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RW-1212 Manual

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1. O 2015 DMF Inc All Rights Reserved Page 8 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 1 3 Railgear Installation Rails In order to install the Railroader to get proper tire traction on the rail it is necessary that standard gauge rails or Installation Rails be fabricated from 3 standard channel per Figure 1 5 Drive the truck into the work area pulling forward and back several times to align the axles and up onto the Rear Installation Rails The rear inside tires should be on the rails with the rear outside tires off the floor The Front Installation Rails are not needed at this point NOTE Before proceeding be certain that the front truck tires are chocked and the brakes are set Figure 1 5 3 wide CHANNEL ee EE C RE LM ON d 4 o Be Front Installation Rails 4 d Rear Installation Rails 10 Cap ends of rails td P E d Figure 1 6 O 2015 DMF Inc All Rights Reserved Page 9 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 1 4 Preliminary Installation Remove the truck front bumper Bolt the Frame Extension to the truck frame refer to Figure 1 1 amp Figure 1 2 Make sure that tilt cabs of hoods will clear the Frame Extensions Trim the brackets and re gusset them if necessary All truck Frame Extensions that are bolt on brackets must use 5 8 18 fine thre
2. With the Axle Tubes now centered and brake configuration determined the Axle Tubes should be tacked to each outside Pivot Arm The inside Pivot Arms should not be welded to the Axle Tube to facilitate ease of disassembly for repair or future maintenance Final welding is performed after alignment in Section 5 0 The front Railroaders are ready to be lowered on the Installation Rails As the rail gear is lowered check the clearance from the truck tire to the Rail Wheels If there is interference stop lowering the wheels and retrace the installation steps to fix the problem When the Railroaders are completely lowered the front truck tires should be approximately 2 inches above the Installation Rails If rail gear will not lift the truck check that the cylinders are not cross plumbed that the system pressure relief valve if present is set high enough and that the pressure relief on the Front Railroader Valve is set high enough Re check the center alignment of the Rail Wheels to the truck frame If it is off break the tacks between the outside Pivot Arms and Axle Tube and slide the Axle Tube to the correct position and re tack in place O 2015 DMF Inc All Rights Reserved Page 21 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 3 3 Final Front Installation If the Spring Bracket location had to be adjusted make sure that the hex nuts two per stud on both Spri
3. v3 001208 NAMIOO DNIMI3IS ONNOS IN3NIT3A HOLYT pel mem I LALO DN Leva NALI LALO ON Lava NALI Page 51 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 6 4 Hydraulic Brake Connections NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance e Refer Brake Control Schematic Drawing for more information The wheels and brake assemblies are on the axles The brake valving is pre plumbed from the solenoid diverter valve through the brake relief valve e Attach the 48 braided steel hoses to the wheel cylinders on the brake assemblies Run the lines along the outboard side of the pivot arms to the pivot pin Leave a little slack hose looping around the front side of the pivot pin and run the hose up along the outboard side of the outboard long arms and over the top of each pair of long arms to the center of the vehicle The hoses are attached to the long arms with J clips just above the pivot pins These hoses are joined at the center of the vehicle above the railgear with a brass tee Connect the brake relief valve port marked FB to this tee with a 48 braided steel hose Four wheel brake kits only
4. 2 01 en Tes AJA YIENNN l gt LYO Ad GddV Ad NAVMO sz ZIST SL8CvOPY INI SAOLVIINAV4 TYLIN C3IJISN3AIG f Fl LE 13VH2 N LLVOLJILN3UI 133HM 21 2121 M8 des SEN Ke 137111 ddy A8 NDOILdISOS3G EI SES A3S 0ES2I AOLVINSNI Id 2 133HA Caddy Eo02 81 Y HV Q3 TIVLSNI SIDVE M G31VTISNI NON ULSC N d ING T33HM GLE MY 3s wel WESSEN E SR EECH TEM DNILSVO 133HM s r Casa oeSet I NOLLdIM2S3 ALO ON Lad W31I G3TW 1SNI S39VS qalv YISNIW 9 Qasos38 ZEST N d ING TSSHM ZLEL MY 3LON BO AMPF OL YO dod 002 ANP ONIS DOY OTTIVLSNI S3OVMH A YOLVINSNI Dd OTTIVLSNI SIVAMA YOLYINSNI Ide 81871 Nd SING 133HM TLEL Me ERC N d SIN TSSHM TLZL M8 y SS ee SN NN V ALLS fF de OR EA AS bee d Zyt 97 gt gt SS q L NAN NA NOU NNN NU A A A Page 26 of 69 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC d erre 3UIS SAJANI AQIS SAIDNISSYd ECG GC 6600F2ALl N d 00T0FZAL N d V V JN 130 V V IV LAC DN CTS MIDNISSYd 201 SAJAND erun ep GMEMIS 9T T 6 X CO X INDE 2 T gt e Bat a ATENISSY YIONITAD DIINYATAH LND ZTET A N mL DES SINE ddV AG NUTLdIS2S 37 aT AJN xr 1 Lu A lad lend Ji My UN3 3SVH NL p NI ONS H DE Sp k N3dO 91 11 0c PE I3SDI IO II 9I E 9 m t ddeb Le 91 Z2 1 204 e j and ES d EDR s LU E LI A AW Mi
5. Hydraulic oil e Unax RX 46 hydraulic oil or equal Wheel bearings Grease Fittings e Factory Standard Citgo Syndurance Premium Synthetic 460 2 e Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent O 2015 DMF Inc All Rights Reserved Page 60 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC y PP B6 1 01 ID a iiec AE Odd 148 NAVY ECH gg inii E s E x E 1371111 NUILdISOS3U 3lvu Aaa ions t Locati In Grease Po SJENL SST OU YIONITIADO AY 38 Drawing Page 61 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 APPENDIX A TECHNICAL DATA A 1 Working Pressure Ratings for SAE Hose and Fittings The following table gives the recommended working pressures for SAE J517 Hose and SAE J 516 Fittings Hose Diameter 100 R1 100 R2 po AT 2750ps 5000psi 6 2250psi 4000psi 8 2000psi 3500psi Contact hose supplier to confirm that the hydraulic hoses and fittings meet these pressures ratings and that they conform to SAE J 517 Hydraulic Hoses and SAE J516 Hydraulic Fittings NOTE The SAE ratings for hoses can be found stamped on the hose outer surface A 2 Welding Information e Dual Shield Wire spec gt AWS E71T 1 e Low Hydrogen spec gt AWS E 7018 Low Hydrogen Electrodes AWS E 7018 Manufacturer Equivalent 7018 gt 70
6. sBupy ojnne1pAH eunsseld uBIH puy tunip N Bury O JO uopel ejsu SUL J04 SPON uoponpaid usiqejsa OL 3SOdYNdA uonegejsu Bum Bury O SvS SLL c 9 sed 6 ad dy lt eil c Ce LL eil lt pe O LLI lt un m lt DILdTMOS3C LALO ON Led NLT Page 63 of 69 2015 DMF Inc All Rights Reserved e T H c I I g t H t lI I 2 1 H I P E kI t E t g BI B E BI 1 L2 8 1 L2 8 1 ldN ZIS posusyl edjd c o J L 6 had du c Oo c Ce LL Lei ul Q x lt Q 2 D A lt q lt DI VERSI FIED METAL FABRI CATORS INC DILdTMOS3 C LALO ON Led NLT N e N E 3 NOLLYTTYLSNI DNILLIA 3dId B d tc r00 ANTONA WOLLT 7 Mc x xiii dv A8 NBILJINJS3U Cam EN 888f 9 J OM JO euo o peyuur 3 Bupi edid y peaciddy HE TE EE TY Bupeeu buz uy suopenys yeep uj pesn eg Aey ede uoyel SINAINNOD az s Dun 4 4 SONI1113 YJAHL 3dld 13315 Ajquiesse esoy Jo eqn Bujuoo uj eAjese o peubjje ai Pupu pedeys jo pue eqn JEU ens SJEN Mojeq Ye yo ul UMOYS L 3 3 1 WPL JEBuj4 woy SUN ejepdoudde ey o Bulu Su u uBp Yous q uonisod Bn JeBuy gu o uod edid ejeue oyu Bumy mers 5 uopeujurgjuoo ujejs s pjoAe 0 peJeAooun Ye eq snu spesJug Me Jay ey jenbe peAoudde DuueeuiBuz Jo esed uoye IM jue ees peeuur Qr jf xejeuueg Ajuo esp speautp edid jew 0 juesuqn puejess Addy g 938 UIP SING eu jo Gey eje spe
7. Manual Pin off with Slotted Lower Links Link Kit Position P N BO Short Links Upper Front Passenger 10718 Upper Front Driver Upper Rear Passenger Upper Rear Driver Link Kit Position P N BO Long Links Upper Front Passenger 10716 Upper Front Driver Upper Rear Passenger Upper Rear Driver Link Kit Position P N BO X Short Links Upper Front Passenger 10726 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger O 2015 DMF Inc All Rights Reserved Page 41 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 Remote Pin off with Standard Lower Links Link Kit Position P N BO Short Links Upper Front Passenger 10722 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver Link Kit Position P N BO Long Links Upper Front Passenger 10720 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver Link Kit Position P N X Short Links Upper Front Passenger 10724 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver Remote Pin off with Slotted Lower Links Link Kit Position P N BO Short Links Upper Front Passenger 10723 Upper Front Driver Upper Rear Passenger Upper Rear Driver Li
8. Rear Einen ge aser iecur bebat etr p a cena E Pi ca dtp be ob D ecd E PA e iP ida 41 Drawing Rear Link DIMENSIONS nnne ehe hase nnns 43 5 0 Front To Rear Alignment ssswsnaananaananaananaanaananaa 44 SL RD ANINO NE aA E A ntaaeeeanauseuinis 44 Drawing Alignment Procedure and Traction Adiustment mnn 46 O 2015 DMF Inc All Rights Reserved Page 1 of 69 DI VERSI FI ED METAL FABRICATORS I NC RW 1212 6 0 Installation or OPTIONS uyu Ra ROCA CIERRE ER ERROR EE RECURSO SR YR NR ACH RE RR RD RR 47 OL UR Ne 47 Drawing Railsweep Assemblies and Variation 48 GZ Remote PN OT PN geet E cer ER EMG e RO CHAR E api d 49 63 Steenna Wiel LOK EE 50 Drawing Steering Wheel Lock Assemblies r mmm 51 6 4 Hydraulic Brake Connections iic exo X ERA OO E CER CA UXOR SO ACE EE GR ERO EE ed be adc 52 Drawing Hydraulic Brake Assemblies u uuu Henne nnn 53 Drawing Hydraulic Brake Adiustment IH emma 54 6 5 Instruction and Safety Decals cccc cece cece eens cece eens eee nnne ense nnn 55 7 0 Final Checklist 56 DMF RW 1212 Railroader Installation Check Gheer nan cnn nn rr 56 8 0 Engaging the UR 57 Sk Getting On the Ral aevi ded ee 57 9 2 Getting TER allies ibis Vk vidis ox amid nere 57 9 0 Routine MaiDtenalle EE 59 9 1 Inspection amp Maintenance 59 92 Eubrication SPEER NTG 60 Drawing Grease Polnt LOCGEIONS See 61 Appendix A
9. TVLIA dvodnH z 09621 ti AINO NOLLWOITedV G3LVINSNID 37XV ONIN SOLVINSNI 2 98s21 Ier lt OT NL gt X3H 37Xv INN 2 sesar at 01 HM AVL 371XY 43HSV A 2 86821 H 0IGIe b 3NDNOL 37xv MI3HSYM 2 96521 or G3TTVLSNI S32VH SINA VAEOI SNI NON 133HA ZOT orca 6002 24 LSOd I311V1SNI SIVA SNI Ode 133HM T1490 0es21 S002 2 OL XOl d T3TIV1SNI S30v8 SNI MI IIIHA 00 ege 6 010208 WH 32V3 ONINV38 06521 8 670Z08 WH JNOO 9NINV38 16521 Z 898P 82 AYVONVLS was 2 236521 9 JYLT 37XW ALNA AAV3H 1 S0921 S NDILV1OS IINV A007 YIHSYM 1 99921 p NOLLYLOX ILNY NId IL poser 301IS S 239N3SSVd ICIS NId NON 1ND34j ASSY 3 nl 31XY T opgi 2 3018 SAJA 3IIS NId 1NUMj ASSY 3ENL 31XY T Orgel I LA TEO AJO DN lavd WIL D Q Q dy u lt D x lt Y EI Q J lt e im LL Drawing Page 24 of 69 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FI ED METAL FABRI CATORS I NC lew gt po Q Lo o Q X LLI I gt Ke Q u ui t D X lt Y EI Q E J lt e im LL Drawing e gaer un ease gt X KEE HE IN YOEBCTAL 46 90 21 3018 SSaAmddg tS 3S NFIN o ipe 319d Ad Idd AG NAVA T33KHM GSlV INSNI ZISI SL8 v0F INI SHOLYJIISEVI WLIW G3LJISS3AIG ASSY G nn C3IV SNL SIZES ddv AG NOLLdIS
