctly and may
cause derailment.
Figure 2-1: Rear Railgear Operation
OPERATION 2-6
• For PTO equipped vehicles: While moving the vehicle in the next
! step, ensure the engine is not revved beyond the maximum RPM of
the PTO with the PTO engaged. It is recommended to disengage the
PTO while moving the vehicle.
7. Lower the front railgear: (refer to figure 2-2)

a) With the rear railgear correctly deployed on rail, reverse the vehicle until the
front rail wheels are directly over the rails.
b) Place the vehicle’s automatic transmission in “PARK” (manual transmission in
“NEUTRAL”), apply the parking brake and re-energize the pump if required by
turning on the respective dash switch, or engage the PTO as previously
described.
c) Raise the railgear off the lock pin by selecting “Up” on the front control box
(Item 1) or by actuating the operating valve lever. Disengage the lock pin
(Item 2) by moving the locking handle (Item 3) towards the left side of the
vehicle. Do not force the handle. If the pin cannot be disengaged, raise the
railgear further by selecting “Up” on the front control box or the operating valve.
Hold the locking handle in the disengaged position.
d) Lower the railgear by selecting “Down” on the front control box or the operating
valve.
e) Release the locking handle once the railgear has rotated below the road locked
position.
f) Continue lowering the railgear until the hydraulic cylinder (Item 4) is fully
extended. In this position, the railgear should be 2°-3° over-center. The lock pin
should engage, and lock the railgear in the rail position.
g) Ensure that the front railgear is properly deployed and the lock pin has engaged
before proceeding.
• While the railgear is taking some of the vehicle’s load, the railgear
suspension (Item 5) should be observed compressing. With the vehicle
! unloaded, the nuts (Item 6) should be about 1” above the spring plates
(Item 7) once the railgear is fully deployed. If this is not the case,
check for adequate guide tube lubrication and proper rail wheel load
setting. If the inner tubes are not free to move or if the rail wheel load
is not correct, the spring suspension will not work correctly and may
cause derailment.
OPERATION 2-7
Figure 2-2: Rotating Front Railgear Operation

3
4
6
2
7
5
FORWARD
TRAVEL
NOTE: OPTIONAL BRAKES NOT SHOWN

FOR CLARITY
8. De-energize the pump by turning off the respective dash switch. Disengage the PTO
if equipped. It is not recommended to drive the vehicle with the PTO engaged.
9. If equipped, energize the rail wheel hydraulic brake pump by turning on the dash
mounted switch.
10. Engage the steering wheel lock. Depending on the vehicle, one of two steering wheel
locks is used. Use the appropriate procedure for your particular steering wheel lock.
a) For vehicles fitted with the R-2879 steering wheel lock (refer to figure 2-3):
i. Turn the steering wheel (Item 1) until the front tires point straight ahead.
ii. Flip the locking lever (Item 2) over, and into the notch between the two
ears on the latch plate (Item 3).
b) For vehicles fitted with the ‘Hook and Loop’ steering wheel lock (refer to
figure 2-4):
i. Turn the steering wheel (Item 1) until the front tires point straight ahead.
ii. 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.
OPERATION 2-8
Before proceeding with rail travel:
! • Ensure the front axle lock-up hooks are engaged.

• Ensure that the railgear pump has been de-energized. Ensure the
PTO has been disengaged to avoid damaging the PTO.
• Where equipped, ensure the rail wheel brake pump has been
energized.
Figure 2-3: Steering Lock Operation - R-2879
2
1
3
Figure 2-4: Steering Lock Operation - ‘Hook and Loop’

2
1
3
OPERATION 2-9
2.3 TRAVELLING ON RAIL

Before proceeding to travel on rail, ensure that:

- The railgear cylinders are fully extended.
- The steering wheel lock has been engaged with the front wheels pointing
straight ahead.
- The pump has been de-energized or the PTO pump disengaged to avoid
accidental raising of the railgear.
- If equipped, ensure the rail wheel brake pump switch is energized.
• Railway company rules governing rail travel must be observed at all
! •
times.
Do not operate vehicle on rail if the vehicle weight exceeds either the
maximum GVWR rating of the railgear or the GVWR of the vehicle.
• The steering wheel lock must be engaged at all times while on rail.
• Ensure that the railgear pump has been de-energized to avoid

accidental raising of the railgear.
• Ensure the PTO has been disengaged to avoid damaging the PTO.
The vehicle may now be driven as if on the road without steering, however speed must be
reduced. Note also that braking ability is decreased while on rail.
2.4 BRAKING ON RAIL
This railgear equipment allows the vehicle’s tire contact with the rails to provide the
braking action, identically as if on the road. Also, where fitted, the optional rail wheel
hydraulic brake provides additional braking. However, it is important to apply the brakes
gradually in order to avoid locking up the vehicle’s tires. Note also that braking ability
while on rail is considerably reduced, and can be adversely affected during inclement
weather.
Note: As long as the optional front rail wheel hydraulic brake

switch is turned on, the front rail wheel brakes will apply
automatically when the vehicle brakes are applied. It is
recommended to turn off the rail wheel brakes when
traveling on the road.
OPERATION 2-10
2.5 REMOVING THE VEHICLE FROM RAIL

• Operating instructions provided below only address the Rafna
! Industries railgear equipment. Applicable railway company

procedures and policies must be adhered to.
• At level rail crossings, ensure that no other vehicles are approaching

and flag the crossing to ensure safety. This vehicle will not operate
crossing signals.
• Understand equipment operation before operating equipment.
• Ensure the front and rear railgear lock pins are fully engaged before
operating the vehicle on the road. Failure to do so may cause damage
to the equipment and / or personal injury.
1. Approach a level crossing or other suitable location, and prepare to remove the
vehicle from the rail by placing the vehicle’s 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
pump is an intermittent duty pump, which will only run while activating the railgear
controls. Some vehicles may utilize a PTO driven hydraulic pump in which case, the
PTO must be engaged. Follow the manufacturer’s recommendations when engaging
the PTO.
3. Note that the vehicle is removed from rail 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 the rear railgear is selected by
pushing the “Up” or “Down” button on the respective control box. This switches the
respective hydraulic solenoid valve and starts the pump motor.
5. On vehicles equipped with a PTO pump, the hydraulic flow is selected by actuating
the lever on the respective railgear operating valve.
OPERATION 2-11
6. Raise the front railgear: (refer to figure 2-2)

a) Disengage the lock pin by moving the locking handle to the left. Do not force
the locking handle. If the pin cannot be disengaged, lower the railgear further by
selecting “Down” on the front control box or operating valve. Hold the locking
handle in the disengaged position.
b) Raise the railgear by selecting “Up” on the front control box (Item 1) or
operating valve.
c) Release the locking handle once the railgear has rotated past the rail position.
d) Continue raising the railgear until the lock pin (Item 2) clicks into the road
locked position. The hydraulic cylinder (Item 4) will be completely retracted.
e) Ensure the lock pin is completely engaged before proceeding.
7. Raise the rear railgear: (refer to figure 2-1)
a) Raise the railgear by selecting “Up” on the rear control box (Item 1) or operating
valve.
b) Continue raising the railgear until the lock pins (Item 2) click into the road
locked position. The hydraulic cylinders (Item 4) should be fully retracted.
c) Ensure the lock pins have completely engaged before proceeding.
8. De-energize the pump by turning off the respective dash switch. Disengage the PTO
if equipped.
9. If equipped, de-energize the rail wheel brake pump by turning off the respective dash
mounted switch.
10. Disengage the steering wheel lock (depending on the steering wheel lock style):
a) For vehicles fitted with the R-2879 steering wheel lock (refer to figure 2-3):
i. Disengage the steering wheel lock by flipping the locking lever (Item 2)
over, and out of the latch plate (Item 3).
b) For vehicles fitted with the ‘Hook and Loop’ steering wheel lock (refer to
figure 2-4):
i. Firmly grasp one side of the ‘hook’ portion (Item 1) of the ‘Hook and Loop’
steering wheel lock, and pull to remove.
ii. Store the ‘hook’ strip in a secure location 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 ‘loop’ strips may give way and
be removed. If the ‘loop’ strip is removed, replace it at the earliest
convenience.
OPERATION 2-12
Before proceeding with road travel:

• Ensure the front railgear lock-up pin and rear railgear lock-up
! pins are completely engaged.
• Ensure that the railgear pump has been de-energized. Where
equipped, ensure the PTO has been disengaged to avoid damaging
the PTO.
• Where equipped, ensure the rail wheel brake pump has been
de-energized.
11. Carefully drive the vehicle off rail and onto the road.
SERVICE 3-1
Section 3.0 SERVICE

SERVICE 3-2
SERVICE 3-3
3.1 RAIL WHEEL BEARING ADJUSTMENT

The rail wheel bearings require periodic adjustment in order to keep the endplay within
specification. If the rail wheel bearings are not correctly adjusted, failure may occur and
will not be covered under the Rafna Industries Warranty.
The following procedure details the adjustment of the rail wheel bearings:
• 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 road position and with the rail wheels
free to turn. If necessary, lower the railgear to ease access, but ensure the railgear axle
is supported.
2. Using a magnetic base dial gauge, measure the endplay of each rail wheel bearing.
3. Compare the above readings with the specifications in table 3-1 below.
Table 3-1: Rail Wheel Endplay Specifications

Minimum Maximum
Endplay 0.001” 0.005”
4. If rail wheel bearing endplay is not within specifications, proceed to adjust as follows
(refer to figure 3-1):
a) Remove the rail wheel hubcap (Item 1) and gasket (Item 2) by unbolting the
three hubcap retaining bolts (Item 3).
b) Remove and discard the spindle nut cotter pin (Item 4).
c) Ensure the rail wheel bearing cavity is full of grease. Refer to the Routine
Railgear Service section of this manual for lubrication points.
d) While rotating the rail wheel forward, torque the spindle nut (Item 5) to 20 ft-lbs.
e) Slightly loosen the spindle nut.
f) Re-torque the spindle nut to 6 ft-lbs.
g) Recheck endplay and re-adjust if required.
h) 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 ½ flat of the nut.
i) Reinstall the gasket, the hubcap, the bolts and lock washers (Item 6). Torque the
hubcap retaining bolts to specifications.
SERVICE 3-4
Figure 3-1: Rail Wheel Bearing Adjustment
5. If a torque wrench is unavailable, the following procedure may be substituted for

steps 4 d) through 4 g) above:
a) Tighten the spindle nut until the wheel cannot be turned by hand.
b) Loosen the spindle nut then hand tighten.
c) Continue hand tightening as the wheel is turned by hand and cotter pin can be
installed.
d) Readjust with a torque wench as soon as possible.
SERVICE 3-5
3.2 RAIL WHEEL LOAD ADJUSTMENT

The percentage of the vehicle load carried by the railgear must be properly adjusted to
ensure sufficient traction and guidance while avoiding overloading the railgear. The load
on the rail wheels is an indicator of the amount of load carried by the railgear and is
adjusted as described below using a hydraulic bottle jack equipped with a gauge. If the
gauge on the hydraulic bottle jack reads in Pounds per Square Inch (PSI), use Table 3-2
along with the jack bore diameter to convert this reading to Pounds (lbs). If the gauge
reads in pounds, then no conversion is required. The rail wheel load adjustment is done
at installation and only requires readjustment if the railgear is moved or vehicle
equipment is changed. The rail wheel load need not be adjusted with minor load changes
in the vehicle. This procedure is identical for all rail gear models except where indicated.
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 only be carrying the permanently attached load
and any normally carried non-attached load during this
procedure. Do not include operator or passengers.
• Ensure an inspection of the railgear has been carried out before
any rail testing is performed.
• Ensure the vehicle’s tires have been inflated to the manufacturer’s
recommended air pressure.
1. Place the vehicle on a straight and level section of rail with the railgear deployed to
the rail position.
2. Ensure that the vehicle’s tires are inflated to the correct air pressure and are not in
contact with any obstructions except the rails.
3. Check each rail wheel load as follows (refer to figure 3-5):

a) Place the jack (Item 1) on a solid railway tie (Item 2) beneath the rail wheel
spindle housing (Item 3) and jack the rail wheel off the rail.
b) Insert a piece of paper (Item 4) between the rail and the rail wheel. 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 and observe the jack
gauge. When the paper can be pulled out, stop jacking.
d) Record the load or pressure reading on the jack gauge.
e) If necessary convert the pressure reading to a load reading using table 3-2.
SERVICE 3-6
Figure 3-2: Rail Wheel Pressure Measurement
SERVICE 3-7
Table 3-2: Rail Wheel Load vs Jack Pressure and Bore

Jack
Pressure Jack Cylinder Bore Diameter (inches)
(PSI) 7/8 15/16 1 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8
500 300 350 390 440 500 550 610 680 740
520 310 360 410 460 520 580 640 700 770
540 320 370 420 480 540 600 660 730 800
560 340 390 440 500 560 620 690 760 830
580 350 400 460 510 580 640 710 780 860
600 360 410 470 530 600 660 740 810 890
620 370 430 490 550 620 690 760 840 920
640 380 440 500 570 640 710 790 870 950
660 400 460 520 590 660 730 810 890 980
680 410 470 530 600 680 750 830 920 1010
700 420 480 550 620 700 780 860 950 1040
720 430 500 570 640 720 800 880 970 1070
740 440 510 580 660 740 820 910 1000 1100
760 460 520 600 670 760 840 930 1030 1130
780 470 540 610 690 780 860 960 1060 1160
800 480 550 630 710 800 890 980 1080 1190
820 490 570 640 730 820 910 1010 1110 1220
840 510 580 660 740 830 930 1030 1140 1250
860 520 590 680 760 850 950 1060 1160 1280
880 530 610 690 780 870 970 1080 1190 1310
900 540 620 710 800 890 1000 1100 1220 1340
920 550 640 720 820 910 1020 1130 1240 1370
940 570 650 740 830 930 1040 1150 1270 1400
960 580 660 750 850 950 1060 1180 1300 1430
980 590 680 770 870 970 1090 1200 1330 1460
1000 600 690 790 890 990 1110 1230 1350 1480
1020 610 700 800 900 1010 1130 1250 1380 1510
1040 630 720 820 920 1030 1150 1280 1410 1540
1060 640 730 830 940 1050 1170 1300 1430 1570
1080 650 750 850 960 1070 1200 1330 1460 1600
1100 660 760 860 980 1090 1220 1350 1490 1630
1120 670 770 880 990 1110 1240 1370 1520 1660
1140 690 790 900 1010 1130 1260 1400 1540 1690
1160 700 800 910 1030 1150 1280 1420 1570 1720
1180 710 810 930 1050 1170 1310 1450 1600 1750
1200 720 830 940 1060 1190 1330 1470 1620 1780
1220 730 840 960 1080 1210 1350 1500 1650 1810
1240 750 860 970 1100 1230 1370 1520 1680 1840
1260 760 870 990 1120 1250 1400 1550 1700 1870
1280 770 880 1010 1130 1270 1420 1570 1730 1900
1300 780 900 1020 1150 1290 1440 1600 1760 1930
1320 790 910 1040 1170 1310 1460 1620 1790 1960
1340 810 920 1050 1190 1330 1480 1640 1810 1990
1360 820 940 1070 1210 1350 1510 1670 1840 2020
1380 830 950 1080 1220 1370 1530 1690 1870 2050
1400 840 970 1100 1240 1390 1550 1720 1890 2080
1420 850 980 1120 1260 1410 1570 1740 1920 2110
1440 870 990 1130 1280 1430 1590 1770 1950 2140
1460 880 1010 1150 1290 1450 1620 1790 1980 2170
1480 890 1020 1160 1310 1470 1640 1820 2000 2200
1500 900 1040 1180 1330 1490 1660 1840 2030 2230
1520 910 1050 1190 1350 1510 1680 1870 2060 2260
1540 930 1060 1210 1370 1530 1710 1890 2080 2290
1560 940 1080 1230 1380 1550 1730 1910 2110 2320
1580 950 1090 1240 1400 1570 1750 1940 2140 2350
1600 960 1100 1260 1420 1590 1770 1960 2160 2380
1620 970 1120 1270 1440 1610 1790 1990 2190 2410
1640 990 1130 1290 1450 1630 1820 2010 2220 2440
1660 1000 1150 1300 1470 1650 1840 2040 2250 2460
1680 1010 1160 1320 1490 1670 1860 2060 2270 2490
1700 1020 1170 1340 1510 1690 1880 2090 2300 2520
Rail Wheel Load (lbs)
SERVICE 3-8
4. Compare the rail wheel load reading to the specifications in table 3-3.
Table 3-3: Rail Wheel Load Specifications

Minimum Maximum
Rail Wheel Load* 800 - 1000 lbs N/A
* Initial Load Setting
The starting range should be as indicated in the minimum section of the table. There is
no upper limit for steel wheels. Unless the permanent equipment in the vehicle changes,
there is no reason readjust the rail wheel pressure.
5. If the load on the rail wheels is not within the specifications, adjust as follows (refer
to figure 3-3 and figure 3-4)
a) Raise the railgear until the rail wheels are unloaded.
b) Loosen the lower jam nut (Item 1) under the lower spring plate (Item 2) for each
rail wheel.
c) Adjust the lower spring plate and upper lock nut (Item 3) up to increase the load
or down to decrease the load on the rail wheel. Both front rail wheels should be
adjusted by the same amount. Both rear rail wheels should be adjusted by the
same amount.
d) Once adjusted, there should be a gap of 1-½” – 3” from the bottom of the lower
spring plate to the top of the railgear axle. If the correct loads cannot be obtained
within this range, adjust the height of the railgear in the mounting plate holes.
The rear railgear is designed for a railgear mounting to ground distance of 21-½”.
If the railgear to ground distance is different than mentioned, and/or the correct
loads cannot be obtained within this range, it may be necessary to respring the
vehicle. Respringing the vehicle is not part of the Rafna railgear package.
e) Lower the railgear and recheck each rail wheel load. Readjust if necessary.
f) Tighten the lower jam nuts against the lower spring plates.
g) Raise the railgear and tighten the upper lock nuts until the rubber springs just
start to compress. Do not pre-compress the rubber springs. The rubber springs
should measure 3-⅜” in the road position when properly adjusted.
h) Lower the railgear to the rail position. The upper lock nut should be about
¾” - 1” above the upper spring plate.
• The rail wheels should be approximately 7-½” above the ground when
! in the road position. If this minimum distance cannot be achieved

with the correct rail wheel loads, contact Rafna Industries for
assistance.
SERVICE 3-9
Figure 3-3: Rail Wheel Load Adjustment - Front

3
INCREASE
1
LOAD
1.5" - 3" DECREASE

GAP
Figure 3-4: Rail Wheel Load Adjustment - Rear
INCREASE
21.5" TO 2
GROUND 3
LOAD
1
DECREASE
1.5" - 3"
GAP
SERVICE 3-10
3.3 RAILGEAR ALIGNMENT

The Rafna railgear must be correctly aligned in order to perform properly, safely, and
avoid excessive wear. All four rail wheels can be independently aligned while lateral
adjustment of the front and rear railgear is accomplished through adjusting the railgear on
the mounting plates. A parallel line system and the following procedure should be used
to perform the railgear alignment. Rafna Industries can also supply a special alignment
tool kit (order part number R-066K), with which separate instructions are supplied. The
following procedure is identical for all railgear models unless otherwise indicated.
• The vehicle should have had a four-wheel alignment with the railgear
! on the vehicle prior to performing the railgear alignment. The

vehicle’s tires should be inflated to the manufacturer’s recommended
air pressure.
• This procedure should be done with the vehicle parked on a straight

and level section of rail 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. Fabricate a parallel string line system. Rafna Industries suggests the following (refer
to figure 3-5):
a) Fabricate two metal alignment bars (Item 1) with ½” diameter posts (Item 2) on
each end 18” tall and about 10’ apart.
b) The alignment bars may also have support legs (Item 3) to sit on the railhead.
c) Create a series of circumferential grooves in each post at 1” intervals to hold the
string lines.
d) Ensure that the two alignment bars are fabricated identical to within 1/32”.
2. After installing the railgear, and adjusting the rail wheel loads, ensure the vehicle has
had a four-wheel alignment and the tires are properly inflated prior to performing the
railgear alignment.
3. Lower the front and rear railgear to the rail position on a straight and level section of
rail.
4. Ensure the vehicle’s front tires are pointing straight ahead and engage the steering
wheel lock.
SERVICE 3-11
Figure 3-5: Railgear Alignment Bars
5. Set up the parallel string line system (refer to figure 3-6):

a) Fasten the alignment bars to the head of the rail about 2’ ahead of and behind the
vehicle. Ensure that the alignment bars are perpendicular to the rail and can be
slid side to side for adjustment.
b) Run a string line from the front alignment bar post to the rear alignment bar post
on each side of the vehicle using the appropriate grooves cut in the posts.
c) Ensure that dimensions Y and Z are equal to within 1/32”, and dimensions W and
X are equal to within 1/32”.
d) Proceed to adjust the side to side location of the alignment bars until the
distances between the vehicle’s front wheels and each string line are equal to
within 1/16” (dimensions A, B, C, and D) and the distances between the vehicle’s
rear wheels and each string line are equal to within 1/16” (dimensions E, F, G, and
H). Note that dimensions A, B, C, and D may not equal dimensions E, F, G, and
H. Measuring from the tire wall will not yield accurate measurements.
SERVICE 3-12
Figure 3-6: Railgear Alignment Measurements
ALIGNMENT MEASUREMENTS
Truck Model Truck Number