10. T 29207 3019 S M3DN3SSVd AYIA WD TAH T oemz faz JIIS SAJAT YY3Y TAS TAH T Dostera vz ACIS S VIDN3SSYdA INOJ ID TAH 7 102043 ET JUIS S MIART 1NOYA AD OAH f m pmsg WI RA A UN Rd NLT K ox S1MOd LSAL TYNSSIYd FMV ZdL Y bdl ALON VINO SDIVHE INO NMOHS LON OTIOAINVA DIVYA ZGFOL N d 3LON SDAY UV Y LNOU NMOHS Q7OJINVHN DIVYA PEPDL Nid LON Ce Isd 024 049 431738 ayuda SVIN TL seu NOLLINOI 90 AZ MALLVE 90 ACH HOLMS TV 3d Siva JO AVALSNI CIORLLNOO Diva ATIVA DINONLO375 0125 TYNINHAL 3801 SCHO NO ALON S IH3HM 3 die NOY3 Page 14 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 Nid ALIAVO gt N 0E B0d9 I Did IS GE 2507089 duo 819 N NF 80 IS 0D N 0 09 804S I TAS t SCHEER 081 05 N n 892 0A3 T 7A 2 WE NE BDAS Z0 ZI N D HeE B0Nd I Wi 1 LIL NOILJI NOS IT Page 15 of 69 Dfild Jdid Oflld Jdid J3A0N338 3AUW38 HM Zdl HI LUN LUN DI VERSI FIED METAL FABRICATORS I NC F6Fr0TIH H Tal TGF TIH N d 403 NYSDVIT LOS x gt o e a x Lef S3Ovld 3 TT _ JOCIALAVD NAHL YE 0 E TIYLSNI SII 9nd ALIAYI IIS X E uU JADKWIY lt OLDN ARA _ AE E ES gt 399714 3L0N I399f ld SON Ka lt 26 y0TUH gt om HSN SID 22 E 35511 ld NAHL 9 FE D pa
11. Techinical Daud 62 A 1 Working Pressure Ratings for SAE Hose and Fttngs nnn 62 Az Wedin INO MacOS 62 AS SAE e E glate Etna NSA BON GA 63 AA NPT Pipe Thread Fitting Installation coocccccccccnnnccccnnccnnnn cnn mnm 64 A 5 SAE JIC 37 Deg Flare Fitting Installation HH 65 Ap Purchased Fastener Torque Specification rr 66 A 7 Railwheel Bearing Adjustment Guidelmes nnn 67 A 8 Hi rail Cylinder Assembly Procedure I Hmm nnns 68 DMF Limited Warranty POlICV su ee Deeg Ne E Ne EE e DUREE EE 69 O 2015 DMF Inc All Rights Reserved Page 2 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 SET UP I Pre I nstallation NOTE Read all instructions and check that all required parts and Kits are included before beginning the installation The proper installation of this equipment is solely the responsibility of you the authorized installer When in doubt contact DMF for assistance Tools Required for I nstallation e Electric Welder Arc or Mig e General Mechanic Tools e Cutting Torch e Hoist or Floor Jack e OLx 1 1 2 dia Tube or Bar e Hand Grinder e Frame Drill w 5 8 Drill Bit e Protective Clothing e Goggles Supplied Parts Check List Manuals P amp S and Install Including Decal Package Front RW 1212 Rail Gear Rear RW 1212 Rail Gear Rear Mounting Plates 4 X 6 X 12 w 4 Holes Front Frame Extensions if Required Fro
12. spring or suspension components E E TandeimAxier 1 20 1 4 x 19 16 1 4 x 19 If the truck frame does not extend the minimum of 19 1 4 for single axle or 15 1 4 for tandem axle trucks it should be properly lengthened to provide the necessary mounting clearance for the rail gear In addition because the rail gear typically drops straight down but it can also articulate from side to side to allow alignment of the vehicle with the rail a clear space of 19 inches must extend outward from each side of the frame in this area to allow for proper articulation see Figure 4 1 It is important that nothing encroach upon this space i e outriggers lift gates body tie down bolts Figure 4 1 SINGLE AXLE TRUCK O 2015 DMF Inc All Rights Reserved Page 28 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 Figure 4 2 CLAMPS TRUCK FRAME TRUCK TIRE REAR FRAME BRACKET TEMPORARY 6 SPACER E ng O 2015 DMF Inc All Rights Reserved Page 29 of 69 DI VERSI FI ED METAL FABRICATORS I NC RW 1212 4 2 Spacer Installation Before proceeding place a temporary 6 x 6 x 3 8 wall steel tube spacer between the truck frame and Rear Mounting Bracket see Figure 4 2 Actuate both Rear Cylinders to raise the Rear Frame Bracket up to the truck frame NOTE With the Rear Railroader in position temporarily secure clamp chain etc in place to p
13. 3 SPACER Top required AXLE 4 RUBBER SPACER ci 5 REAR MOUNTING PIN 6 FRC RAIL WHEEI 7 PIVOT ARM 8 FRO CYLINDER 7 O 9 ONG ARM 10 FRO MOUNTING PIN 11 FRAME MOUNTING BRACKET E EXTENSION if required 13 STEERING WHEEL GUIDE Figure 1 2 O 2015 DMF Inc All Rights Reserved Page 7 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 1 2 Rear Railgear Figure 1 3 shows the individual parts of the installed rear Railgear with the Rail Wheels in the rail position down The item descriptions will be used throughout this installation manual Figure 1 3 TRUCK FRAME TRUCK TIRE NN o PP A ad PEN FEN Item Description GRE leet ea 8 E TT Nr Wu Z H A AR FRAME BRACKET do e n OUNTING PLATE inside Bracket sculls N SE CAP d Item Description SPACER if required REAR VALVE ASSEMBLY G REAR CYLINDER UPPER LINK REAR AXLE OWER LINK REAR RAIL WHEEI
14. 5 SLIDE dvodnH 8 801008 at COIP 8 1 9 TIvlad dm 2 Deet u AINO NOILVIIIdd G3LVINSNI gt 37XW ONIN aOLVINSNI 2 agesat OT lt OT NL gt X3H 37Xv LINN 2 Geet 6 COT HM AVL I7TXV 3HSV z B6Sa 8 01516 N gt 3NONDL 37Xv 3HSV 2 96821 4 Q3TIV1SNI S329V3 Saved DN SNI NUN 133HA 2491 oset S002 4 LSOd I311V1SNI S32V3 SNI Ode TASHA 100 DES G002 Z OL YOINd I3T1V1SNI SI SNI OdT 133HA 1400 gisar 9 0T0408 WH 308 9NIMV3H meest S 6y0408 WH gt JNOD 9NI3V38 y T6s2t v 898vE32 CAVONVLS Mis 2 z6sa IDN 37XW ALNG AANH I God 2 Saved ON IN3WIT3A 3 33 ASSY 38nl 9 31v 1 06821 D MULLdIMOS3Q AL DN Lais N3LI gt y Q 3 Q x DI I 2 m u Vv lt x lt y d iem o ol Drawing Page 38 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC du x Q in ic Cyl Rear Hydraul Drawing TOFTE2 AL E DE E M DD TY3 L Rp p Sien HSL ees Fe ar iiec 148 Odd ug N YSE oy cor M XXX WI s 5 3UIS SAJAN ACIS S N39N3SSVd MIS BERE MEN re SE DAS 00FTFZAL N d IOFTFZAl N d ATENSSSY WGUNIIAO OLTVMIAH AYIA ZIZT Y say EE Y Y 119130 Y Y 19130 ddv AG NUILdISOS3U 300 Asa NER MM A dw KE Y Land GNA 10 gt E T 190d UN3 TON bes
15. E u i 10d UNA asya 7 Yid ON 3SV8 NIdO E 22 ZS 8 Z H al LN 8 5 5NILLIJ 3svamD 1 seme Z EN 2 11 IATENISSY TON 1 verte I CITIS SMIDNISSYD 12 17 32 IATENISSY Tamiya T Terre GUS SAJAND 2 1 8 MIENISSY IIYAYE 40 T Den DEE B d IC4OVH UNID ONRI O T G0etre 6 DEE Z UNPD DNI O T Bogt B Ol2 2 NOLSId DNIN O 7 zome 098 2 99y 93 AAU SSQNTONI LO Twas Z1 096 1008 YAA 1 oppe 9 LN WAS 9ZZ1yZ Nd NO DOST 0052 On Was 1 sopsg S ION 0003 0092 WNOLSId Was 3 roar 9T F S MODTAN INN T eomz TG NY J seas FG NOISE 7 meng T RA ON Iyd NLI Page 39 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC du x Q in ic Cyl Rear Hydraul Drawing ToS Te AL T rever vnr DDEIKZA L Rp pa En IST ees Fe e aivrc ug Oddy vg N YT V sx TUA XXX WI s EI E E AUIS SMIAIT ACIS MIDNISSV A ae SE DAS D0SIFZAL N d IOSTP2Al N d ATHN3SSV YIONTUO OITOVelIAH YYIY elen ZC Bic DE SIND 9 4 119 13d HH 7119130 ddv AG NDT LdIe GG IT awT O Asa F wd A EE L HH EA Lwiiwud ana om P Ga T 190d UN3 TON bes E u i 10d UNA asya Yid ON 3SV8 N3dLl 2 T ece 4350710 8 Z c1 mami J ALT y m ak wh Kg 1 EIT 9 t MN TO0B9 BI 9 6 X OIPeP T MDE
16. F ge LAN NYP 9 8 5 965818 N d W3HSVA MIDT TYNNILNI B S SSEBTBB Be JINTAO NIV DGZBIB N d 3lVd DNILNNOK amp 66878 N d SI p gt LAN X3H ET 3 So ld 2 SGHSVPOIOITI 377 ATEHISSY 440 NId 031Ye43d0 ALY 3lDW3 OL S4340 Nld 31899 310N38 SLYSANOO ZFS8J8 N d CH LON dt ONS X3H 2 B S TWAS MIHSY A907 HLOOL TYNSILNI B S LAN Mt X3H DB GS A or 371899 46 4 SANIT HS X EVO L6 A SANIT LYOHS 31899 2674 SANT DNOT DP Z0T NIILLdTSOSIG N d SLO 09139 4340NId ILONFIG 5 0 d 031Ya3d0 3789 ILONIG OL S D d TYNNYN JM3IANDI OL 03033N Slsvd TY S3UITTONI LO 19 31UN Page 37 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC 33003 JIVHS AY3Y 288211 lt A gt 22 26023 cw r AS SITHNN ONIAVST 31Yd Ad Oddy AS NAVE i 2151 S 8 POT ONI SAOLVOINEV4A TVLIW G3IJISS3AIG C31V II SNI NDN NADHS LY INSNI SVIN ASSY JIXV TASHA 2IZI Ma SS nau ENSE IDL ddy AG NUILdIS2S3 31vq1 A33 mas DES21 JOLYINSNI Id Z 133HA Caddy S00Z 81 Y lew JOS SUSAR 3018 SH39N3SSVd T33HM G3LVTNSNI TSSHM A31VTINSNI NON SE e TIV130d 1332938 TOY 3301NI142 2 972818 St 371404S 37xXV via 2 96921 Io 8 ET9D ONILLI4 354390 2 6z2818 91 NOLLYLOS IINY X307 YIHSYA 1 995821 ST NOILVLOS IINY NId T rot vl E SMIHSYMMIDT dyoENH 8 601008 ET GP E X 8I 91
17. MISI POSS SW TIHA SUR SML NOVO SNId AL34IYS 3AUNWGe 7 SLT ALS wv ON CH JAR FDA STL HL 12333 EN AW Dorun TETAY 3D SKILT wh OW 13T0IH3A U3ddIn03 TyY IH 40 NOWA AOD 30 31v CvOU d 3THVTVAV 40 SIND SSH 3TH3A SHL AUDEH USHSINIA ONY TIYA 1H 40 NOLLYOIIdd HLIA AE ALS NDD 3T9IH3A T SJ3ri3s LNO WOLLOG LON OG ADA Jos sd D002 Pee gt Xe ION D PAPOA 4U0MuJ3 Sd poog Pee gt xXe INN OG LNOP HS od SR Las JAWA 431738 VNOTLAVS V 677006 PADUL PDU UD 403 po uo ADIDAS Sau 4U0UJ H207 SNOILLINYISNI ALAAVS 221008 HAVEL 3404348 38v 138 dNDU IONILVA 340 Seg S900 Ie erm VWNOLLNYIV Seroos 217008 SiN d ve2 2 221008 61008 BTIDDB STIDDB FTIDO8 EITOOB S N d ail 061008 T DILJTMOS3 C LALO ON Lad NLT TIG YD VINVTLV gIST SZ8 TDF Sel NU 3T9IH3A 3ADN39 OL SHOLYIIHEYH TYLIN G3LJISe3 TIG PO WO HI KE a o poy vedo 20 Sal PNOYS SEN DU pun upyaq pur sepa proa Bupspa pur suopupuoo po dq Four oq N l you uo speeds Bupi osado ajos poddnbe A p0 ah Cues 0203 9 pera edo rad Has pun Wid Wo Mad pajoes ap Aa AE 04 Sun Wo psup ANOTE venpod qoi W sud Age gT pba 404 bp puta VE sou nato a oad al You AA pode DIV DP saspat o Wun SPAA Toa uy 445001 I peddpbe A po jag Buer er 9 yos AA oq yan Fal rauen JUDI E VO ado up s4o sud A3agvs fo Gap JANE T 31 M youl os TPA Toa woe 37924 DEU T PO alt Sproul o4 JUDAS aus S Ragen sat y epp ios wo sf alo opa wd Keser teg Sou od Aral 4 Mod
18. MOJOJ v Id Z L Ud pee eijpurds 069 L Aed uinj 8 1 Ue eJoui jou ING ejoy JeuseAopo Keu oj yo nu Bupsn pe sped eAoqe 3 dejs uj Bunes esjeype og g qi u 009 09 dn ye jquiesse epyu 103 pesn eq Aew pua pedu uy eAoqe enpeoojg jejeuec MOD v KL 9 S YO PEOL APUS 0891 Mel un 9 yo nu Bupsnipe peq e oqe 3 deis uj Pupos eu eAjeupe o g BADGE eunpeocag BIGUGE MOI v uinj RTL Jo nu Pugsn pe ypeq eAoqe 3 dejs uj bupes eu SAPPE o1 g BADGE amp npeo04d jeeuec Moo v Id L ZE SI UNN pee ejpuids ELOL MU HON Ad 3eYNA3DOYA DIJIOIAS Pepi cud sueew Aq nu jo uogisod einoes 4 010 03 S00 Jo eBue ey ul sj Aed pue PRE Pupreeq pun 3nu yo jpeg 3 H94 SI pulq 348115 pun Beya Buun eju puey Aq 3nu ueyyBp esoo pun nu go peg q SUOHDEJIIP Oq u WIN ny euo oun ejejoy D qHJ OG 0 97 puey Aq jasey nu Bupsn pe ejpurds eu usyyBL g s8081 Buueeq USEMJEG pue sBuueeq u pexsed eseeJ6 Buipnput sjejep BumeIp Jo suoponujsur Jed sjueuoduuco ejquessy v FYNAIDOUd SU WONO SOW OL uopppy ul 059 L MU O 9 L MU ZEZ AN OHe EO L MU SLOMA 3NNOIDONA SIHL Ag G3SSVdINOON3 ATIVHSINS3O SAMAENISSV swejs s Bupeeg ejpurds pex peyunoyy pepu Bupeeg 0y peaede l jy 01 eqecddy 35VSN NOWNOO sBupeeg 99YM JO jueugsn py eu 104 SPORA uoponpojd ustiqgjs3 o L 3asOdeind seuyepine yueugsn py Buyueeg jeeuwepine FILL du Q E O K d c Q J U any Le el O t Q kel EI Q lt E cc N wl DI VERSI F