Rail Gear S/N
Z
Z
A,B,C,D Must be Equal within 1/16".
Q
E,F,G,H Must be Equal within 1/16". L I
(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" K J
M and N Must be Equal within 1/16" D A
O and P Must be Equal within 1/16"
L and I Must be Equal within 1/8" C B

K and J Must be Equal within 1/8"
P and M Must be Equal within 1/8"
O and N Must be Equal within 1/8"
W and X Must be Equal within 1/32"
Y and Z Must be Equal within 1/32"
W X
H E
G F
P M
O N
Rail wheel Load (lbs) Q'
Y
Left Front
Right Front
Y
Right Rear
Left Rear
Rail wheels Flange To Flange 53 7/16" to 53 9/16" Rail wheel Flange To Gound
Q Q'
Front Front Rear Front Front
Rear Rear Rear
SERVICE 3-13
6. Rail Wheel Alignment (refer to figures 3-6 and 3-7):

a) Secure an 18” long straightedge to the backside of each rail wheel flange.
Measure the distance between the front-most and rear-most points of each
straightedge and the parallel lines (dimensions I, J, K, and L in the front and M,
N, O, and P in the rear). Also measure the distance between the front-most and
the rear-most points of the straightedges (dimensions Q and Q’).
b) Dimensions I and J should be equal to within 1/16”. Dimensions K and L should
be equal to within 1/16”. Dimensions M and N should be equal to within 1/16”.
Dimensions O and P should be equal to within 1/16”. Dimensions Q and Q’
should be between 53-7/16” and 53-9/16”. If this is not the case, adjust the rail
wheel alignment as follows:
i. Loosen the four bolts and nuts (Item 1) securing each rail wheel spindle
housing (Item 2) to the railgear axles (Item 3) such that the wheels are free to
rotate on the horizontal plane yet snug enough to stay in place.
ii. Adjust each wheel to the centered position (I and J equal, K and L equal, M
and N equal, and O and P equal). Note that dimensions I and J may not equal
K and L and dimensions M and N may not equal O and P at this point. Also
ensure that dimensions Q and Q’ are between 53-7/16” and 53-9/16”.
iii. Re-torque the rail wheel fasteners to specifications.
c) Recheck alignment measurements, and readjust if necessary.
d) Leave the straightedges in place, and proceed with the lateral alignment.
Figure 3-7: Rail Wheel Alignment
ALIGNMENT
SERVICE 3-14
• When adjusting the lateral alignment of the front and rear railgear,
! do not use any force against the suspension guide tube assemblies.
This may cause damage, which would restrict the suspension
movement of the railgear.
7. Front railgear lateral alignment (refer to figures 3-6 and 3-8):

a) With a straightedge secured to the backside of each front rail wheel flange,
measure the distance from the front-most and rear-most points of the two
straightedges to the parallel lines (dimensions I, J, K, and L).
b) Dimensions I and L should be equal to within ⅛”. Dimensions J and K should be
equal to within ⅛”. If this is not the case, adjust the front railgear lateral
alignment as follows:
i. Raise the railgear off rail and loosen the six bolts (Item 1) that secure the
railgear (Item 2) to the front mounting plates (Item 3).
ii. Adjust the railgear laterally until centered (I and L are equal, and J and K are
equal).
iii. Re-torque the six mounting bolts to specification.
c) Lower the railgear to the rail position and re-check the dimensions. Readjust if
necessary.
Figure 3-8: Railgear Lateral Adjustment - Front
2
AL
IG
NM
EN
T
SERVICE 3-15
8. Rear railgear lateral alignment (refer to figure 3-6 and 3-9):

a) With a straightedge secured to the back side of each rear rail wheel flange,
measure the distance from the front-most and rear-most points of the two
straightedges to the parallel lines (dimensions M, N, O and P).
b) Dimensions M and P should be equal to within ⅛”. Dimensions N and O should
be equal to within ⅛”. If this is not the case, adjust the rear railgear lateral
alignment as follows.
i. Raise the railgear off rail and loosen the eight bolts (Item 1) that secure the
railgear (Item 2) to the rear mounting boxes (Item 3).
ii. Loosen the eight bolts (Item 4) securing the cylinder mounts (Item 5).
iii. Adjust the railgear and cylinder mounts laterally until centered (M and P
equal, and N and O equal). Ensure the cylinders are perpendicular to the
railgear to avoid binding.
iv. Re-torque the sixteen mounting bolts to specification.
c) Lower the railgear to the rail position and recheck the dimensions. Readjust if
necessary.
Figure 3-9: Rear Railgear Lateral Alignment
9. Remove the straightedges from the rail wheels, remove the parallel string lines, and
remove the vehicle from rail.
SERVICE 3-16
3.4 REAR RAILGEAR LOCK-UP SYSTEM ADJUSTMENT

Once the rear railgear rail wheel load is set, and is adjusted laterally, the rear railgear
lock-up system must be adjusted. The following procedure details the adjustment of the
rear railgear lock-up system. Refer to figures 3-10 and 3-11:
1. With the rear railgear in the typical road position, loosen the four bolts (Item 1)
holding the lock-up support table (Item 2) to the rear railgear lock-up frame (Item 3).
2. Loosen the four bolts (Item 4) holing the lock-up plate assembly (Item 5) to the rear
railgear lock-up support table.
3. Adjust the lock-up system up or down, front or back such that the contact surface of
the angle plate (Item 6) and the surface of the lock-up pins (Item 7) are parallel and
the angle plate should contact the pins between ¾” and ⅞” overall (refer to
figure 3-11).
4. Once the position of the lock-up is correct, tighten all eight bolts to specification, and
tack weld the assembly in place as follows:
a) Tack weld the lock-up support table to the lock-up frame.
b) Tack weld the lock-up plate assembly to the lock-up support table.
c) Tack weld the lock-up frame to the railgear mounting boxes.
Figure 3-10: Rear Railgear Lock-up Adjustment
SERVICE 3-17
Figure 3-11: Rear Railgear Lock-up Detail

5
3 7
4" - 8"
CONTACT CORRECT
NOT CORRECT
NOT CORRECT
7
3
AXLE
THE 2 CRITERIA TO FULFILL ARE:
1) THE CONTACT SURFACE OF THE ANGLE PLATE (ITEM 1) AND THE
LOCKING PINS (ITEM 2) MUST BE PARALLEL.
2) THE CONTACT DISTANCE OF THE ANGLE PLATE (ITEM 1) AND THE
LOCKING PINS (ITEM 2) MUST BE BETWEEN 3/4" AND 7/8"
SERVICE 3-18
3.5 OPTIONAL RAIL WHEEL HYDRAULIC BRAKES ADJUSTMENT

The following procedure details how to adjust the optional rail wheel hydraulic brake
system. The brakes are adjusted in two steps; first a mechanical adjustment and secondly
a hydraulic pressure adjustment. This procedure must be initially performed when the
brakes are installed and whenever new brake shoes are installed. If the vehicle’s
permanent load changes, the hydraulic adjustment should be carried out to ensure correct
braking action. Refer to figures 3-12 and 3-13.
Brake shoe clearance and mechanical adjustment: (refer to figure 3-12)
1. The clearance between the brake shoe (Item 1) and the rail wheel (Item 2) should be
⅛”. If this is not the case, adjust as follows:
For the Front brake:

a) Remove the spring between the brake shoe housing and the brake shoe.
b) Loosen the jam nut (Item 3) located above the brake shoe clevis (Item 4).
c) Where fitted, loosen the setscrew in the collar on the retaining bolt (Item 5) that
secures the brake shoe to the clevis. Remove the bolt.
d) Adjust the clevis up to increase brake shoe to rail wheel clearance. Adjust the
clevis down to decrease brake shoe to rail wheel clearance. The clevis push rod
is free to rotate, and must be secured while making the adjustments.
e) Reinstall the bolt and collar, where removed, that secures the brake shoe to the
clevis.
f) Where replaced, tighten the setscrew in the collar on the retaining bolt, and
tighten the retaining bolt.
g) Finally, tighten the jam nut against the clevis and reinstall the spring.
For the Rear Brake:

a) Loosen the jam nuts (Item 3) located above and below the brake shoe arm
(Item 4).
b) Adjust the jam nuts up to increase brake shoe to rail wheel clearance. Adjust the
jam nuts down to decrease brake shoe to rail wheel clearance. The push rod is
free to rotate, and must be secured while making the adjustments.
c) Tighten the jam nuts against the brake arm.
SERVICE 3-19
Figure 3-12: Optional Rail Wheel Brake Shoe Adjustment

NOTE: BRAKE HOUSING NOT SHOWN FOR CLARITY
4
3 5 4
1
3
2 1
2
FRONT BRAKE REAR BRAKE
CLEARANCE BETWEEN BRAKE SHOE

AND RAIL WHEEL MUST BE 1/8" OR LESS
Hydraulic pressure adjustment:
The pressure provided by the brake pump must be adjusted in order to achieve the desired
braking effect. If the pressure is too low the brakes will not properly engage. If the
pressure is too high, the rail wheel will lock up and skid causing a flat spot on the rail
wheel.
The vehicle should be at its minimum service weight. Only the permanently installed
equipment, and permanently carried equipment should be on the vehicle.
1. Bleed the air from the brake lines.
2. Place the vehicle on rail. Apply the brakes while the vehicle is in motion. Have an
observer watch the rail wheels for signs of stoppage.
3. If the rail wheels skid / lock-up while braking, lower the brake pump pressure until
they no longer lock-up.
4. If the rail wheels do not slow down during braking, raise the brake pump pressure
until the rail wheels lock-up. Then slowly decrease the brake pump pressure until the
rail wheels do not lock-up.
5. Readjust the pressure relief valve until adequate braking is achieved.
SERVICE 3-20
3.6 ROUTINE RAILGEAR SERVICE

The railgear must be serviced to ensure proper operation and avoid damage to the
equipment. Refer to table 3-4 for the Recommended Service Schedule.
Grease fittings are provided at most lubrication points, however other parts on the Rafna
railgear also need lubrication (refer to figures 3-13 and 3-14). The recommended
lubricant for this equipment is ESSO LONAX EP2 GREASE or equivalent (operating
range: -22°F to 275°F (-30°C 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 or
equivalent.
Torque vehicle wheel lug nuts to 165 ft-lbs as per sequence shown in figures 3-15
and 3-16.
Should any loose nuts and bolts be encountered on the railgear during the inspections or
during maintenance of the railgear units, refer to figures 3-17 and 3-18 for non-standard
bolt torques and to table 3-5 for standard bolt torques.
• If the vehicle should derail, a thorough inspection of the complete
! railgear assemblies for damaged parts should be carried out before

being put back into service.
SERVICE 3-21
Table 3-4: Recommended Service Schedule
Initial 8hr
Monthly
Every 3
Every 6
Months
Months
Weekly
of use
Daily
Service Required
Visually inspect the railgear prior to

1 9 9 9 9 9
use for damaged or worn parts.
Check for loose rail wheels and
2 9 9 9 9 9
fasteners.
Ensure the rail gear locking
3 9 9 9 9 9
mechanism is functioning properly.
Check and adjust vehicle tire
4 pressure as per the manufacturer’s 9 9 9 9 9
specifications.
Ensure the vehicle is in good
operating condition based on the
5 9 9 9 9 9
vehicle operating and maintenance
instructions.
Inspect railgear wheel flanges for
6 wear. Use the Rafna Wheel Flange 9 9 9 9
Indicator for measurement.
Inspect all hydraulic fittings and
7 9 9 9 9
hoses for leaks or wear.
Inspect rail sweeps for close
8 9 9 9 9
proximity to railhead. (⅛” max.)
9 Torque vehicle wheel lug nuts. 9 9 9 9
Grease hydraulic cylinder pivot
10 9 9 9
points.
11 Grease inner tube lower pivot points. 9 9 9
12 Grease guide tubes. 9 9 9
13 Grease locking mechanism. 9 9 9
Check fluid level in hydraulic
14 reservoir. Top off with appropriate 9 9 9
filtered fluid.
Check and adjust rail wheel bearing
15 9 9 9
endplay (0.001” to 0.005” max.).
Grease rail wheel bearings
16 (3 months or 3,000 rail kms 9 9 9
(1,900 rail miles), whichever is less).
Inspect and repack rail wheel
17 9
bearings.
SERVICE 3-22
Figure 3-13: Railgear Lubrication Points - Front

GREASE LOCK-UP
MONTHLY
GREASE CYLINDER
END MONTHLY
GREASE GUIDE
TUBES MONTHLY
GREASE GUIDE
GREASE RAIL WHEEL EVERY TUBES MONTHLY
3 MONTHS OR 3000 RAIL KM
GREASE INNER TUBE

LOWER PIVOTS MONTHLY
GREASE RAIL WHEEL EVERY
3 MONTHS OR 3000 RAIL KM
FORWARD
TRAVEL
Figure 3-14: Railgear Lubrication Points - Rear
SERVICE 3-23
Figure 3-15: 8 Stud Vehicle Lug Nut Torques
Figure 3-16: 10 Stud Vehicle Lug Nut Torques
SERVICE 3-24
Figure 3-17: Railgear Non-Standard Bolt Torques - Front
BEARING CAPS SNUG

NO PLAY IN BEARING
UPPER SUSPENSION
NUT SNUG - DO NOT
PRECOMPRESS SPRING
INNER TUBE PIVOTS SNUG

DO NOT TORQUE
FORWARD
TRAVEL
Figure 3-18: Railgear Non-Standard Bolt Torques - Rear
SERVICE 3-25
Table 3-5: Standard Bolt Torque Values

Bolt Detail Bolt Torque Value (ft-lbs)
¾” UNC Gr. 8 Fasteners 175
⅝” UNC Gr. 8 Fasteners 150
½” UNC Gr. 8 Fasteners 100
⅜” UNC Gr. 8 Fasteners 40
¼” UNC Gr. 8 Fasteners 12
SERVICE 3-26
3.7 HYDRAULIC SYSTEM RELIEF VALVE SETTING

This system is equipped with one relief valve located on the railgear pump. The relief
valve will require adjustment at installation and if ever there appears to be inadequate
hydraulic pressure to operate the railgear. The procedure is the same for all hydraulic
systems, except where indicated.
Refer to figure 3-19 or 3-20 throughout the following adjustment procedure for your
particular pump.
1. Locate the hydraulic hose (Item 1) that supplies the D2 port of the front railgear
hydraulic cylinder lock valve from the pump pressure port and disconnect it from the
pump.
2. Install a hydraulic pressure gauge (up to 3000 PSI) (Item 2) between the disconnected
hydraulic hose and the pump pressure port. The pressure gauge will indicate the
relief valve (Item 3) setting when the pump is loaded.
3. With the railgear pump switch energized, raise the front railgear completely. Push
the “Up” button on the front control box so that the hydraulic cylinder creates a load
on the pump by trying to “dead-head”. The pump should start and the pressure
reading on the pressure gauge should climb to 1800 PSI.
4. If the pressure is not correct, release the front control and adjust the relief valve on
the pump accordingly. Loosen the lock nut and turn the setscrew in to increase the
pressure or out to decrease the pressure.
5. Once the correct pressure on the pump relief valve is obtained, ensure the lock nut on
the relief valve is tightened. Release the pressure in the system and remove the
pressure gauge. Reconnect all hydraulic hoses.
6. Bleed the air from the hydraulic system.
7. De-energize the railgear pump switch.
SERVICE 3-27
Figure 3-19: Hydraulic System Relief Valve Setting - R-060
1
TO
REAR
RAILGEAR
2
A B
A B
PUMP
FRONT
RAILGEAR
Figure 3-20: Hydraulic System Relief Valve Setting - R-062

1 2
TO
REAR
RAILGEAR
FRONT
RAILGEAR
3
PUMP
SERVICE 3-28
3.8 ELECTRICAL SYSTEM TROUBLESHOOTING

The following basic test can be performed to check the integrity of the railgear electrical
system. Refer to the electrical schematic in figures 3-21 and 3-22
Should the railgear pump fail to operate, first check the fuse or the circuit breaker and all
wiring for shorts. Then the following test can be performed to verify the integrity of the
pump motor and the pump solenoid.
1. Pump motor test:

a) Connect one end of a 4 gauge shunt wire to the railgear pump motor power
terminal (terminal A) and touch the other end to the battery positive terminal.
b) The railgear pump motor should run upon touching the shunt wire.
c) If the railgear pump does not run, the railgear pump motor is defective, or the
railgear pump is not properly grounded.
d) If the railgear pump motor runs, test for defective the railgear pump solenoid.
2. Solenoid test:
a) Connect one end of the shunt wire to the switching terminal (terminal D) on the
railgear pump solenoid and touch the other end to the battery positive terminal.
If the railgear pump does not operate, the solenoid is defective. If the railgear
pump operates, the problem lies with the fuse / circuit breaker, wiring and/or
switches.
Should the railgear 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. Disconnect the wire from the railgear pump solenoid switching terminal (terminal D).
If the railgear pump continues to run, then the railgear pump solenoid is defective.
2. Check the front and rear control switches for sticking or shorting out.
SERVICE 3-29
Figure 3-21: Electrical System Schematic - R-060

DASH MOUNTED SWITCH EXTERIOR CONTROL
RAILGEAR
ON REAR CONTROL BOX FRONT CONTROL BOX
GREEN
GREEN
WHITE
WHITE
BLACK
BLACK
BLACK
BLACK
RED
RED
3 FT CABLE
35 FT CABLE
WHITE BLACK
VALVES
D BLACK
10 AMP CIRCUIT BREAKER
WHITE
WHITE
A
C B
- SOLENOID
+
PUMP
MOTOR TANK
BATTERY
ROCKER SWITCH CONFIGURATIONS

(VIEWED FROM REAR OF ROCKER SWITCHES)
RAISE NEUTRAL LOWER
ON OFF
PUMP DASH SWITCH RAILGEAR CONTROL BOX
Figure 3-22: Electrical System Schematic - R-062

RAILGEAR
ON FRONT TOGGLE REAR TOGGLE
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
RED
RED
BLACK
BLACK
35' CABLE
3' CABLE
D WHITE
FUSE / CIRCUIT BREAKER
A
C B
SOLENOID
- +
PUMP
MOTOR TANK VALVES

BATTERY
TOGGLE SWITCH CONFIGURATIONS

(VIEWED FROM REAR OF SWITCHES)
ON OFF DOWN OFF UP
PUMP DASH SWITCH TOGGLE SWITCH
SERVICE 3-30
PARTS 4-1
Section 4.0 PARTS