19. Ub payas P puo para Ans Seat iod w T ad Daag pva PATM EA Y wo Mnd eme mW palos Sal you MEA Raa y Sea YOu wo Wi UN peusiuss Aya ou s Jod JI V sees Yea 39044 E 3549 sped son ani E 4544 PASANDO sq Au saqi ood Jo 3942 JAM V sup Rays Mond puq 44049 ADM POL BAD eau 204 7 Demo pod aep SA S ME T DTO MOD Y baue Duro uq FP PAMU T yel NO 370IH3A 399714 OL NILSAS T33HA 2010 J W U 40 NOLLYSIdO FTID0OB g INV 119 gISI S 8 CRONT SYOLYOINEYH WLAN G3LJISS3AIG puewe e Heli 19 INNDAP Y MT IA TTYANNY yonbe 405 425 X905 y W440j JO prag v Dun sdv20qnu 20 day asoa4D ajos VAN Pais 08 Ap eo pjnous AJA DD asoca4D au pauinbsu s Dup42vde4a gl P9AITADA UD PDA DHMSA SY DL pesu 40u op Sbu Gen SLL pst2sdsns S wejgoad DukGan ssayun sdoSgnu Bujjioways Aq ALAY osova4D puo sumoa 42adsu CLS A4 S MD2 ADBADYIJUA sujiuou 9 AD Sail pppD z vaa ssuoaA4D Buppan ay 2adsu AJQUISSO ADS UD pT Mae 4no y Kusa RP VP sea is ATIM se0uv j jouoDv p Aj4ejn2p440d AoA 403 Sau 4UBM puo JO auodwog je 2nnoap u 40 je e Sau a2uos sa4 AD aS ou Bupuoar Auo Bupp ou sjeauk Mog yo uds MDS s sse2Xe puv s4euejsoj SSOD SAVA 2n vapAu 403 DEG TU q2edsu ANSIA IA TIG NILSAS T733HA 2010 J W U 40 3ONVN3INIVW ONY NUILLO3dSNI Page 55 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 7 0 FINAL CHECKLI ST L Rail test the truck to check for good traction and braking A good industr
20. Z E05818 E SINYNE Hel INI LINOYSE ONTLNNOW d33ASTIVM T zra 2 SDivelg HT NOA LINOvSE DNILNNOWN d33ASTIYE J rer T Nos AID DN Leid WALT SIAYA JSM NO 1700 ATENISSY d33 S TIVA INDUS OILgSI8I530 t Ser u LT Ze Ia T seet a LA ZB Y Lain ON e Wal Page 48 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FIED METAL FABRICATORS I NC RW 1212 6 2 Remote Pin Off Pins Cable operated Pin Offs are available on the Front Single 3 4 or Rear Dual 1 The Front Cable Remote Pin Offs weld onto either the outer or preferably inner Long Arms The Rear Remote Pin Offs components are shown in the Pin Off Drawing The Rear Remote Pin offs can be operated with a manual cable assembly or air actuated Remove the 1 4 20 hex nut 7 16 14 hex end cap and the internal tooth lock washer Slide the cable through the fixed pin off plate Replace the internal tooth lock washer 7 16 14 hex end cap and the 1 4 20 hex nut Add a 1 4 lock washer on the end of the cable and screw the cable into the sliding pin plate Tighten the 1 4 20 hex nut on to the lock washer and pin plate Mount two cable handle mounting plates not supplied These plates should have a 3 4 hole to attach the handle end of the cable to This plate should be securely located near the rear rail wheel valve Remove the T handle and the 5 8 11 hex end cap Thread the cable through the m
21. e Connect the rear pressure reducing valve port RB to the rear braided steel hose tee with the supplied 25 steel line Shorten or coil the excess of this line as necessary Tie strap the upper end of the rear braided hose to the center of the rear mounting bracket All Units with Optional Brakes e he brake control panel consists of a double pole single throw switch and an indicator lamp The lamp is connected to the switch by the red lead and is to be grounded by the black lead Locate a suitable spot for the control panel e Connect the lamp ground to a location under the instrument panel Connect the center terminals of the switch the ones with the jumper wire to the cold side of the stop lamp switch at the brake pedal with a wire tap connector NOTE On Fords connect the center terminals of the brake switch to the C210 terminal under the instrument panel One of the two remaining terminals of the switch is wired out to the grounding control terminal on the power unit the same one that the push button switches are wired to The last terminal is wired out to the tab terminal on the brake solenoid diverter valve e When the control panel is properly wired the indicator lamp will illuminate the solenoid valve will spool the coil will get warm and the power unit will operate when the switch is in the on position and the brake pedal is depressed far enough to trip the stop lamp switch e While an assistant depr
22. raise and lower functions and operate the guidewheel brakes Refer to schematics on the following pages e Install the hydraulic system as in the basic system above however Plumb from the pressure port on the Power Unit to port P on the solenoid diverter brake valve Plumb from port DH on the solenoid diverter brake valve to the inlet of the front directional valve 2 3 Hydraulic Brakes Only NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance e Ifthe chassis has been outfitted with a PTO hydraulic system The railgear raise and lower function may be plumbed into that system Using an appropriately sized manual diverter valve such as a Gresen S 50 the railgear may be tapped into the loop and plumbed as in section 2 1 above e To operate the railgear brakes the 12 Volt DC Power Unit may be used to operate the braking circuit only This prevents having to run the PTO circuit while traveling down the rail e Install the Power Unit and connect to the battery as above Plumb from the outlet of the brake system pressure control valve to the brakes per the OPTIONS section that follows WARNI NG Railroader valves have built in pressure reliefs and the hydraulic working pressure
23. ser o _ 3181 Pe sse sor os ax ss ee em mo S1 108 OV3YHL NI enbJo seAjc ULINIOD puy MON JO uopoesieju SUL uunioO pejejd JO Urejd PUY OPES SUL UMOG PUY MOY SC SU Sot peoy 3 ui amp jd JO peyeld SI JEG euL 4eueuM Ajuepi q WE PUL JO epeJo Ajpuepi 9 peres LEE ey uj Moy ejeyudorddy ey Paes you Jed Speedy puy ewe 9zIS teuejsey EL Ajpuep g mojeg yeu eyeudouddy ey pees DESIUL 991807 JO 9urJ Jeu Sy Jeugjse J eut Ajmuep Y INNMAZDONYA syog AOV pZSV NLLSV JO PUY 8 Puy 9 epeio zpr IVS JO 59ZlS OU S0N xnnd3o0d SIHL Ad GaSSVdWOONG ATIVHIN39 SLYVd Vous puy Ajquiessy Jed eijdnin JO Sey JSON JDVSN NONWOO SIOUGJSEJ pepeelu L POSEAN UCUILUCJ JO UOREJFEJSU SUL Jo SPORAN uoponpoig usiiqejsa OL 3sOdelnid uopesypeds enbio jeuejse peseunng JILIL Page 66 of 69 DI VERSI FIED METAL FABRI CATORS I NC DL dTSI2S 3G LALO ON Led NLT c 9 m i Q Q V Q O Be O im Q cs Q dad dy 0 LL Lo Q du lt U Aen Q v lt 2015 DMF Inc All Rights Reserved RW 1212 IN3NISTITUV DNIMV3H T33H 400 ef 3onmid NOLLONAO Ad SIVE SES AN EH Vy LE enpeooJd SIUL ISAO eougaejeld UM peuuojreg eg JSNN guud UO PSJON Ajeoyreeds 98 MP8901 SININNOO ey nu z wn ZL L yo nu Bugsnipe yosq eaoge 3 dejs u Bunes eAreuoe 01 g qi 005 c3 dn ye Ajquiesse jepjuj 40 pesn eq Aew YDUGJM ESOU uy eAoqe eunpesojd jeJeuec
24. slid up or down by loosening the bolts in the slots Also tack the Spacer into place as shown in Figure 4 6 Figure 4 5 TRUCK FRAME N 27 WELD e CENTER i TOP amp BOTTOM de ex ead Bolt Ax 5 8 11 Grade 5 X J AN NC MOUNTING PLATE NOE s A NG m A e EI tr N SIS e d gt TACK WELD Peo e Z v NN gt se A St QUE A Mui REAR FRAME BRACKET r P e X O 2015 DMF Inc All Rights Reserved Page 33 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC offs in A C E z 2 2 m du Vv lt C Q E ol de C Q ol Drawing S4JO NId IYNNYH AYSY TYIIdAL i ATENISSY MV3DTIVM AYIN ZIZI Y gt er xs M ex GUIL Ze EIL dd AG NOLLSINOS 31 aLI A38 Ed LON 3355 HA GF ED SVIN ASSY 440 NId CAI 91818 T E3 LON 33S HI Gt E YYIN ASSY 440 Nld Cage E9TB8IB ET 0 18 X k T NId H3LL00 8Se8IB 25 e 1 1 NHTS X3H DLITE 4nN 932818 IT T I D 1914 SS 3HSYA 682818 OT Ge X 97 5 gt NId Y31100 8 Brz8IB 6 8 1 NHTS gt X3H TALLOS inN Z21818 8 DNILNNON SI OT awa ASSY NId 3 1853051 Z ONILNNOW MIddN ayaa ASSY NId 2 0S207 9 SAUNA FLIT NId 3 Oreet S 31Y1d 1390y8E DNILNNON sv3el
25. 14 locations on rear assemblies e Check level of hydraulic oil and all other fluids e Check air pressure in tires and inflate to proper inflation pressure if necessary Bi annual Maintenance or as required In addition to the items listed in Daily Maintenance and Weekly Maintenance perform the following e Remove the hubcaps from the railwheels and inspect for deterioration or loss of wheel bearing grease Unless there is a problem the cavity may be topped off with the recommended grease without removing and or re packing the bearings If parts appear worn or damaged replace and repack as shown in Section 5 5 4 11 5 4 12 amp 5 5 5 e Clean the hubcap and mating surfaces and apply a bead of silicone gasket and re attach securely e Clean the strainer filter in the hydraulic power unit tank e Inspect wheel flanges for excessive wear If abnormal pattern is noted check railgear alignment see alignment procedure e Rail test for proper traction and braking If abnormal adjust properly see traction procedure O 2015 DMF Inc All Rights Reserved Page 59 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 Annual Maintenance or as required In addition to the items listed in Daily Maintenance Weekly Maintenance and Bi annual Maintenance perform the following e Disassemble inspect repack and reassemble Rail Wheel Bearings as shown in Section 5 5 4 11 5 4 12 amp 5 5 5 9 2 Lubrication Specification
26. 18 O 2015 DMF Inc All Rights Reserved Page 62 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC NOILYTIVLSNI DNILLIS ONIS O EDD 3efn 3oned NDILOPULRId NOILJI NOS IT azis poauu 4404 IYS SONILII4 378Y LSNFUY NON SONILITS 338V1Shnf v Hod jo exe uo Je sjees xeyleysem dn JEG pue peuypurd you si Bury O JEU ensue o pedsu 9 um my Jo UppZ L JEW y 1 snup JO snid SI Buueyupn uo eouEJejo UN e JO jg o enbe sI xey e uo je BUD Mojeq yeyo ereenipv UON SLU Jo ELE exqejsn py eu seupre ul L 3 33 30811 16Bui4 WOI eet pejesipur eu Tpe uou Bunyy Jo ejqejsnipe nu 290 ueju amp i 4 469 1eBuy pun esej yod o umop nu mes uonisod ui DIOU 0 uoueJ esf LUN ny euo uey eou jou q junowe peuisep Aq mejosun Suny ejqeysn pe ue ubye 01 3 Auesseoeu eq Aew BuluoueJw W I ee pod peuaos pinoys pe uou ese xeu Jo ejqejsn pe JeyseM dn peg juBp 1eBuy pun pod out Bupyy meng q nu o dn peusnd si pue esoo jou SI J YSEM dn peq eins exe ejqissod se ej se mu 350 yo yoeq sBumy ejqejsn pe 104 9 llo ejqneduuoo Jo piny wWa sAs Jo 3800 WD uiv Bury O eye uqn g seppied uBjeJoj Aue Jo seuojgJos sypju sung jo es eje sued Bupew yog JEU eunsue oj ppedsu y JYNA3IDOYdA spee L 3ufiens IVS Puy sies Bunj O UNM SHUMI peseyoind snadioosid SIHL Ad GASSVdWOONS ATIVHSIN39 S Dvd Dune yuguoduuoO uinuulullN 10 Sd 000p ojeg seunsseg Jy SPin 4 peseg unejoneg UM Bupeledo suejs s ojmejp H 39VS NOWAOO