4.1 Railgear Assembly - Rotating Front................................................................ 4-2
4.2 Railgear Lock-up Assembly - Rotating Front ................................................. 4-3
4.3 Railgear Lower Assembly - Rotating Rear ..................................................... 4-4
4.4 Railgear Upper Assembly - Rotating Rear ...................................................... 4-5
4.5 Railgear Lock-up Assembly - Rotating Rear .................................................. 4-6
4.6 Railgear Mounting Assembly - Front.............................................................. 4-7
4.7 Steel Rail Wheel Assembly ............................................................................. 4-8
4.8 Rail Sweep Assembly - Front.......................................................................... 4-9
4.9 Rail Sweep Assembly - Rear ......................................................................... 4-10
4.10 Steering Wheel Lock Assembly - R-2879..................................................... 4-11
4.11 Steering Wheel Lock Assembly - ‘Hook and Loop’ ..................................... 4-12
4.12 22.5” Wheel & Tire Modification ................................................................. 4-13
4.13 Pump Mounting - R-060 ............................................................................... 4-14
4.14 Pump Mounting - R-062 ............................................................................... 4-15
4.15 Front Bumper Assembly ............................................................................... 4-16
4.16 Pump Assembly - R-060 ............................................................................... 4-17
4.17 Pump Assembly - R-062 ............................................................................... 4-18
4.20 Hydraulic Assembly - PTO ........................................................................... 4-21
4.21 Electrical Schematic - R-060......................................................................... 4-22
4.22 Electrical Schematic - R-062........................................................................ 4-23
4.23 Optional Brake Assembly - Front ................................................................. 4-24
4.24 Optional Brake Assembly - Rear .................................................................. 4-25
4.25 Optional Brake Pump Assembly .................................................................. 4-26
4.26 Optional Brake Electrical Schematic ............................................................ 4-27
4.1
28
"A"
24 9
19
16
18
"B"
Issued April 2002 (Rev A)
30 "C" 15
20
28 30
24 21
26 26
27
26 17 26
28
28
6 TO "B"
8
25 23
7 5
26
30 21 26
RAILGEAR ASSEMBLY - ROTATING FRONT
22
3
PARTS
TO "A"
13
TO "C" 12
20
30 11
21
10
4
FORWARD
21
TRAVEL 1
22
PARTS LIST
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY
1 R-1600 10" WHEEL ASSEMBLY 2 16 R-3613 HYDRAULIC CYLINDER (Ø2" x 8" STROKE) 1
2 R-2409L RAIL SWEEP 1 17 R-602 BELLOW CLAMPS 2 RAFNA
3 R-2409R RAIL SWEEP 1 18 - 3/8" UNC GR. 8 BOLT X 1" LONG 4
RAILGEAR
4 R-4857 AXLE ASSEMBLY 1 19 - 3/8" SPLIT LOCK WASHER 4
5 R-3562 SPRING PLATE 2 20 - 1/2" UNC GR.8 BOLT X 2-1/4" LONG 12
6 R-130 RUBBER SPRING 2 21 - 1/2" GR.8 WASHER 24
A Global Railway Industries Company
7 R-4867 INNER TUBE 2 22 - 1/2" UNC GR.8 NYLON INSERT LOCK NUT 12 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
8 R-3590 BELLOWS 2 23 - 3/4" UNC GR.8 BOLT X 2-1/2" LONG 6
Bulletin MO45RRFOT
4-2
9 R-4850 FRONT CROSS FRAME 1 24 - 3/4" UNC GR.8 BOLT X 5" LONG 1 ROTATING FRONT
10 R-3602B BEARING END CAP 2 25 - 3/4" UNC GR.8 BOLT X 5-1/2" LONG 2 RAILGEAR ASSEMBLY
11 R-3602A SHIM 4 26 - 3/4" GR.8 WASHER 20 R-450 OT
12 R-3618 SPLIT BEARING 2 27 - 3/4" UNC GR.8 NYLON INSERT LOCK NUT 6 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
13 R-2589 SPLIT COLLAR 2 28 - 3/4" UNC GR.5 THIN NYLON INSERT LOCK NUT 5 R-4820E PGS
14 R-2690 FRONT CYLINDER FRAME 1 29 - 3/4" UNC GR.3 JAM NUT 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
15 R-2593B TRUNNION CAPS 2 30 - 1/8" NPT GREASE FITTING 7 MO45RRFOT 0 1

4.2
2
Railgear Lock-up Assembly - Rotating Front
6
PARTS
7 3
6 1
4
7
8
8
5
6
7
9
RAFNA
FORWARD RAILGEAR
TRAVEL
PARTS LIST 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
Bulletin MO45RRFOT
4-3
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ROTATING FRONT
1 R-4870 ROTATING FRONT ASSEMBLY 1 7 - 3/8" UNC GR.3 NYLON INSERT LOCK NUT 3 RAILGEAR ASSEMBLY
2 R-2408 HANDLE 1 8 - 3/8" LARGE SAE WASHER 2 R-450 OT
3 R-2692 PIN EXTENSION 1 9 - 3/8" UNC GR.3 JAM NUT 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
4 R-3561 SPRING 1 R-2689D PGS

5 R-3609 PIN 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
6 - 3/8" SAE WASHER 4 MO45RRFOT 0 2

4.3
10
19 9
17
16
8
7
12
13
6
4 11
5
Railgear Lower Assembly - Rotating Rear
19
18
PARTS
15 3
16
17
13
1
14
REARWARD
TRAVEL
2
RAFNA
PARTS LIST
RAILGEAR
1 R-001 10" STEEL WHEEL ASSEMBLY 2 11 R-4646R REAR RAIL SWEEP (RIGHT SIDE) 1
2 R-4646L REAR RAIL SWEEP (LEFT SIDE) 1 12 - 1/2" UNC GR. 8 BOLT x 2-1/4" LONG 8 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
3 R-4813 REAR AXLE ASSEMBLY 1 13 - 1/2" GR. 8 WASHER 16
Bulletin MO45RRFOT
4-4
4 R-4812 REAR INNER TUBE 2 14 - 1/2" UNC NYLON INSERT LOCKNUT 8 ROTATING REAR
5 R-4588 SPRING PLATE 2 15 - 3/4" UNC GR. 8 BOLT x 5" LONG 2 LOWER RAILGEAR ASSEMBLY
6 R-476 RUBBER SPRING 2 16 - 3/4" GR. 8 WASHER 6 R-450 OT
7 R-3590 BELLOWS 2 17 - 3/4" UNC NYLON INSERT LOCKNUT 4 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
8 R-602 BELLOWS CLAMP 2 18 - 3/4" UNC JAM NUT 2 R-4869 PGS

9 R-4800D OUTER TUBE ASSEMBLY (LEFT SIDE) 1 19 - 1/8" NPT GREASE FITTING 4 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
10 R-4800P OUTER TUBE ASSEMBLY (RIGHT SIDE) 1 MO45RRFOT 0 3

4.4
13
21 12
20
18
20
22 20
19 21
15
8
20 16
21
9
6
12
7
20 11
16
20 17
14
13
16
Railgear Upper Assembly - Rotating Rear
11 12
12
PARTS
5 10
4
12
13 12
16
11
17
2 TO REAR LOCK-UP REARWARD

TRAVEL
1
IDENTICAL FASTENERS NOT
PARTS LIST SHOWN FOR CLARITY RAFNA
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY RAILGEAR
1 R-3602B BEARING END CAP 4 12 - 1/2" GR. 8 WASHER 40

2 R-3602A SHIM 8 13 - 1/2" UNC GR. 8 NYLON INSERT LOCKNUT 20
3 R-3618 SPLIT BEARING 4 14 - 5/8" UNC GR. 8 BOLT x 2" LONG 8 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
4 R-4809 REAR BEARING BOX 2 15 - 5/8" UNC GR. 8 BOLT x 2-1/2" LONG 6
Bulletin MO45RRFOT
4-5
5 R-4872D REAR MOUNTING BOX (LEFT SIDE) 1 16 - 5/8" GR. 8 WASHER 28 ROTATING REAR
6 R-4628 HYDRAULIC CYLINDER 2 17 - 5/8" UNC GR. 8 NYLON INSERT LOCKNUT 14 UPPER RAILGEAR ASSEMBLY
7 R-4649 PIN 2 18 3/4" UNC GR. 8 BOLT x 2-1/2" LONG 2 R-450 OT
8 R-4818 HYDRAULIC CYLINDER SUPPORT 2 19 - 3/4" UNC GR. 8 BOLT x 3" LONG 2 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
9 R-4872P REAR MOUNTING BOX (RIGHT SIDE) 1 20 - 3/4" GR. 8 WASHER 8 R-4869 PGS
10 R-4820 LOCK-UP MOUNTING FRAME 1 21 - 3/4" UNC GR. 8 NYLON INSERT LOCKNUT 4 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
11 - 1/2" UNC GR. 8 BOLT x 2-1/4" LONG 20 22 - 1/8" NPT GREASE FITTING 2 MO45RRFOT 0 4
4.5
xx
7
4
9
5
6
10
12 13
11 12
2
8
Railgear Lock-up Assembly - Rotating Rear
9
PARTS
TO REAR RAILGEAR
LOCK-UP MOUNTING FRAME
1
10 3
14
RAFNA
REARWARD RAILGEAR
TRAVEL
PARTS LIST RAFNA INDUSTRIES LIMITED
19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY TITRE/TITLE
Bulletin MO45RRFOT
4-6
1 R-4823 LOCK-UP SUPPORT 1 8 - 3/8" UNC GR. 8 BOLT x 1.75" LONG 4 REAR LOCK-UP
2 R-4826 LOCK-UP PLATE ASSEMBLY 1 9 - 3/8" GR. 8 WASHER 10 ASSEMBLY
3 R-4838 LOCK-UP CABLE 1 10 - 3/8" UNC GR. 8 NYLON INSERT LOCKNUT 5 R-450 OT
4 R-4832 LOCK PIN 2 11 - 1/2" UNC GR. 8 BOLT x 2" LONG 4 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
5 R-3561 SPRING 2 12 - 1/2" GR. 8 WASHER 8 R-4837 PGS

6 R-4831 BUSHING 2 13 - 1/2" UNC GR. 8 NYLON INSERT LOCKNUT 4 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
7 R-4834 LOCKING CABLE BAR 1 14 - 'PULL TO UNLOCK' DECAL PLATE 1 MO45RRFOT 0 5

4.6
9
10
ORIGINAL FORD
6
FRONT BUMPER
9
10
13
9
12
10
6
5
4 11
10
RAILGEAR MOUNTING ASSEMBLY - FRONT
3 7
PARTS
14
2
10
5
11
IDENTICAL FASTENERS
NOT SHOWN FOR CLARITY
10
8
RAFNA
FORWARD
RAILGEAR
TRAVEL
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY TITRE/TITLE
Bulletin MO45RRFOT
4-7
1 R-4860D MOUNTING PLATE (LEFT SIDE) 1 8 - 1/2" UNC GR.8 BOLT X 3" LONG 8 FRONT RAILGEAR
2 R-4860P MOUNTING PLATE (RIGHT SIDE) 1 9 - 1/2" UNC GR.8 BOLT X 2" LONG 14 MOUNTING ASSEMBLY
3 R-4675D FRAME REINFORCEMENT (LEFT SIDE) 1 10 - 1/2" GR.8 WASHER 44 R-450 OT
4 R-4675P FRAME REINFORCEMENT (RIGHT SIDE) 1 11 - 1/2" UNC GR.8 NYLON INSERT LOCK NUT 22 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
5 R-4894D SHIM KIT (LEFT SIDE) 1 12 - 5/8" UNC GR.8 BOLT X 2-1/4" LONG 2 PGS
6 R-4894P SHIM KIT (RIGHT SIDE) 1 13 - 5/8" GR.8 WASHER 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
7 R-4893A REINFORCEMENT ANGLE 4 14 - 3/8" X 3/8" BAR STOCK X 4" LONG 4 MO45RRFOT 0 6
4.7
17
7
18
8
STEEL RAIL WHEEL ASSEMBLY
5
6
6
5
4
3
2
PARTS
1
3
19
16
13
15
12
14
11
10
PARTS LIST RAFNA
1 R-017 HUB CAP 1 R-018A SPINDLE INSULATOR (REAR WHEEL)