27. 2 ADT FITEVL JIS V 5135858110 DIE x ey E Z X g I X B T IS HH AYE Y3IDVAS B Z L X TWA r E X 2 INDC S38nl SSON al Xy E 8 X 2 1 MIJAH L3SS n5 al X 6 X B E MdH GLY 1d CALLOS 0 amp X 0T X B E Ta 111914 JA WA LILLdTSOS 20 WS P 357 LA EE AID Casse 82205 y 28001 ger Z raan UN Lad N3LI Page 36 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC NIB MI DIANID LIM LI40138 24 ILON ATENISSY 44D NId 3780 31DW34 ZreT AY TIAS SEND GUILL E ACTED dd AG NOLLSINOS 3l aLI A3 b o ON ATENISSY MIV 330 NId 3LOKWIN LAN ASH 2 7 6 r InN X3H 2 1 du i dvI CNS X3H 2991 42 Q 2 YIHSPA MIDT TYNMILNI 9LI Lo c M um i T LP ee ee ee ee aei iiiii ii i lt l Q Q Tw O INN Met X3H 2 91 ps Y e N E pr I 9 2 M3HSV 19714 91 Z Ka H3HSY ODT 91 Z L i S gt Neo st N INN X3H Det T PX e ar T Re x it N3HSV NOI A HEL Ems e e ss z A EECHER mw Em T SINT 3IDWGB SE WGONISSVd Sdt T xm E 46 NS LN Mi JL GH v T 286818 E 3147 ONTINNON J40 Nid 310038 7 essere Z GSuow 318VO 440 Nid 310438 7 T 3IUN 1 LEES INTA IN Jet d LRSL Drawing S3 8HVO LNINIOVTdIN NUILVOITddV eA S114 1S38 LYHL 31899 JHL AJIS3dS IT LON INN XH 9F I 25 865818 N d
28. 6 BRACKET I SPRING HANGER Y A edt a TI C TUP ULP yeg SE E RW 1480 84 1 2 peer LE Ke REAR PIN HEIGHT PIN RW 1630 12 3 4 RW 1420 11 3 4 RW 1212 10 3 4 O 2015 DMF Inc All Rights Reserved Page 17 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 Figure 3 2 Frame I Extension A k f M mE AT eer E E wee hs a Wi e E Frame Mounting ag Bracket bw If they are required per Table A the 1 x 2 flat bar Spacers are placed between the Spring Hanger Bracket and the underside of the truck spring Use the 8 bar to lever the Long Arms and Spring Hanger Bracketss up to the springs as in Figure 2 1 After lifting the Long Arms attach each Spring Hanger Bracketss to the truck spring using a Rubber Spacer directly above the spring a 1 x 2 flat bar Spacer on top of the Rubber Spacer and two 3 4 10 hex nuts per stud Push the Spring Hanger Bracket back against the axle beam and tighten the hex nuts two per stud onto the top Spacer to cage the springs The nuts should be tightened down until the Rubber Spacer begins to deform from the downward pressure squeezes out between the top Spacer and spring Remove the Front Pin Offs and set the steering tires straight ahead The front Railgear can now be actuated with the hydraulic system which will cause the Long Arms to be raised up to the Frame Extension see Figure 3 2 The Frame Mounting
29. ATLANTA DMF 665 Pylant Street Atlanta Georgia 30306 Parts 404 607 1684 Parts Fax 404 879 7888 parts dmfatlanta com Service Department 404 879 7882 serviceodmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com O 2015 DMF Inc All Rights Reserved Page 69 of 69
30. After the Front and Rear Railroaders have been properly aligned complete structural welds may be applied at these locations that were previously only tacked o Onthe Front Railroader between the Frame Mounting Bracket and Frame or Frame Extensions if required o Onthe Front Railroader between the Axle Tube and outside Pivot Arms a continuous weld on the inboard side of the outside Pivot Arm is required NOTE For all structural welds either low hydrogen rod or dual shield Mig wire should be used refer to Appendix O 2015 DMF Inc All Rights Reserved Page 44 of 69 DI VERSI FI ED METAL FABRICATORS I NC RW 1212 Figure 5 1 INSTALL SHIM HERE d N O 2015 DMF Inc All Rights Reserved Page 45 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC qr q po 16 02 81 31V uj SUR DEA pue ops eu O Seed Bupunou au 308 61 SANTIO IN3AISDCUV NOLLOYAL me pue RENE AD 09 i Vi NR E rip E on e Pis A jux SC E PUB PNA eu JO uuopoq BU EE o UJEBE oouo eoDqe1 geen S 133HS AYAL 3890030044 INGANETT AS Feta AEN 9589 94 OJ US SADLUNJU PUR WOEN 0 US PPY pel Bupunou 91 eu uo Jays SU pue SUE NY eu jo wopoq eu ueawjeq pajs oj 1878 uius Jeoeds ppe JO AAOWEY y HESH JUN SU UA 4o you ool 8 up Bofe ou Bupioddns Jeefe ep JOMOT syoq Bupunow ERR Jee g SU uesco Z J1908K Bupunou Jee 91 ye soed Bugunoui ejou sno Z eu uo Spjam eu yo puu9 1 SMOJOJ SE epeul eq UBD jueunsn pe BORI
31. Bracket only needs to be brought up to where it touches the Frame Extension or truck frame not raised all the way to lift the truck frame and raise the truck tires In order to install the front of the front Rail Gear at the correct height the center of the Front Mounting Pins must be located at 23 1 2 from the ground with the truck tires on the ground as shown in Figure 3 1 If required shim the Frame Mounting Bracket to obtain this 23 1 2 Any shims used should be load bearing members no thin wall tubing If necessary a different Frame Mounting Bracket can be used to obtain the desired height of the Front Mounting Pin Check for truck frame spring steering gear or other truck component interference with the Railroader equipment particularly the Long Arms see CLEARANCE NOTE in this section Front Mounting Pin ground clearance may be reduced to as low as 22 to provide for proper fit NOTE If the vehicle is supplied with an integral extended front frame or a set back front axle the Frame Extension will not be required The Frame Mounting Bracket can be brought up to the extended frame as shown in Figure 3 3 Follow all instructions for finding the Front Mounting Pin height with the Frame Extensions Solid or load bearing Spacers may be required between the bracket amp the bottom of the frame to obtain the desired 23 1 2 from ground to Front Mounting Pin O 2015 DMF Inc All Rights Reserved Page 18 of 69 DI VERSI F
32. DI VERSI FI ED METAL FABRI CATORS I NC O Installation and Parts amp Service Manual RW 1212 jT a EE May 2015 SERIAL NUMBER FRONT SERIAL NUMBER REAR NOTE Please refer to the serial numbers when ordering parts or inquiring about warranty items DMF 665 Pylant Street Atlanta Georgia 30306 Parts 404 607 1684 Parts Fax 404 879 7888 parts dmfatlanta com Service Department 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 TABLE OF CONTENTS Table OF CoDtenDESusiiis iE veta dE Ra 392213 aaa 1 EE ee s 3 l Presta NAO a NO ia 3 Il FABS BEE SEN ias 5 Like ue HR e tg ge Ne EE 6 1 0 Railgear Components amp General Information 7 Lol FOM RANE Hae 7 AMNIS TT TE TIPS 8 L o Ralgear EH Eug e te RH CEET 9 Td JPrelmuanaryinstallatloLs uuu p Ce eR CERE Ki e DO OR EE 10 2 0 Hydraulic System Connection onse ek On ge PR ERE MORENO REOR RC UBER XI BE X CREER P 11 22 NON Hydraulic Systema enee E AR 11 2 2 Byaraulc 5vystem WIEN EE EE EE e Pa aides cd odia a Fi ke bonas 12 2 3 Hydraulic BRAK eS ONIY ivervintint Yd kuspa Po EE era EP RrbVbd uot epp Uv Up ER ores eeen ide 12 Drawing Hydraulic System Old Stviel Imm emen 13 Drawing Hydraulic System New Style uuu yu s upp IH nnns 14 Drawing Brake Valve Manifold A
33. GA jueseid JOU sj uopo eyenbepe jeu JUSAS gu uj yb jay jeopieA eu JO jueunsn pe e1 enba jou seop Ajeuuou pue piBu sj 1696 181 1691 9u 1 y 39039097 INSALSTTOV NOTO Var uie JOAJd eu uo ooed oyu WS eL pom peupeyqo ueeq seu Buruugus sodod souo epe 18968181 Weu SU pujueq Way eqessgooe JSOU S LURE SU JOJ 104890 SUL Ajquiesse Ee 9 xe SU uy Ee oju Seu Y IOYM PUB UE JOAId eu uo je SU UGGMJEG BLIGJELI WYS 88d SMO JO SB S Sj JO eunpeooud ey Ope eq jsnui reaDgeu poy eu Jo jueugsn pe aouen JO no jueweinseeui guoBelp y epis 0 epis way juejsrsuo Se y 96 Bua se suopeod JUBJUPAUOD Aue woy SPEL eq ugo SJUGLUG JNSES LI 9994 9J0N epeul eq ue sjueuenseeul pPuoDb p pue 1881 0 3u0JJ JELD OF IS GL 0 JeeDj eJ eu JOAO RI Venus O jeuugtp E JO SIE jeAe PUB 3uBrens uo epiuea eogjg Z ap Jo eeum eu jo Bupe wnwujujuu eu o pejeyu eq Pinoys sep ep e uj eansssud ye ppeuyo 1 uopoedsuj prey Jo dous o sejdde eunpeocud Buymojjo eur g dous juewufijre peyenb e Aq Papey eq Pinoys sp ejDue nun 0 eAejuoe o euoDe p eu uo WNWPEW BILL up eure O erenbs eq pinoys ere BAP JESY Z JeuoBejp ap uo WNLUPEU BIL uj pp 0 eenbs eq pinous sue amp n250 BujBuey ejsseaxe eje eu JO juewubye Jaye y pesseJppe eq Ajo pinoys pue suopeayreds urp eq oj POLUNSSS es pus Sp pejs ul peyerduco eq zenu Z pue y SdalS v Sn diootd INSNNOTTY J lt Q du Lo lt q c E J U k Lei
34. I ED METAL FABRI CATORS I NC RW 1212 Figure 3 3 c Front Mounting N Pin i Zei N gt Integral Extended Truck Frame ze N or set back front axle N CLEARANCE NOTE Proper clearances will allow the rail gear to move up and down with the truck front suspension As the truck tire hits bumps in the road the truck spring allows the front axle to move upward see Figure 3 4 Since the rail gear is attached to the spring just in front of the axle sufficient clearance must be allowed to prevent interference with other parts on the truck i e frame steering boxes shocks oil filters spring hangers hydraulic lines etc The Front Mounting Pin does not move in relation to the vehicle frame because it is fastened through the Frame Extension or directly to the truck frame As the Front Mounting Pin does not move and the Rear Mounting Pin at the axle does the rail gear effectively rotates about the Front Mounting Pin Therefore the part of the rail gear near the Rear Mounting Pin moves more than the part near the Front Mounting Pin and attention needs to be paid to the possible clearance problems that can be caused by this movement O 2015 DMF Inc All Rights Reserved Page 19 of 69 DI VERSI FIED METAL FABRICATORS I NC R
35. IED METAL FABRICATORS I NC Page 67 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC A 8 Hi rail Cylinder Assembly Procedure PE 00L 8800PZ Nid 31695 UTISId ATENISSY S3UNITAQ 800 INHO NOLLONAOD Ad enpeooid siup JeAo 93U9JgJ91d uy peuuojed ee sjupd uo Ajquuesse oypeds SLN3WWOO Pauspduoooe Ajinjesseoons ueeq aAey sdejs Pujpeoeud je uay eei ene pr E sBumy yod uo sde Ja eaa pue y Un Jewod eBeyeo Jo 889 18 uoyoq Jepuj pue ees JO puejD eos pal auod pedsu E SE eunsseud Bujupueu eju JUEPE Lee Je spuooes GL Gd DOES Je art DUR up Se ly og ep Te SIINeupAY uesp LAV DW PUB Je Kat 0 woo YONOIL 1epu epu 03 yun aod Qne E E SNLLSALL TSS da EE SCH bu SE OM jesu pue eqn BLEI spejuoo pues pun gan Deg usq D feos is hoe Hob ek Dom We pus beg je euoq aqng uy uojsyd ufe uoprsod jeonieA BCE queste pou oe o ola brat Nr SEAN q A joedsu S E pue xq piles seig QI dri veer Ajessgooeu ep unqoq Sum OU pue SDESAD g esp uinuujujul JO Spod Jepu5 12edsu ATENSSSV YSQNMAO enbuo spunod joo DOE o jnu poJ Duppo jes jesu H oque junos up sjees BUO JELH UPL eg 3 das uj DuuC Bupey euogisjunos ol 099 Aquuesse ute eil 9 EP 10 Bu PAR uy Sor weu 3 pue pou euy Bupe epp p1eoqgno eig UM pal 0940 jquiesse Puer jejsuj q Ajquiesse Uy DIS o jo ojneupAu u amp ep esn 2 FOO Jed pu al ul estab jasu 8 sBu p pue seu elis 10 GOBLINS yeus uj pu
36. ILNNON sv3el c ZrFOOT 24 JLON 33 ASSY LIAOYYE DNILNNON AYJ C 03381 E CHE GLEN 33 ASSY 149 UNY DNIT 8533 Ci pls H1 NO Nid NOILYLON ILNY A SVIN ASSY ZENS T33HA 1 28821 T ita AID ON ed NLT FEL JO INSNOdINOO V SI CL NELL SIGN SNOISNANIO SNOLLVIHVA SINT NO NOLLYFRIOSNI HON HO ZZ 7 SZ 8 36 vd EIS AION SLDPVUE DNLINNON HWH NO NOLLVARIOANI SHOW HOH 97 SOY d 335 ION Page 35 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC U Pei Q X d 0 im co ing Rear Mounti ing Draw y2ZZTAL Deel G29NDN DNIAYYT SLISSND DIG TAVINY LS ATEHW3SSV LDOYYE DNILNDUN YY3Y ZTZI AN GUILL NOILJI NOS IT 39 ect 922816 5 ES sees y EJ 83301 P E L X23 T X B T MINH NYE MI0vdS 2 6220 2 08 XDF X 8 E TAH GOIN SAWA 7 reent T DILdTMOS3 C LALO ON Lad NLT T PE amp 8007 91 E VE T8001 8 1 SE 6EZZT 8 E vE 82321 SE 86231 91 0 tE Lag 8 1 E 08001 8 L v 9E el k L kE 92221 NIISN3NIG Va 8133980 DIE E PE LEM 9T E VvE Gaddi 8 S pe Eee x B I rE reest 2 T PE UE Ce NOISNSWIG ON Lyd D i O3HSINTA 3133900 CRIVONVLS 31333900 GUVONVLS CdD SSOV id Y3HLO EA LITH E dA SUNS NO TAM ON CdAD S209 HLOG NO TEM LITE W C YELLN3O OL HALNEIO TTOH 27 1 2
37. ISIT m 39 mas DES2T HOLVINSNI Jd Z 133HA 300Y C002 81 Y kr 9002 2 LSOd Hn OSANLOVIANANVIA YOLVINSNI 323ld Z I O O S002 4 OL a dn OSANLIVIANVYIA YOLVINSNI 393ld L C E SIIHSYMAJOA dv9dgnH 8 601008 tl Gk E X SI 91 S S104 dvJENH 8 801008 et COP 8 1 9 INL dv9 amp hH 2 O9SeT ATNO NUILVOIlddv G3LVINSND 3 Xv ONIY YOLYINSNI 2 9989210 Im COT NL gt X3H 3 xv INN 2 Gest oT OI HA AYL 3 XV W3HSV 2 86521 6 COTSI6 A 3NDNOL 3I7XV ASHSVA 2 96521 8 CATIWISNI S329VM U3AVIE LX3 SNI NUN T33H moej m i S002 Z 1SOd GATWLSNI S32VB SNI 2d2 133HA moo DES G002 4 OL H0I8d CITIVLSNI S30v8 SNI Jdt IIIHM 1990 Sigi Z 010208 WH 279 DNINV3S8 06s21 9 6v0 08 WH 3ND3 DNINV38 Tt6s2t S 898239 TAVONVLS Was 2 26521 v TIWL3C IXY ALNG AAV3H T 0921 ACIS NId NON ACIS 339N3SSVd INDAJ ASSY Bani 379 T osar AQIS NId gt 3CIS S 33AIMI IND34 ASSY BNL 31XY T r821 2 S002 1SOd gt BBIVTnsNI adavogino T 82sbt 9 fel 3I100VS 31XY JAVA vadoo Seat T S002 1S0d gt SYOLVINSNI CAVOANI T ZeSrt ST NOLL IIS 3T LALO ON Lawd N31I Page 25 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC Chart ion Icat RW 1420 Wheels Ident Drawing GEI 1 86
38. Je J eeBeq Ze OI IVS UM SBumid peseuoung zsndaioosd SIHL Ag G3SSVdINOSN3 ATIVHSN3O SLYVd Dune jueuoduog wnwjul JO Sd 000p MO eg seunsseJd jy Spin peseg unejoneg uM Buneredo eege 9 NB1P H 3Ovshn NOMINOO sBumi ojnmeip AH eansseag uinipeN DIP IVS JO uopejeisu eu L 104 SPORON uononpoJd usiiqejs3 o1 35S0duUNd DILdTMOS3 C LALO ON Led NLT uopeyeysu Bupyy eeJBeg Ze SIT AVS ITLIL Page 65 of 69 2015 DMF Inc All Rights Reserved RW 1212 NDIILVOIJIO3dS INDYDL YINILSVA 900 I8NTIDEYd NOLLINTOYd mees Los wee owe Leo oser sem en sz oszt osez oom oser 9 8re r sr oser oser sv r ore oem ese porer f soe re pus ose 8 11 In L3 TMDNOD ALD TI YLSY WISV SINN X3H DNIHO LYN LAN 300804 SNITIVA 33d 8 X9 YO 3N0Y01_ UTJUNIKNODOIS 1708 IVIYHL 3SYVOO Miva AVA nr Jeuejsej penb o pessegs JYBIY P esn eJ JeAeN DUZ JO 28 vue a he Up uj senjeA bei OIE GAR Vu eq pi mo jnugu yog Y pesn eq SNL enbe jo sJeusen jeld O D doin amp J8 SENGA Spuno Apu 49 EL Aq Ajdpinw ELI Spunog 300y ul hr AY nbus eu Peye jou ssop 939007 JO asn SYL ae a d rider d aaa ip pejjdde ee pee eyuA 10 Jeddoo eyudinsp pem EH Res iem N Sp LYNS Apedes 58 95 uBju JO SJUEIPAN paid qu Du JO si ENPRE YM 10 JOJ GJE peypeds seniBA anio v S1NHINNOO sse Los o osse svor sere 21 215 1 en ore seve owe scar 6291 e eve 1 oron seer sem
39. LL ADUANA lIN3K3OV 71038 LENS 310NYH Cl eeng Zr 91 65 QT 60 X IN EE AECH ONILLIA GH IDN ANID N3S3MD FINSK3OV daa 3JONYH Cep Song 9T DNIN H 3vs 90 X OIF 08 ATST DNILLIA GINO 3 INVED N3SG3D FINSNSOVW 938 I3 lUNVH Ca 3018 ot ATENISSY ADUANA FINSINJOVId3N 310NVH CID rang pr LDI ANITZA N3S33D MININIOVTd3N 3 T0NVH CID 13018 ET SDNLLLI4 A JATYA N3S3MD fav ATEKHISSY CIRD 073018 SONILILJ JAWA ADMINI LINDONA ATHA3SSY Cage 03018 In Mr oe i TN avd NAT ep o 2 90808 6 v BUDE e 206018 2 B 90012 9 TJ CG TE T ers Ir T ere Page 16 of 69 2015 DMF Inc All Rights Reserved DI VERSI FIED METAL FABRICATORS I NC RW 1212 3 0 FRONT RAI LGEAR NSTALLATI ON NOTE The Railroader unit that we have shipped to you has been designed for your specific truck However before starting the front Railroader installation check the vehicle s front tire spacing The front rail gear operates between the front steering tires therefore you must have a minimum of 65 between the tires If this is not the case contact DMF With the front Railroader under the truck frame Spacer thickness can be determined Spacers may be required to place the front rail gear at the proper height Measure the ground clearance of the front spring just in front of the front axle beam A as shown in Figure 3 1 The correct distance from the ground to the center of the R
40. LUN eil 0024242424 424 lt FO 3vVS Je SIYOA SSHLO TT cavae ONY INS OTOSINYN JATYA Diva va F6 0TUH 8 LAN Z2 8 T dev AA Ade vedly vela Ima ATNO LINON OTOJINGYA 3 TSA SVE v3 eprpmm ae N M a DILdIMOS3C ALO ON vd NLT 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC Le Schemati Le o i Lei gt Y les Valve Assembli Drawing SZZIML BE LD DI SAIDNITAD ayaa SM30INITAO ANER GEM DNIAVMI aye gIECI EZBCKDE NI SMUILLVOTHEV d TYLIN I3LJISS3ATIT 27M WG dev Ad NAVY OLLYN3HOS OTINVATAH SITIENISSY SA THA GUILL TER ddV AG NLTLdIS2S 30 31v A3 F gr y LE R O E YA TIVLSNI AG G3lIddNs 3S0H ANYL DIINYYIAH LOSCH IIAH BNHSIX3 A S ei Sce TING vi di Cen Eer Sa ef CIRD Drang re CIRD 089018 Es Cad Desang Tee aa eeng T NT TST AON Sd TN L de bg Ce Fd pone DNLLL3S 43171338 lt UILNIAIT NOMS a w SUNS UNIT YIUNTUO LAN P AD XYK Ted ooog DNLLL3S 430739 ONa mm N3INDUO 13ND 3AWA INI WOM UNA UNITE MAXINIMO NS SUN3 U0 AJUNITAD i 2 lt O SONILLI41 DDT S N3S3BO G3IM3AIT GATA C43D 922018 03 SONILLLLFT E amp 4 S NISIND MILNIAIT SATA JCD msn er SONILLLi 2 1 amp 08 S IN3SIND MILNIAIT SATA cased 0y2018 BT GAVEL uel L
41. NITAD Iyaa Cased 1231 OF Z20 84 gt AN AOYE DNIM O MIONITAD Syed Cage eT 6 220 2 ONTA O M3UNITA2 3AVYYE C43D 03 31 8 GK9E JdS DNIMdS MUSSON SIUNITAD 33788 CARD gazar Z DD M3UNITAD Zug Caa Ever 9 52 0078 gt DNIS dYNS TYNMELX3 M3INITAO Saved Cased er S 09T0P4LON B T gt ABYDOS YATE MIONITAD Iyaa Ciel 92227 py ZXgGE DNILLIA BM3INITAO SYNE C riet E TIYL3C INL M3UNITAO AVAE C4ID Wet 2 OIINYYIAH 3UNITAO dove T Umz T NT ATS ALD IN Le LT ASSY TAD ANE OTZ2T N d 439 Page 53 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 Drawing Hydraulic Brake Adjustment 1 8 MIN SHOE TO ADJUST REMOVE ROD END PIN AND THREAD ADAPTER TO DESIRED LENGTH TIGHTEN JAM NUT TO CYLINDER BODY REINSERT ROD END PIN mS 2 r or w ADJUST TO 1 16 R REPLACE SHOE IF UNABLE TO ADJUST TO MAX ALLOWED 1 4 I D ooo A pr a O 2015 DMF Inc All Rights Reserved Page 54 of 69 RW 1212 DI VERSI FI ED METAL FABRICATORS II _ Instruction and Safety Decals 6 5 s i BYE AG Odd Ad NAVEL The all 41 Tm ch o d D i p E DND 75 SIA DU HIE LAIA 223 NM 2 RO SON ELL ava Aaa NOILYOO edid NI SNId ALSAYS 3991439 E NOLLISOG AV HDIH TiNd a NULLISUd 1198 HSNd Y av HOD SELLO SMALE WI YO JATYA 31VAILOV 2 DW
42. O 2015 DMF Inc All Rights Reserved Page 50 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC DBZTAL ZISI ELB 0 gt DNI SYOLVOIME 4 WLAN I3LJISS3ATII SNUILVIBVA SASSY A907 GSHA DNIS33LS LIL NOILJI NOS IT nti 01308 N d E TH3H DNIdOIS373 1 4 2 0474 YINITLHDIIGH les Wheel Lock Assembl ing Steeri Drawing 41 86 11 15 NGENNN DNIAVMI a iva ug Ode OD Wd N VS AYYVO IM LYHA 20 3TdNVS Y ISNP v SI SIHL SA9NYL LSOW 1134 OL X907 733HM DNIV331S Y SYH JWT Teen il 3IVU EE 091208 N d CHOOSE ND 291208 N d D0S2 WD O S s Be v007808 N d ALND MIdNS Gen a ES PS Se WA E o M Sa S DETZ08 N d D n TYNOILYNAALNI JY LSIAVN be D0I208 N d AU ers ep 0yT308 N d d Dn TIYSNOOD SS _ gt e EN 9 9A HA TA IL p9 DA DATDA A04 34vTd T33H 5NIN331S T prrz08 OT _ hi D j o 42 054 X3H INN g Booe 6 v3 ostzos 6 6 1 X ve DIH Lig 2 zoe 8 v3 041808 p ipovad 22011 7 201008 v3 seng EANHL A380S 7 sem 9 _ v3 097808 9 DS Hoivi 7 205008 S v3 vosrzog_ amp IN3NTIT3 A Nid T gien v3 Orfeo ANSKUTIM HILYT 7 erte wa 061208 E IN3NIT3A Nid F 93308 2 v3 vozo Z WD DNIM33LS 1974 IN3NI13 Ho1v1 1400 oeren
43. T3SONILIIJ c 9001r2 ET ldN 8 T DNILLIA 3SY38YD 1 parre at EN 2 11 AIBNISSY COY paarya TU C3IIS S MIDNISSYD 2 1 2 MIENISSY TINNYE nem2 GUS SAMIAIND Z T 2 IATENISSY TINNYE Oma or DEE B dN NOYE UNV DNRI O G stse 6 DEE Z UNYID DNI O T Bogt B DIg 2 NOLSId DNIS 0 1 2012 Z 8982 99 r 93 NELLI SSQNTONI LD Twas I 0r6 1008 H3dI 1 90142 9 IDI W3S 9ZZ1yZ Nd JACI 00ST 0052 QU Was 1 somre S ION 0003 0092 WNOLSId Was 3 roar 9T F S MODTAN INN T eomz TG NY J seas FG NOISE 7 meng T RA ON Iyd NLI Page 40 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 4 5 Rear Link Variations Manual Pin off with Standard Lower Links Link Kit Position P N BO Short Links Upper Front Passenger 10717 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver Link Kit Position P N BO Long Links Upper Front Passenger 10715 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver Link Kit Position P N BO X Short Links Upper Front Passenger 10719 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver Lower Rear Passenger Lower Rear Driver
44. UBLI UE N dZ H92 01A8 YYIAH 431738 3Xvelg INEBJ ATA T paror Z SUSI N d DP BUAS VAH TANTOS DN ANA HO LIMS Tydad DYHA 40 AVALSNICIOHLNOO Divya dH k dS N3S39D NS dA W ATTIVA OINOHLOSTT3 0125 TYNI NEAL ISN SCHO NO LON 2 1 002Y49 ADN3N3 NOUS AA OGAFST 92E N INN N3 Ud HONVNU 30IS S 43DNISSYd YY3Y UD TAH T m mrs az 3015 SAJAT AvA UO UAH T postere v2 ACIS SMIDNISSYd INOYA AO TAH T TOZO ET JUIS SAMIART INOM4 7142 AH FT 002078 Ier NTE dree 0 ALD ON Ld NALI Page 13 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC Y gt un lt Tw dy gt un Le Hydrauli Drawing TALS MIND HILSAS 2OITWUAH ZT27 A3 1371111 Dog 11319 3 lo E E 222 IN r Ss ddv Ag NOILJINOS 31 3140 Aga KE r Y EE LY Wb isd 0081 0091 431738 SIE je k r VIE LN LIST LHDIT snivormNI dat 1 meer SaNa T3AIAS SIF 3 1vW34 M PM DODT 3VS LIX DNIHWY ld T man OT CSH INT SVN CICA WSLS SSSINIVIS 9 opp 6 TENEDB LSdO 31990L HOLIMS T POD B ZI UEDUG d3ss3H 3700 NOLLNEHSNE HOLIMS 1 Sen Z CATINO 1N H335 NAOHS LOND INYSE TIOSINYN T zemi 9 Cada PUD INO NADHS 3AYYE Dim 07 resp 9 dH k k dS NISIND YIM IATA 1 Dore S 2 T 002 YA9 ADMINS UNOS SATA T kpeng y OIAZP SZE N INN N3 And HoONsvNDW