11 1 RAFNA INDUSTRIES LIMITED
2 R-017A GASKET 1 R-1603 SPINDLE INSULATOR (FRONT WHEEL) A Global Railway Industries Company
3 R-016 3/4" UNF SLOTTED NUT 2 R-401 SPINDLE HOUSING (REAR WHEEL) 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
12 1 TITRE/TITLE
4 R-014 TONGUE WASHER 1 R-1593 SPINDLE HOUSING (FRONT WHEEL)
Bulletin MO45RRFOT
4-8
5 R-010 TAPERED ROLLER BEARING CONE 2 13 R-005 INSULATING BUSHING 1 STEEL RAIL WHEEL ASSEMBLY
6 R-011 TAPERED ROLLER BEARING CUP 2 14 R-021 GREASE RELIEF 1
R-450 OT
7 R-020 10" STEEL WHEEL 1 15 - 1/4" UNF GR.8 BOLT X 0.75" LONG 3
8 R-009 OIL SEAL 1 16 1/4" SAE LOCK WASHER 3 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
R-019 SPINDLE (REAR WHEEL) 17 1/8" NPT GREASE FITTING 1 R-001 / R-1600 PGS
9 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
R-1602 SPINDLE (FRONT WHEEL) 18 3/16" COTTER PIN X 2" LONG 2
10 R-007 INSULATING WASHER 1 19 3/4" SAE WASHER 1 MO45RRFOT 0 7
4.8
5
RAIL SWEEP ASSEMBLY - FRONT
1
PARTS
4 3
RAFNA
PARTS LIST RAILGEAR

ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY A Global Railway Industries Company
19300 Clark Graham, Baie D'Urfe, Quebec Canada H9X-3R8
TITRE/TITLE
Bulletin MO45RRFOT
4-9
1 R-2410R/L RAIL SWEEP BRACKET (RIGHT / LEFT) 1

2 R-2411 RAIL SWEEP RUBBER 1 LEFT SIDE SHOWN RAIL SWEEP ASSEMBLY
3 R-5561 SWEEPER PLATE 1
NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
4 - 1/4" UNC GR.8 BOLT X 1-1/4" LONG 2
5 - 1/4" SAE WASHER 4 R-2409R/L PGS
NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
6 - 1/4" UNC GR. 3 NYLON INSERT LOCK NUT 2 MO45RRFOT 0 8

4.9
1
RAIL SWEEP ASSEMBLY - REAR
5
PARTS
5
3 4
RAFNA
RAILGEAR

ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY TITRE/TITLE
Bulletin MO45RRFOT
4-10
R-4644R RAIL SWEEP BRACKET (RIGHT)

1 1 LEFT SIDE SHOWN REAR RAILSWEEP ASSEMBLY
R-4644L RAIL SWEEP BRACKET (LEFT)
2 R-2411 RAIL SWEEP RUBBER 1
R-450 OT
3 R-5561 SWEEPER PLATE 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
4 - 1/4" UNC GR.8 BOLT X 1.25" LONG 2 R-4646R/L PGS

5 - 1/4" SAE WASHER 4 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
6 - 1/4" UNC GR.3 NYLON INSERT LOCK NUT 2 MO45RRFOT 0 9

4.10
5
4
4
3
4
1
STEERING WHEEL LOCK ASSEMBLY - R-2879
PARTS
RAFNA
PARTS LIST RAILGEAR
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY RAFNA INDUSTRIES LIMITED

1 R-2880 LATCH SUPPORT 2 19300 Clark Graham, Baie d'Urfé, Québec Canada H9X 3R8
TITRE/TITLE
Bulletin MO45RRFOT
4-11
2 R-5665B LATCH 1
3 - 1/4" UNC GR. 8 BOLT x 1-1/2" LONG 1 R-2879
- 1/4" SAE WASHER 10 STEERING WHEEL LOCK
4
- BUSHING (R-130) 2 ASSEMBLY
5 - 1/4" WAVE SPRING WASHER 2 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
6 - 1/4" UNC NYLON INSERT LOCKNUT 1 R-2879 PGS

7 - 4 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
8 - STEERING WHEEL LOCK DECAL 1 MO45RRFOT 0 10

4.11
1
4
PARTS
STEERING WHEEL LOCK ASSEMBLY - ‘HOOK AND LOOP’
RAFNA
RAILGEAR

19300 Clark Graham, Baie d'Urfé, Québec Canada H9X 3R8
TITRE/TITLE
Bulletin MO45RRFOT
4-12
PARTS LIST 'HOOK AND LOOP'

ITEM
STEERING WHEEL LOCK
PART NO. PART DESCRIPTION QTY/ASSEMBLY
ASSEMBLY
1 S-001050 2 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
2 S-001050A 1 PGS
3 - 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
STEERING WHEEL LOCK DECAL
4 - STEERING WHEEL AND COLUMN - MO45RRFOT 0 11
4.12
4
2
7
22.5” WHEEL & TIRE MODIFICATION
PARTS
6
5
1
3
7
FRONT WHEEL
6
5
IDENTICAL FASTENERS
REAR WHEEL NOT SHOWN FOR CLARITY
PARTS LIST
RAFNA
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY
RAILGEAR
1 R-4882 22.5 ACCURIDE WHEEL 6
2 R-4883 FRONT WHEEL SPACER 2
3 R-4884 REAR WHEEL SPACER 2
9 RAFNA INDUSTRIES LIMITED
4 R-2426 FRONT TURNING STOP BLOCK 2 10 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
5 R-4881 DISK LOCKNUT M22x1.5 40
Bulletin MO45RRFOT
4-13
9 9
6 - 22.5 TIRE (NOT SUPPLIED) - 22.5 WHEEL AND TIRE
7 - ORIGINAL FORD WHEEL LUG NUTS - 12 MODIFICATION
8 S-204001 EYE BOLT WITH NUT 2 11 R-450 OT
9 - 1/4" UNC NYLON INSERT LOCK NUT 4 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
10 S-204005 FENDER WASHER 4 FRONT BRAKE LINE TIE-BACK PGS

11 - 1/4" UNC GR. 8 BOLT, 1" LONG 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
FORD 4x2 MODEL VEHICLES ONLY
12 S-204010 'P' CLIP 2 MO45RRFOT 0 12
4.13
4 1
2
PUMP MOUNTING - R-060
3
PARTS
RAFNA
FORWARD RAILGEAR
TRAVEL
TITRE/TITLE
IDENTICAL FASTENERS
Bulletin MO45RRFOT
4-14

NOT SHOWN FOR CLARITY R-060 PUMP MOUNTING
1 R-060 PUMP 1 R-450 OT
2 - FRONT RAILGEAR -
3 - 3/8" UNC GR. 8 BOLT x 1.25" LONG 4 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
4 - 3/8" SAE WASHER 8 PGS

5 - 3/8" SPLIT LOCK WASHER 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
6 - 3/8" UNC GR. 3 NYLON INSERT LOCKNUT 4 MO45RRFOT 0 13

4.14
6 7
5 1
2
PUMP MOUNTING - R-062
3
PARTS
IDENTICAL FASTENERS
FORWARD
TRAVEL
RAFNA
RAILGEAR
PARTS LIST
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY A Global Railway Industries Company
TITRE/TITLE
1 R-062 PUMP 1
Bulletin MO45RRFOT
4-15
2 - FRONT RAILGEAR - R-062 PUMP MOUNTING

3 R-2846 PUMP SUPPORT BRACKET 1 R-450 OT
4 - 3/8" UNC GR. 8 BOLT x 1/25" LONG 4
5 - 3/8" SAE WASHER 8 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
6 - 3/8" UNC GR. 3 NYLON INSERT LOCKNUT 4 PGS

7 - U-BOLT (SUPPLIED WITH PUMP) - NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
8 - BRACKET (SUPPLIED WITH PUMP) - MO45RRFOT 0 14

4.15
3
FRONT BUMPER ASSEMBLY

PARTS
6
5
2
5
4
FORWARD RAFNA
TRAVEL RAILGEAR

TITRE/TITLE
Bulletin MO45RRFOT
4-16

FRONT BUMPER ASSEMBLY
1 R-2687AL FRONT BUMPER 1
2 R-2688 FRONT BUMPER SPACER 2
R-450 OT
3 R-051 SIDE WAND SET (WITH FASTENERS) 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
4 - 1/2" UNC GR. 8 BOLT x 4" LONG 4 PGS

5 - 1/2" GR. 8 WASHER 8 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
6 - 1/2" UNC GR. 8 NYLON INSERT LOCKNUT 4 MO45RRFOT 0 15

5
4.16
18
21 26
19
4
23
20
2
9
24
25
8
6
9
PUMP ASSEMBLY - R-060
7 10
17
16 11
1
30
15
PARTS
12 3
14
13
29
28 NOTE:
IDENTICAL FASTENERS NOT
22 27 SHOWN FOR CLARITY
PARTS LIST
15 R-061-15 RESERVOIR 1
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY 16 R-061-16 VENT PLUG 1
1 R-061-1 ELECTRIC MOTOR ASSEMBLY 1 17 R-061-17 CLAMP 1 RAFNA
2 R-061-2 BEARING 1 18 R-061-18 VALVE ASSEMBLY 1
RAILGEAR
3 R-061-3 SOLENOID SWITCH (MOUNTED UNDER HOOD) 1 19 R-061-19 SOLENOID VALVE 2
4 R-061-4 SCREW 2 20 R-061-20 SCREW 8 RAFNA INDUSTRIES LIMITED
5 - 5/16" GR. 3 UNF NUT (SUPPLIED WITH MOTOR) 1 21 R-061-21 SCREW 3 A Global Railway Industries Company
6 22 R-060-2 MOUNTING BRACKET 1 19300 Clark Graham, Baie D'Urfe, Quebec Canada H9X-3R8
R-061-6 PUMP ASSEMBLY 1
TITRE/TITLE
Bulletin MO45RRFOT
4-17
7 R-061-7 O-RING 1 23 - 1/4" UNC GR. 5 BOLT x 7" LONG 2