45. V N3INITAO OlinvegAH 1 660072 15 ei Sya ON SNI NOND LNH334 AdHW3SSVv 3801 3 31v T 0883 OF S3015 HIE NANNI 1NOY4 ATdHW3SSv Mai DNOT 3 Seier 6 JUIS SAMIDNISSYd YSLNO LNONA ATENISSY NAY ONO SIS SAJAT YILNO 1NOYA ATHW3SSv Wale DNOT T OIE Z BP 33 NEL JO SINVNOdFNOO JAY 92 8 VZ 34 AGL SION 3018 SAMIDNISSYd INIM ATHW3SSV WAY LOAId 2 20121 9 JUIS SAMIANRT LINON ATHWGSSV Weit 3 most S NOLLYOMdd OL ONCUODOY AMVA NYO ZZ 91 y EL GARELL SION 090 YAONITIAO ANOMS mes r oner y 2 X OF HOS F E NId 311 3H8nL AIOVAS 3 818758 WY LOAId ATENISSY NId JIL 2 Gsm 3 ONILNMON INOYWA ATENISSY NId Fez T TTS A ON Lyd SLT 2 Q Q m 7 E k Q E oc m c O lt TE Drawing Page 23 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FI ED METAL FABRICATORS I NC 9EBCSIML 838 WIN 4 on auna e WLIW G313ISS3AIGC U34V TNSNI NON NMOHS 31 7TNSNI 1NOY3 ASSY 3 7XV T33HA ZIZI AJ JALIL ddy A8 NBILdISJS3 3140 ES mas DESS AOLVINSNI Od Z 133HA Caddy sooesst z Y 3018 SYIANYG 3018 S 4IONISSVA eG T33HM G3LVTNSNI T33HM OZUYINSNINON Tos EN Wei Z dee WHY GIJENILX3 M DIINYICAH ASSY 33938 vg 2 20 21 81 Gel 31109S 31XY awed vano SGzel ar GPE SYIHSYMMIOT dv98nH 8 601008 9T Gb X BI 9 9 SLIDE dv9dnH 8 801008 ST C9IP 8 I 9
46. W 1212 3 2 Align Front Railgear The front Railroaders now are ready to be squared up and aligned Three measurements need to be taken to insure that everything is aligned properly To align the Long Arms check 1 That they are parallel with each other and the truck frame The outside Long Arms should be the same distance apart at the Rear Mounting Pin as they are at the Front Mounting Pin This prevents the mechanism from binding during up down operation of the rail gear Also the distance from the Long Arms to the truck frame should be the same on each side 2 That they are the same distance forward Measure the distance from the Front Mounting Pin to a common point in the truck frame i e a grease fitting on the Spring Hanger If the measurements are off square the Railroaders by loosening the nuts on one spring hanger and moving forward on the truck spring and re tighten To check the Spring Bracket location check 3 That the Spring Bracket to truck axle distance is same on both sides Measure the distance from each Spring Bracket back to the truck axle Since the forward position of the Long Arms has been verified Check 2 an off measurement here probably means the front truck axle is mis aligned and needs to be corrected After these alignment checks and after insuring there are sufficient clearances the Frame Mounting Brackets can be tack welded to the Frame Extensions NOTE Do not attach the welding machine
47. ad bolts hardened steel washers and Grade 8 prevailing torque locknuts All of the 5 8 18 Gr 8 fasteners should be tightened per Purchased Fastener Torque Specification Table Dwg PP006 in Appendix A Check that the Frame Extension tubes are level front to rear and side to side with the frame NOTE DMF front frame extensions are designed to support the front hi rail gear only It is the installer s responsibility to properly engineer bracketry for rail racks boom rests etc In normal applications mount the Front Valve Plate Assembly between the Frame Extensions with the Energy Valve on the underside and the handle facing forward and weld in place In case this is not possible mount Valve Assembly in the most appropriate and easily accessible location NOTE If the vehicle has been supplied with an integral extended front frame or set back front axle the Frame Extensions will not be required The Front Valve Plate can be attached directly to the extended truck frame Roll the Rear Railgear up on the Rear Installation Rails under the truck frame in the back The rear rail gear is usually installed with the Safety Pin Offs either manual cable or air operated towards the rear However truck body work may dictate locating the Pin Offs on the front side If the Rear Pin Offs must be located toward the front and the Railgear is supplied with insulated Rail Wheels make sure to swap the left and right Rail Wheels The insul
48. ated Rail Wheels should always be on the driver s side of the rail gear The unit can be leaned upright against the truck frame block the wheels to prevent movement during the hydraulic system connection O 2015 DMF Inc All Rights Reserved Page 10 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 2 0 HYDRAULIC SYSTEM CONNECTI ON 2 1 New Hydraulic System e lf only DMF Railroaders are to be installed and there is not an existing hydraulic system outfit the truck with the supplied 12 Volt DC power unit This unit will be used to actuate the railgear raise and lower cylinders only Refer to schematics on the following pages e Mount the Power Unit Assembly in the desired location This might be under the hood behind the cab under behind the steps to the cab or another location that will provide suitable vandal protection Connect the large stud on the Power Unit solenoid to the battery with the supplied 1 0 cable Connect the grounding control terminal on the solenoid to an ignition switch energized push button switch to be located near each manual valve When either push button is held down the power unit should function e The hoses that connect the directional valves to the cylinders are supplied in the kit All hoses to from the Power Unit and between the valves are to be supplied by the installer All hoses are to be SAE 100R1 1 wire braid 4 with female swivel JIC 4 ends e Using a pair of 38 hoses supplied loose in the k
49. brakes are required by federal law to also include ABS Anti Lock Brake System The system is designed to prevent wheel lock up and jackknifing during braking It also provides increased vehicle stability and driver control The ABS consists of wheel speed sensors an ECU electronic control unit and all wiring and airlines that link the ABS components to the brakes and the truck s electrical system During braking the sensors will detect if one or more of the wheels are locking and automatically engage the ABS The ECU then signals the system to apply and release brake pressure as much as 15 times per second allowing the wheel s to turn just enough to maintain optimum traction Vehicles equipped with WABCO or Kelsey Hayes ABS have an amber dash mounted warning diagnostic lamp During normal road operation the lamp will come ON when the truck engine is started and depending on the type of system will go OFF after about 3 seconds or when the truck reaches a speed of approximately 5 7 mph A self diagnostic check of the ABS is conducted during this time If the lamp stays on or comes on any other time during road operation a possible malfunction is indicated which will shut off only the part of the system at fault The affected wheel s will revert back to conventional braking For complete information and instructions relative to the ABS system please refer to the truck s operati
50. c ZrFO OT 24 JLON 33 ASSY LIAOYYE DNILNNON 8993900339 03381 E CHE GLEN 33 ASSY 149 NV DNIT ayga jeiz S020T 2 H1 NO Nid NOILYLON ILNY A AYIN ASSY ZENS T33HA T 28821 1 tea C AID ON Lyd NLT EN 3 438 NELL JO SANSNOJINOO SHY LY EL AE NELL SIGN SNOISNANIG SNOLLVIHVA SINT NO NOLLYFRIOSNI HON UO ZZ Y SZ VE 36 Vd EIS AION SLDPVUE DNLINNON HWH NO NOLLVARIOANI SHOW HOH 97 SOY d 335 ION Page 34 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC offs In A Q had e Q or lt S z gt Ke Q m T lt q _ o Q E oc E Q oc Drawing S440 NId 31DW3M M SVIN TYIIdAL ATANASSY WV3DTIVM AYA 2531 AY Sun DEG NDILdIS2S 30 SIE AJN CDT VE BL 9 08 Te DED SHLONIT INIA C NI S3HODO ASSY J40 NId SLOWSS 804 31899 Tind Hsnd e Cag t EH JLON 335 gt SANIT DNOT SO4 Nid HU ASSY 440 NId C438D DSSBIB uo 6 LON 33 S3NIT LYOHS NO4 NIJET ASSY 440 NId C338D TSSBIG ET 0 18 X F D NId H3LL00 8S5e8IB ler L 1 T NHIS X3H DLITE 4nN 932818 IT F I D 1914 S93HSYA 6s8z818 OT Ge X 97 5 gt NId Y31100 8 Brz8IB 6 8 1 NHTS gt X3H TALLOS inN Z21818 8 DNILNNON SI OT awa ASSY NId 3 1853051 Z ONILNNOW MIddN ayaa ASSY NId 2 0S207 9 SAUNA FLIT NId 3 Ozar S 31Y1d l3 OVelg DN
51. e uggj y ATENSSSY OO dejs anon Pigoqui Bue evens ensouos OO uo m ECH Bu I Juouode de lt Jeu ep pos Tugoqui Bu KE OMe papu rey UWA GJOG UI E dE 0 di pogo Bup J dij yya RU y Buy Mi PIE luesse2oeu se unge seDpe dieys 10 ejoq pus G 298 uojsid Jesop eu Bus epis wes Bu Yr ame n DA re Gous WIM DO MOJA pus UE g Ajessgooeu eg ed sebpe deys 10 pedsu Y NO 1SId SIE Med ATENSSSV YI6L01 Yu SZ Inge UT OLDEN GT VOF O0F KZ MOL GLOL Ld S E LO8 0080PT AT GLOL Ld S p LOZ Vel GES 13 S S GLP 00PDPT 1 ipo O ae ao ed EE Vel HL 0891 Ha S E 802 G0ZOPZ Vel 0691 Ye EE 0C O0ZOFZ SPUS 9JneJpAH peargosjnuey SAO enO3908d SIHL Ag GSSSWdNWOONS ATIVH3SN39 SIuvd SPPOW IN 39VS NOWNOO sJ PUI D JO Ajquiessy SUL 104 SPOUSN uoponpoJd usiqes3 01 350duNd yquuessy pupo LLLL i Eu im g a modulor 8 E i i 3 AAA L LALO UN lad LRSL Page 68 of 69 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS I NC RW 1212 DMF LIMITED WARRANTY POLI CY Diversified Metal Fabricators DMF products are designed to provide the utmost service and reliability Competent workmen guided by stringent quality standards manufacture the products from high grade material DMF warrants products of its manufacturer to be free of defects in material and workmanship under normal use and service for a period of ONE CALENDAR YEAR DMF s obligation under this warranty is limited to repairing or re
52. eJuj ejewej pue GJEL Jey ensue o sjueuoduioo od joedsu y 3NHMUIDOYA speeuu L edid peJede uy sPugyJ peseupung asnaaood SIHL Ag GISSYdNODNA ATIVHSN3O SLuUVd Bugey jueuodwog ununi JO Sd 000 Moeg seunssejd jy SPIN peseg unejoed uA Bugeedo suejs s ognejpAH 3ovsn NONNOO SBU 9jn amp 1pAH ensseag unipeiWw LAN JO uoneirejsu SU 104 SPOYSN uoponpoug usiqejs3 OL ASOdYNd uopglie sul Bugy LAN PESJUL edid euonen FTLIL Page 64 of 69 O 2015 DMF Inc All Rights Reserved RW 1212 DI VERSI FIED METAL FABRICATORS I NC lt J S had dr lt e c Ce LL Q m S LL e Q A m m pr O LLI lt un u NOLLYTIVLISNI DNILLIJ QIC 500 Jefu33onUed NOLLONEOYH I NOILJI NOS IT 133 MOL AAA U0 1 23 Uu OO 3SOH AD eon 4nN IAS SDun314 8494 cl B Z I 21 B G I gi 91 8 I eI 91 1 I 3 91 E 81 91 6 De 91 L EX 3 IVS Um Iin JO UIPZ L JEL p p snujuu Jo snid ei BujuejuBp uo eoueJejo uim my e Jo ujs 0 enbe i xeu e uo Jey BUC eu Ae eu Bunsim piore o Buruejufn epum jueuuBie doud u esou eu DIOU 0 YDUSJM puo2es e esf Mojeq euo eus ui Deen L 37272 34611 4eBurJ wo 93814 pepu EUR JNU ey uejuBi 5 nu 94 pue esou Buy eu ueemjeq eJey eqn ey Bujdwep wn Buy mu eu uo mens pue Apog Bupiu Jo esou jsujeBe eey eqn Uh g euejeui uDje10 Aue JO seyoye os EE sung JO eey ee syed Bupeu yey ensue o sjueuoduioo Bumy y2edsu y JANGIDA spu3 pe
53. ear Mounting Pin with the front truck tires on the ground should be 10 3 4 In order to obtain this 10 3 4 distance 1 Spacers should be used between the spring and the Spring Bracket Spacer distance is dependent on the Spring Bracket supplied Nominal 4 or 6 c top dimension 2 7 8 or 5 1 2 To determine which Spring Hanger Bracket is supplied measure the distance from the Rear Mounting Pin center to the top of the Spring Hanger Bracket as shown in Figure 3 1 For Spring Hanger Bracket other than the 4 or 6 please call DMF See the following table to determine the number of Spacers The number of Spacers shown in this table does not include the top Spacer that is used above the truck springs The top Spacer has no effect on the height of the rail gear and is only used for clamping purposes Table A Spacers Required RW 1212 w 4 Spring Hanger Bracket 2 7 8 c top w 6 Spring Hanger Bracket 5 1 2 c top 44 n H 44 n n 44 n n of Spacer A 13 5 8 of Spacers Spacer A 16 1 4 13 5 8 to 14 1 8 O to 1 2 Use 3 Spring Hanger Bracket 14 1 4 to 15 1 8 5 8 to 1 1 2 Use 3 Spring Hanger Bracket 15 1 4 to 16 1 8 1 5 8 to 2 1 2 0 16 1 4 to 17 1 8 2 5 8 to 3 1 2 0 to 7 8 17 1 4 to 18 1 8 Use 6 Spring Hanger Bracket 1 to 1 7 8 Figure 3 1 1 SPACERS TRUCK FRAME Z 4 DR 6 578 O O eg Tr COMMONLY REFERED TO AS pa A RUBBER SPACER X THE 4 OT
54. eel to the right rear guidewheel D 2 These measurements must be within 1 4 inch Measure from the left front guidewheel to the left rear guidewheel C 1 then from the right front guidewheel to the right rear guidewheel C 2 These measurements must be within 1 8 inch If D 1 and C 2 are shorter than D 2 and C 1 shim the right front railwheel forward The left front guidewheel should be shimmed forward in the opposite case These shims can be flat bar located between the bottom of the long arms and the welded stop block on the pivot arms If the C dimensions are equal and the D dimensions are not the front guidewheel axle can be slid to the side within space limitations to help equalize these dimensions Maintain a minimum 1 4 gap between the guidewheel and the inside of the steering tire Start with a 1 8th inch shim and place it between the stop block welded to the pivot arm and bottom of the stationary arm near the axle mounting bracket All four pivot arms have stop blocks Add shims as required so the load is carried by all blocks When the proper spacer thickness has been found to square the guidewheels tack each shim to the top of its stop block per drawing below If equipped with railsweeps rotate each front axle tube half until the railsweep rubber is vertical Weld three 1 2 tacks each axle tube half to its outside pivot arm The inside pivot arms are not welded allowing cylinder removal
55. esses the brake pedal loosen the bleeder fitting at each brake until the air is expelled As the system is bled keep fluid in the reservoir to prevent pumping air back into the lines Bleed each wheel once then repeat to make certain that all the air is bled out O 2015 DMF Inc All Rights Reserved Page 52 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC n 9 Brake Assembli IC Hydrauli Drawing gISI SZB 07 HI SYOLVIREYI TYL3IN U3LIESSH3AII ACHM3SSV DIVE OITTIVMUAH ep 3181 N viv TILL AAA MAL edv AG UILJIMUS3U SII JAN LEA i lee Long par A JUYACSYA DNILNDEM 92 Se S Mall Dien TT IS Uva T yr a OBRA D XOU W3HSVA erer 93 845 X ETI Z D V3H X3H IDE ever EES NId AS a T varer v BNI SOLD E 954818 es SHOE SNILNNON 3DHS SE E9Z AO IND 20HS Hyaa vip Nid COM M3INITAO Svea T 09227 OZ GED ASSY Kay YA Divas F SeZzeT Ier Jan 37XY NO SINOD Ger 3110Y5 Zap velo 2 Seier Ier 1390v88 BOIS YIONTIUO 2 SrZet LI NId JOHS 3382 Linus ANNON s3INIMO Tt 29 818 Ier JNBZ T DNILLLJ 3SY3ND MIONITAD Syed C4ID EDTETE SF NOISN3LX3 UM BGUNITAO zbiveEp C435 91231 V 9 3IdAL ANN 2 48 E ND LNN X007 M3UNITA2 Saved CAD ANd ET ETT DODEND DNRI dYNS TYNHILNI MIUNITAD 3298 Caa ever DF 40 06 GgGETS D MIdIM TYIS M3UINITAO Syed Cage Sezet In ONYTD MIO
56. frame Extend the Rear Railroader to the rail position which will raise the truck frame The truck inner duals should be flat to slightly cupping the installation rails Too much weight on these tires truck frame too low will cause rapid tire wear Not enough weight truck frame too high will cause wheel spin and poor braking see Fig 4 3 If necessary adjust the Spacer thickness to achieve the proper tire cap on the Installation Rails O 2015 DMF Inc All Rights Reserved Page 30 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 Figure 4 3 1 1 1 Frame Frame Too Frame Too Properly Set High Low Figure 4 4 EAR TRUCK AXLE ALIGNMENT CHECK A B within 1 1 6 C D within 1 8 REAR RAILROADER AXLE 2015 DMF Inc All Rights Reserved Page 31 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 4 3 Square Rear Railroader with Truck Axle Once the proper height and tire to rail gear location has been achieved the Rear Railroader needs to be made absolutely square with the rear truck axle Four measurements shown in Figure 4 4 need to be taken to insure this requirement 1 The distance from the truck axle to the Rear Railroader Axle at each end In Figure 4 4 distance A must be equal to B within 1 16 This is an important alignment check 2 The dia
57. gonal from the truck axle to the opposite Rear Rail Wheel In Figure 4 4 distance C must be equal to D within 1 8 NOTE Although the previous mounting conditions and alignment may be met be certain that enough room exists between the Rear Railroader and other equipment In general this should include a 2 clearance around the rail gear more clearance will be needed if Remote Pin offs are installed Also insure that there is clearance to remove the Pin Offs from their holes O 2015 DMF Inc All Rights Reserved Page 32 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 4 4 Final Rear Installation NOTE If more than 1 16 inch of space exists between the truck frame and the Rear Frame Bracket on each side it will be necessary to install shim plates to center the Railroaders These should be 12 x 12 shims of the proper thickness with equal thickness used on each side These can be fabricated or DMF shim plates may be used Using the Mounting Plate as a drill template drill four 5 8 holes through the truck frame Locate the Mounting Plate so as to allow for maximum adjustment of the Rear Frame Bracket see Figure 4 5 Bolt the Mounting Plate to the Rear Frame Bracket through the shims if required and truck frame with 5 8 11 Grade 5 bolts amp nylock nuts Tack weld the Mounting Plate to the Rear Frame Bracket If re adjustment is later needed the welds may be ground off amp the Rear Frame Bracket
58. ground clamp onto the Rail Wheels This will cause arcing across the bearings inside the wheels and lead to premature bearing failure Raise the front Rail Wheels just above the floor enough to slide the front Installation Rails into place under the Rail Wheels Because the Railroader Axle assembly is not fixed to the Pivot Arms the Rail Wheels need to be centered To center measure the distance from the inside of the Rail Wheel to the truck frame If the measurements are off slide the Rail Wheels and Axle assembly to one side the Axle Tube will slide through the holes in the Pivot Arms Depending on the brake configuration used the Axle Tube will need to be rotated in order to locate front Railroader components in the right position The possible configurations are Without Brakes If the rail gear is not supplied with any brakes the Steering Wheel Locks must be aligned as shown in Figure 3 5 When the front Railroaders are down in the rail position these Steering Wheel Locks prevent the front truck wheel from interfering with the rail gear operation With Cobra Hydraulic Brakes If the rail gear is supplied with Cobra Hydraulic Brakes factory installed then they need to be rotated around so that they are oriented in the correct position see Figure 6 4 For the rest of the Brake installation see Section 6 3 O 2015 DMF Inc All Rights Reserved Page 20 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 Figure 3 5
59. ial siding or some authorized track time will be required Check that rail wheels with brakes do not lock up or slide LJ Adjust the rail gear height as required O Cross check the Rear Railroader to the rear axle again L Weld the Mounting Plate to the Rear Frame Bracket with one 2 weld on the horizontal edges two welds per Mounting Plate Welding the plates must be done DO NOT forget it L Double check all welds and fasteners and Mounting Pin cotters Tie strap all hydraulic air hoses and electrical wires away from exhausts and moving parts Insure that all hydraulic and air hoses have sufficient radius at bends L Top off the hydraulic oil in the tank LJ Touch up the black acrylic enamel paint on the Front and Rear Railroaders L Raise the Railroaders road position and install all of the pin offs LJ Apply the Decal Kit L Check tire pressures DMF RW 1212 Railroader Installation Check Sheet Front Alignment Front Mounting Pin height 23 1 2 inches Rear Mounting Pin height 10 3 4 inches Rear Alignment po SingleAxle Tandem Axle 6 0 GAP x 60 Check overall measurements Rear Truck Axle to Rear Railroader Axle straight A B within 1 16 Rear Truck Axle to Rear Railroader Axle diagonal C D within 1 8 Front Railroader to Rear Railroader straight E F within 1 8 Front Railroader to Rear Railroader diagonal G H within 1 4 2015 DMF Inc All Right
60. it connect the rod end of each front cylinder to one working port on the front manual directional valve with a 4 JIC tee Use the other pair of 38 hoses to connect the blind ends of the cylinders to the other work port e The rear valve is pre plumbed to the cylinders and mounted on the rear mounting bracket This may be relocated as required e Plumb from the pressure port on the Power Unit to the inlet of the front directional valve Plumb from the outlet of the front directional valve to the inlet of the rear directional valve and from the outlet of the rear directional valve to the tank return fitting on the Power Unit K WARNI NG Be certain that the front and rear valves are plumbed correctly Each valve port is marked IN or OUT Plumbing the valves backward will cause an unsafe condition possible injury and or damage O 2015 DMF Inc All Rights Reserved Page 11 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 2 2 Hydraulic System with Brakes NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance e Kits supplied with guidewheel brakes have the Power Unit plumbed to the braking valves The Power Unit Assembly will be used to operate the railgear to