8 R-061-8 POPPET CHECK VALVE KIT 1 24 - 1/4" WASHER 4 R-060
9 R-061-9 O-RING 2 25 - 2 PUMP ASSEMBLY
10 R-061-10 SEAL 1 26 - 5/16" LOCK WASHER (SUPPLIED WITH MOTOR) 2 R-450 OT
11 R-061-11 RELIEF VALVE KIT 1 27 - 3/8" UNC GR. 8 BOLT x 1.25" LONG 2 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
12 R-061-12 RETURN TUBE 1 28 - 3/8" LOCK WASHER 2 PGS

29 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
13 R-061-13 FILTER SCREEN 1 3/8" WASHER 2
14 R-061-14 SUCTION TUBE 1 30 R-060-1 DUAL PUSH BUTTON CONTROL (NOT SHOWN) 2 MO45RRFOT 0 16
4.17
14
2 20
3
21
15
31
16
19 18 17
4 22
9
32
PUMP ASSEMBLY - R-062
11
8
5 7 10 12
6
PARTS
13
30
23
29
24
22
28
27 25
26
PARTS LIST
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY NOTE : IDENTICAL FASTNERS
1 R-062-1 O-RING 1 17 R-062-17 SOLENOID SWITCH 1
2 R-062-2 O-RING 1 18 R-062-18 ELECTRIC MOTOR 1
3 R-062-3 MANIFOLD 1 19 R-062-19 BEARING 1 RAFNA
4 R-062-4 ELECTRIC VALVE 2 20 R-062-20 NUT 1
RAILGEAR
5 R-062-5 VENT PLUG 1 21 R-062-21 WASHER 1
6 R-062-6 RESEVOIR 1 22 R-062-22 STAR LOCK WASHER 4
7 R-062-7 SCREW 12 23 R-062-23 SCREW 2
8 R-062-8 TUBE 1 24 R-062-24 LOCK WASHER 2 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
9 R-062-9 PUMP ASSEMBLY 1 25 R-062-25 MOUNTING BRACKET 1
Bulletin MO45RRFOT
4-18
10 R-062-10 O-RING 1 26 R-062-26 SCREW 2 R-062 PUMP ASSEMBLY

11 R-062-11 O-RING 1 27 R-062-27 SCREEN 1
12 R-062-12 SEAL & GASKET KIT 1 28 R-062-28 TUBE 1
R-450 OT
13 R-062-13 RELIEF KIT 1 29 R-062-29 ADAPTER 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
14 R-062-14 STRAP 1 30 R-062-30 TUBE 1 PGS

15 R-062-15 SCREW 2 31 R-062-31 CONTROL BOX 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
16 R-062-16 TERMINAL 1 32 R-062-32 U-BOLT CLAMP ASSEMBLY 1 MO45RRFOT 0 17

4.18
14
3 3
13 5 5
15 2 2
18 18
8 8
15 17 15
U1 D1 D1 U1
16 16
11 12
6
4 D2 D2
15 A B U2 U2
HYDRAULIC ASSEMBLY - R-060
15 7 15
9 9
17
A B
6 15 15 6
17 17
PARTS
PUMP
6 19 10 10
16 16
1
13 14
FRONT CYLINDER REAR CYLINDERS
RAFNA
PARTS LIST
RAILGEAR
1 R-060 HYDRAULIC PUMP 1 11 - HFS2-04 HYDRAULIC HOSE - 20" LONG 2

2 R-560 HYDRAULIC LOCKING VALVE 2 12 - HFS2-04 HYDRAULIC HOSE - 33" LONG 2 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
3 R-4628 REAR HYDRAULIC CYLINDER 2 13 - HFS2-04 HYDRAULIC HOSE - 35" LONG 2
Bulletin MO45RRFOT
4-19
4 R-3613 FRONT HYDRAULIC CYLINDER 1 14 - 1/4" HYDRAULIC HOSE - TO FIT (NOT SUPPLIED) - R-060 PUMP
5 25UA-06 3/8" NPTF MALE 90° FITTING 2 15 - HU04-04NJ HOSE FITTING 12 HYDRAULIC ASSEMBLY
6 849FS 04-06 1/4" JIC MALE - 3/8" NPTF MALE 90° FITTING 6 16 - HU04-04NJ90T HOSE FITTING 4 R-450 OT
7 844FS 04-04 1/4" JIC MALE 'T' FITTING 2 17 - HOSE FITTING TO FIT (NOT SUPPLIED) 4 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
8 854FS 04-04 1/4" JIC MALE - 1/4" NPTF MALE 45° FITTING 4 18 24SB 06-04 3/8" NPTF MALE - 1/4" NPTF FEMALE BUSHING 4 PGS
9 848FSO 04-06 1/4" JIC MALE - 3/8" ORB MALE STRAIGHT FITTING 4 19 R-1565 FLOW REDUCER 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
10 - HFS2-04 HYDRAULIC HOSE - 8" LONG 2 MO45RRFOT 0 18

4.19
14
3 3
13 5 5
15 2 2
18 18
8 8
15 17 15
U1 D1 D1 U1
11 12
6 16 16
4 D2 D2
15 U2 U2
9 9
HYDRAULIC ASSEMBLY - R-062
15 7 15
6 15 15 6
17 17 17
9 9
PARTS
6 19 10 10
TANK
16 16
1
PUMP
14
FRONT CYLINDER 13 REAR CYLINDERS
RAFNA
PARTS LIST
RAILGEAR
1 R-062 HYDRAULIC PUMP 1 11 - HFS2-04 HYDRAULIC HOSE - 20" LONG 2

TITRE/TITLE
Bulletin MO45RRFOT
4-20
4 R-3613 FRONT HYDRAULIC CYLINDER 1 14 - 1/4" HYDRAULIC HOSE - TO FIT (NOT SUPPLIED) - R-062 PUMP
8 854FS 04-04 1/4" JIC MALE - 1/4" NPTF 45° FITTING 4 18 24SB 06-04 3/8" NPTF MALE - 1/4" NPTF FEMALE BUSHING 4 PGS
9 848FS 04-06 1/4" JIC MALE - 3/8" NPTF MALE STRAIGHT FITTING 4 19 R-1565 FLOW REDUCER 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
10 - HFS2-04 HYDRAULIC HOSE - 8" LONG 2 MO45RRFOT 0 19

4.20
FRONT CYLINDER REAR CYLINDERS

3 3
5 5
14
15 2 2
20 20
8 8
15 17 15
U1 D1 D1 U1
11 12
6 13
D2 D2
4 U2 U2
HYDRAULIC ASSEMBLY - PTO
15 7 15
15
14
13 6 15 15 6
FROM PTO 17
6 18
10 10
PARTS
17
14
9
17 16 16
9 17
TO TANK
1 9
17
6 15
9
1
14
19 17
RAFNA
PARTS LIST
RAILGEAR
1 R-559M OPERATING VALVE 2 11 - HFS2-04 HYDRAULIC HOSE - 20" LONG 2

TITRE/TITLE
Bulletin MO45RRFOT
4-21
4 R-3613 FRONT HYDRAULIC CYLINDER 1 14 - HYDRAULIC HOSE - TO FIT (NOT SUPPLIED) - PTO PUMP
8 854FS 04-04 1/4" JIC MALE - 1/4" NPTF MALE 45° FITTING 4 18 R-1565 FLOW REDUCER 1 PGS
9 FS XX-08 1/2" NPTF FITTING (NOT SUPPLIED) 4 19 FS XX-06 3/8" NPTF FITTING (NOT SUPPLIED) 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
10 - HFS2-04 HYDRAULIC HOSE - 8" LONG 2 20 24SB 06-04 3/8" NPTF MALE - 1/4" NPTF FEMALE BUSHING 4 MO45RRFOT 0 20
4.21

RAILGEAR
ON FRONT CONTROL BOX REAR CONTROL BOX
WHITE
WHITE
GREEN
GREEN
RED
RED
BLACK
BLACK
BLACK
BLACK
35 FT CABLE
3 FT CABLE
ELECTRICAL SCHEMATIC - R-060
WHITE BLACK
BLACK
WHITE
VALVES
WHITE
PARTS
- +
MOTOR TANK
BATTERY
PUMP
ROCKER SWITCH CONFIGURATIONS

RAISE NEUTRAL LOWER
ON OFF
RAFNA
RAILGEAR

PUMP DASH SWITCH RAILGEAR CONTROL BOX A Global Railway Industries Company
PARTS LIST TITRE/TITLE
Bulletin MO45RRFOT
4-22
R-060 PUMP
ELECTRICAL SCHEMATIC
R-450 OT
1 R-060 RAILGEAR HYDRAULIC PUMP 1 5 - FRONT CONTOL BOX (PART OF R-060) 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
2 R-1567 ILLUMINATED ROCKER SWITCH 1 6 - REAR CONTOL BOX (PART OF R-060) 1 PGS
3 R-1577 5 AMP FUSE 1 7 - VEHICLE BATTERY (NOT SUPPLIED) - NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
4 - SOLENOID (PART OF R-060) 1 MO45RRFOT 0 21

4.22

RAILGEAR
ON FRONT TOGGLE REAR TOGGLE
2 5 6
WHITE
GREEN
BLACK
RED
WHITE
GREEN
BLACK
RED
BLACK
BLACK
ELECTRICAL SCHEMATIC - R-062
35' CABLE
3' CABLE
WHITE
PARTS
3
1
- + 4
MOTOR TANK VALVES

BATTERY
PUMP
RAFNA
SWITCH CONFIGURATIONS
PARTS LIST RAILGEAR
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY ON OFF LOWER NEUTRAL RAISE RAFNA INDUSTRIES LIMITED
1 R-062 HYDRAULIC PUMP 1 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
2 R-1567 ILLUMINATED DASH MOUNTED ROCKER SWITCH 1
Bulletin MO45RRFOT
4-23
3 R-1577 5A IN-LINE FUSE 1 R-062

4 - SOLENOID (PART OF R-062 PUMP) 1 ELECTRICAL SCHEMATIC
5 - FRONT TOGGLE SWITCH (PART OF R-062 PUMP) 1
6 - REAR TOGGLE SWITCH (PART OF R-062 PUMP) 1 PUMP DASH SWITCH RAILGEAR CONTROL BOX NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
7 - VEHICLE BATTERY (NOT SUPPLIED) - (ROCKER SWITCH) (TOGGLE SWITCH) PGS

NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
MO45RRFOT 0 22
4.23
17 9
10
18
10
11
15 TO HOOK INSIDE
5 BRAKE HOUSING
14
1 16
4
7
FORWARD
8
TRAVEL
OPTIONAL BRAKE ASSEMBLY - FRONT
15
14
14
PARTS
3
14 12
2
13
18
19
RAFNA
PARTS LIST
RAILGEAR
1 R-4865D/P BRAKE HOUSING (LEFT/RIGHT) 1 11 - 1/4" UNC GR. 3 NYLON INSERT LOCK NUT 2
2 R-4557 BRAKE SHOE LINKAGE 1 12 - 1/2" UNC GR. 8 BOLT X 4" LONG 1 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
3 R-4554 BRAKE SHOE 1 13 - 1/2" UNC GR. 8 BOLT X 4-1/2" LONG 1
Bulletin MO45RRFOT
4-24
4 R-5601 CLEVIS 1 14 - 1/2" GR. 8 WASHER 4 FRONT RAILGEAR

5 R-5602 CLEVIS PUSH ROD 1 15 - 1/2" UNC GR. 8 NYLON INSERT LOCK NUT 2 BRAKE ASSEMBLY
6 R-5603 HYDRAULIC BRAKE CYLINDER 1 16 - 1/2" UNF GR. 3 JAM NUT 1 R-450 OT
7 R-5604 SPRING 1 17 - 5/8" UNC GR. 8 BOLT X 2" LONG 2 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
8 R-5601A LOCKING COLLAR 1 18 - 5/8" GR. 8 WASHER 4 R-4864D/P PGS

9 - 1/4" UNC GR. 8 BOLT X 1-1/2" LONG 2 19 - 5/8" UNC GR. 8 NYLON INSERT LOCK NUT 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
10 - 1/4" SAE WASHER 4 MO45RRFOT 0 23

4.24
10
1
10
2
OPTIONAL BRAKE ASSEMBLY - REAR
13 10
11
14 3 12
PARTS
13
16
4
LEFT SIDE SHOWN
11
FORWARD
TRAVEL
15
PARTS LIST 5
15
R-4895D BRAKE HOUSING (LEFT HAND SIDE)
1 1
R-4895P BRAKE HOUSING (RIGHT HAND SIDE) 13
2 R-2411 RUBBER SWEEP 1
3 R-5603 HYDRAULIC BRAKE CYLINDER 1 RAFNA
4 R-5602 CLEVIS PUSH ROD 1 14 RAILGEAR
5 R-4896 BRAKE LEVER 1
13
6 R-4554 BRAKE SHOE 1
7 R-5561 SWEEPER PLATE 1
8 -
R-5604A SPRING 2 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
9 - 1/4" UNC GR. 8 BOLT x 1-1/2" LONG 4
Bulletin MO45RRFOT
4-25
10 - 1/4" SAE WASHER 6 REAR BRAKE ASSEMBLY

11 - 1/4" UNC GR. 3 NYLON INSERT LOCK NUT 4 6
12 - 1/2" UNC GR. 8 BOLT x 3-1/4" LONG 2
R-450 OT
13
13 - 1/2" GR. 8 WASHER 10 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
14 - 1/2" UNC GR. 8 NYLON INSERT LOCKNUT 2 12 R-4897 PGS

15 - 1/2" UNC GR. 8 JAM NUT 2 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
16 LINK 2 MO45RRFOT 0 24
4.25
13
9 8 11
12
7 15
6 10
OPTIONAL BRAKE PUMP ASSEMBLY
3 17
PARTS
16 5
14
4
PARTS LIST RAFNA
1 R-5801 6 GA CABLE INSULATED W/ LUGS, 4-1/2" LONG 1 12 R-5816 PLUG (VENT) 1

2 R-5802 MOTOR, ELECTRIC 12 VDC 1 13 R-5814 RESERVOIR 3-1/2" SQUARE x 6-1/2" (6.46") LONG 1
3 R-5803 CLAMP 2 14 R-5817 2W-2 POS.-12VDC, VALVE W/COIL 1 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
4 R-5804 SOLENOID SWITCH 1 15 R-5816-1 PLASTIC PLUG 1/8 NPT 1
Bulletin MO45RRFOT
4-26
5 R-5806 PUMP & BASE ASSEMBLY 1 16 - MOTOR SEAL KIT 1 HYDRAULIC BRAKE
6 R-5808 PART KIT, RELEIF VALVE 1 17 - TANK SEAL 1 PUMP ASSEMBLY
7 R-5809 PLUG SAE 3/4 - 16 1 R-450 OT
8 1/4" JIC MALE - 3/8" ORB MALE 90° FITTING 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
9 R-5811 CHECK VALVE PART KIT 1 R-5670 PGS

10 R-5813-1 RETURN TUBE 1/8 NPT 90° HOR (3-1/2" SQ.RES) 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
11 R-5813 SUCTION TUBE 3/8 NPT 90° HOR (3-1/2" SQ.RES) 1 MO45RRFOT 0 25
4.26
-
1
+
RELAY #1 RELAY #2 RELAY #3
87 87 87
87A 87A 87A
3
86 85 86 85 86 85
30 30 30
5
OPTIONAL BRAKE ELECTRICAL SCHEMATIC
FRONT RAILGEAR 9
BRAKE CYLINDERS TO VEHICLE BRAKE
PARTS
LIGHT SWITCH
12
8 BATTERY
RELIEF VALVE PUMP MOTOR 7

ADJUSTMENT SOLENOID
SOLENOID VALVE
11
REAR RAILGEAR
BRAKE CYLINDERS
PARTS LIST
RAFNA
ITEM PART NO. PART DESCRIPTION QTY/ASSEMBLY 10
RAILGEAR
1 R-5690 ELECTRICAL BRAKE BRACKET 1
2 R-5690-1 CAPACITOR 1
3 R-5690-2 RELAY 3
4 R-5690-4 DIODE 1 19300 Clark Graham, Baie d'Urfe, Quebec Canada H9X 3R8
TITRE/TITLE
5 R-5690-3 TERMINAL STRIP 1
Bulletin MO45RRFOT
4-27
6 R-5692 ELECTRICAL BRAKE CONTROLLER 1 HYDRAULIC BRAKE

7 R-1567 ILLUMINATED ROCKER SWITCH 1 BRAKE PUMP ELECTRICAL ASSEMBLY
8 R-5670 BRAKE PUMP 1 R-450 OT
9 R-4560 FRONT HYDRAULIC BRAKE HOSE PACKAGE 1 NO. DE DESS. DE CLIENT/CUST. DWG NO. DESSIGNE PAR/DRAWN BY
10 R-4560A REAR HYDRAULIC BRAKE HOSE PACKAGE 1 PGS

11 R-4574 PUMP MOUNTING BRACKET 1 NUMERO DE DESSIN/DRAWING NUMBER REV. PAGE
12 - 5 AMP FUSE 1 MO45RRFOT 0 26

APPENDIX 5-1
Section 5.0 APPENDIX

Rafna Industries Hy-Rail Mo45rrfot 450-0T

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Rafna Industries Hy-Rail Mo45rrfot 450-0T

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RAFNA INDUSTRIES LIMITED

19300 Clark Graham, Baie d’Urfé, Québec

ON TRACK - ROTATING FRONT – ROTATING REAR

READ AND UNDERSTAND THIS MANUAL

Application Models: 1999 – 2003 Ford F-450 (All Models)

Issued April 2002 (Rev A) Bulletin MO45RRFOT

This page intentionally left blank

CHANGES AND ADDITIONS TO THE MANUAL

Rafna will update this section as changes become available.

This page intentionally left blank

WARNINGS AND CAUTIONS

Warnings and Cautions are defined and formatted as presented below.

• Describes a potential hazard or a procedure that, if not performed

This page intentionally left blank

Section 1.0 General Information .............................................................. 1-1

Section 2.0 Operation............................................................................... 2-1

Section 3.0 Service................................................................................... 3-1

Section 4.0 Parts....................................................................................... 4-1

Section 5.0 Appendix ............................................................................... 5-1

Figure 2-1: Rear Railgear Operation ............................................................................ 2-5

Figure 3-1: Rail Wheel Bearing Adjustment................................................................ 3-4

This page intentionally left blank

Section 1.0 GENERAL INFORMATION

This page intentionally left blank

1.1 SAFETY INFORMATION

The Rafna Industries R-450 OT railgear is a hydraulically operated road-to-rail

Figure 1-1: Orientation Convention

1.3 PUMP IDENTIFICATION

Figure 1-2: Pump Identification

PUMP BRACKET TANK

Equipment or parts not manufactured by Rafna Industries, but which are

The obligation of Rafna Industries under this warranty is limited to the

This warranty is in lieu of other warranties, expressed or implied, including any

PRODUCT IMPROVEMENT LIABILITY DISCLAIMER

Warranty Policies And Procedures For

Installers & Customer Warranty:

To prevent unnecessary delays or misunderstandings in handling Installers’ or

Warranty information and authorization can be obtained from Rafna Industries -

Additional Billing, Installers & Customers:

Warranty Claim information and requirements:

Information Required: 1) Customer Purchase Order number.

Labor Warranty and /or additional labor charges:

Faulty Railgear Installations:

1.5 WARRANTY CLAIM FORM

Shipping instructions: Standard Special Standard Select Expedition Express

PART No. QUANTITY DESCRIPTION

Required Documentation from the Customer (For issuing Credit)

Description of Rafna Parts (Ordered or Used) Invoice # Total Claimed $ US/CAD

RAFNA INDUSTRIES approved by: DATE:

CUSTOMER’S REPRESENTATIVE: DATE:

For Internal Use only:

1.6 SERIAL NUMBERS

Serial Number: __________________

Model Number: __________________

Date of Manufacture: __________________

Serial Number: __________________

Model Number: __________________

Date of Manufacture: __________________

Figure 1-3: Identification Plate

RAFNA INDUSTRIES LIMITED

ROAD-TO-RAIL CONVERSION UNIT

MODEL SERIAL BUILT