61. lt k Lo Q U lt eh ded c Q lt E I E gt k A Page 46 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FIED METAL FABRICATORS I NC RW 1212 6 0 INSTALLATI ON OF OPTI ONS 6 1 Rail Sweeps The components that make up the standard Front and Rear Rail Sweeps are the same for Railroaders without any brakes For Rail Sweeps provided with Cobra Brakes the mounting brackets are shorter Installation of Rail Sweeps is done while the Railgear is in the rail position For standard Rail Sweeps without brakes weld the Mounting Bracket directly to the Railgear Axle Tube oriented so that the Rubber is flush with the rail as shown in the Railsweep Drawing For Rail Sweeps with Cobra Hydraulic Brakes bolt the shorter Mounting Bracket directly to the Brake structure on the front bolt on the side facing forward on the rear bolt to the top of the Air Brake which faces backward For more information see the Railsweep Drawing O 2015 DMF Inc All Rights Reserved Page 47 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC ions lat d Var n 9 Drawing Railsweep Assembl HSL dad in N WG UddY 48 NAVI d33A S Iva 43Q0vosllv LNOYS 2 8a 0 I 289818 6 r 929818 e mow 086818 9 QGB E AD M3HSVA 1973 y enee Ss QT X 91 48 8 SOHH SLIOG ONILNNOW Stret Sd XIEN d s vM
62. nce If your hi rail vehicle is high use or operated under extreme conditions such as operating in mountainous regions or extreme temperatures the levels of inspections listed below may need to be performed more frequently than stated The following are instructions for routine inspections recommended by Diversified Metal Fabricators In some circumstances government or corporate regulations may require additional inspections be performed Please ensure that you are aware of any inspection requirements that pertain to your rail gear and that you abide by all local and national laws regarding rail gear maintenance and safety Daily Maintenance e Visually inspect for hydraulic fluid leaks e Check and make sure that all threaded fasteners are secured NOTE All hex nuts are either nylon insert or slotted hex nuts with cotter pins e Check and make sure all tie straps that secure hoses from moving parts and exhaust systems are in place Replace if cracked or worn e nspect wheel flanges for excessive wear primarily noting difference in wear between wheels on the same axle or diagonally If abnormal pattern is noted check railgear alignment see alignment procedure Weekly Maintenance In addition to the items listed in Daily Maintenance perform the following e Grease and lubricate all grease fittings on front and rear railgear and guidewheel assemblies NOTE There are six 6 locations on front assemblies and fourteen
63. ng Brackets have been tightened down Then with a torch cut the excess stud length on the Spring Brackets If these studs are not trimmed down they may pose a clearance problem with other parts on the truck see CLEARANCE NOTE and Figure 3 4 in section 3 1 Remount the truck front bumper or use 8 std channel welded onto the ends of the Frame Extensions O 2015 DMF Inc All Rights Reserved Page 22 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC SDF DN 13 14 NSNI NON SU deu Ae ATHHGSSV w ren INDUS IZAN Tu ut D GUILL ETE dd AG NOLLSINOS 3l aLI A3 hod 1 wn mm E JE 8 X Dr HIS E gt Nid 311 Rl M e 3 D ner Lie HAV ONO ATGNaSSY Nid 311 2 D er 92 CW ITIS S M3DONGSSVd ATHW3SSV 440 NId 1 rom Se CAD 3UIS S M3AIMOI ATSN3SSV 440 NId T ester Z GP va Y30Y4S DNILNDUN 1339738 DNINGS 9 097878 ez INOX ATENSSSY Lg DNIWAS 3 sosis ze dyd DNLINNON adany 1339998 DNINGS 3 esee IS 2 I 2 P Nid LUD ZElBIB oz Hr 3 1 1414 YIHSYA F 981818 ET IT LL 93 70 X3H Gallois UNN e E z Ge X 97 6 Nid N3lln9 seen Z B P X3H TALLOS UMN eem ot ET FELT JENLSSOMI ONLINNON INOW 3 egge St SUIS S S3DN3SSVd LOVE DNLINNON INOM 1 errors yr E ES SUIS SAAMI LOAA DNLINNON INES T Zro EI UIS S N3ON3SSVd INOM4 AISN3SSV SLL Oman 3 oore er mm e an af 3UIS S M3ATMI INUM3 AJEWGSS
64. nk Kit Position P N BO Long Links Upper Front Passenger 10721 Upper Front Driver Upper Rear Passenger Upper Rear Driver Link Kit Position P N BO X Short Links Upper Front Passenger 10725 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger O 2015 DMF Inc All Rights Reserved Page 42 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC W 2 7 U E e 3 pem o Q D Drawing YOEZOTAL ANI e AT OND I ANI AJAO LAOHS ANI ATADO LALHS A SNOISNANIG NI I SNOISNANIG ANI I Aya Uer reler eW Avia D grl g8iglI 610p A ANI I e dddf OND ANI I ad ddd LAAs ANI I e ddd LALA Page 43 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FIED METAL FABRICATORS I NC RW 1212 5 0 FRONT TO REAR ALI GNMENT 5 1 Final Alignment The rear guidewheel axle is set parallel to the rear drive axle first see Drawing Alignment Procedure amp Traction Adjustment With the guidewheels in the rail position recheck the side and diagonal measurements to the drive axle housing The side measurements should be within 1 16 and the diagonals within 1 8 Loosen the mounting bolts and slide the mounting bracket as necessary Tighten the bolts The front guidewheel axle must be set square to the rear guidewheel axle diagonally measure from the right front guidewheel to the left rear guidewheel D 1 then from the left front guidewh
65. nt Valve Plate Assembly w Hydraulic Hoses amp 2 Push Button Switch 1 Installed Monarch Hydraulic Power Unit Assembly 1 0 Power Cable X 86 w lugs Optional Parts Check List Rail Sweeps Front Right or Left or Axle Set Rail Sweeps Rear Right or Left or Axle Set Remote Pin Off Assembly on Rear Rail Gear Remote Pin Off Cable w T Handle Hydraulic Brake Assembly Front Right amp Left Hydraulic Brake Assembly Rear Right amp Left Hydraulic Brake Control System Front and or Rear Steering Wheel Lock Kit Shim Kit for Rear Bracket 12 x 12 2 ea 1 8 1 4 3 8 O 2015 DMF Inc All Rights Reserved Page 3 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 Additional Material that may be Required Item tye Bolts amp Lock Nuts 5 8 18 Gr 8 if Frame Extensions are Required As Required Bolts amp Nylock Nuts 5 8 11 Gr 5 Rear Mounting Bracket Plates Steel Channel 3 wide x 4 long for Front Installation Rails Steel Channel 3 wide x 10 long for Front Installation Rails Steel Flat Bar 1 2 x 3 x 56 1 2 long for Installation Rails Steel Square Tube 6 x 6 x 3 8 x 12 long Temporary Spacer O 2015 DMF Inc All Rights Reserved Page 4 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 II ABS Brake System Trucks Equipped With ABS Brake System All trucks over 10 000 GVWR manufactured after March 1 1999 and equipped with hydraulic
66. nt tandem walking off in curves Front and Rear Installation Rails In order to install the Railroader to get proper tire traction on the rail it is necessary that standard gauge rails or Installation Rails be fabricated from 3 square tubing per Figure 1 5 Drive the truck into the work area pulling forward and back several times to align the axles and up onto the Rear Installation Rails The rear inside tires should be on the rails with the rear outside tires off the floor The Front Installation Rails are not needed at this point NOTE Before proceeding be certain that the front truck tires are chocked and the brakes are set O 2015 DMF Inc All Rights Reserved Page 6 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 1 0 RAI LGEAR COMPONENTS amp GENERAL I NFORMATI ON 1 1 Front Railgear Figure 1 1 shows the individual parts of the installed front Railgear with the Rail Wheels in the rail position down The item descriptions will be used throughout this installation manual DMF Railgear assemblies are also referred to as guide wheels rail wheels or railroaders Figure 1 1 TRUCK FRAME e r FRONT TRUCK 4 SPRING Item Desc O 1 SPR 2 SPACERS if required FRONT TRUCK
67. of the system is 2000 psi The front valve is preset to 2000 psi at the relief The rear valves are preset to 1500 psi and all other parts supplied by DMF are rated to 2500 psi Care must be exercised that the relief in any of the valves is not inadvertently exceeded It is possible for a relief to be adjusted much higher than it s valve can withstand To ensure correct system pressure check with a gauge e Fill the Power Unit tank with Dextron II ATF e Hold the front push button down while spooling the front valve Operate the front railgear to fill the cylinders with fluid remember to re fill the tank e Repeat the procedure for the rear railgear O 2015 DMF Inc All Rights Reserved Page 12 of 69 RW 1212 DI VERSI FIED METAL FABRICATORS I NC v gt un 2 O Tw dy gt un Le Hydrauli Drawing p ED 1 z po m Te 52 v0 HSL lie exu qp RON ci 4 aic AE ade g NAVY C3JA1S UP HILSAS JITWUAH ZI2gT A me Pm LP IL Ken ddv Ag NILLdISJS 3l 3140 A38 EJ i E EME IET E 2 uva Ji ei NOLLINOI DA ACL LHDIT YOLYOIONI 031 T 17981 ET SINI 13AI S DIF 31vN34 M D D0I 395 LO DNIENN IS 1 Um r HALLIY DA AC 489 ANI VUE C3IIVNE 139315 SSI NIS 9 error T TEXE08Z 1Sd 19901 HOLIMS T On oF 21 08006 33SN3H 3100 NOLINaHSnd HOLIMS T 89 07 6 UZ SI N de HeE BUBNd YHUAH 431738 pied ay HANA J Zero 8
68. on manual Rail Operation of Trucks with ABS Brake System Active While operating on track with the railgear down the ABS becomes ineffective in brake application at lower speeds If the ABS is active and the truck moving on rail with front wheels elevated the amber dash light may come on Since the front wheels are not rotating the motion sensors may transmit a fault indication to the ABS which signals the dash lamp to illuminate inadvertently This will not affect rear truck braking or rail wheel braking if applicable When the truck is returned to road operation the ABS fault must be cleared by turning the engine off and re starting At this time the diagnostic check will repeat as stated above NOTE This procedure is applicable only to WABCO and Allied Bendix ABS Brake Systems For any other ABS Brake System contact DMF for assistance O 2015 DMF Inc All Rights Reserved Page 5 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 ILL Initial Instructions Work Area The area in which the Railgear installation is to occur should meet minimum requirements in order to facilitate the process and provide adequate conditions in which the work can be completed safely accurately and in a timely manner e Floor The floor should be level in order to provide good measurements required to check the alignment of the Railroader e Lighting The work area should be adequately lighted e S
69. ounting plate and replace the 5 8 11 hex end cap Replace the T handle on the cable O 2015 DMF Inc All Rights Reserved Page 49 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 6 3 Steering Wheel Locks Carefully remove the face cover from the steering wheel Position the Lock Bracket at the 12 o clock position on the steering wheel hub The U should be facing the speedometer and at the lower edge of the steering wheel The Lock Bracket should not interfere with any other part of the truck as the steering wheel is turned Mark the hole locations and drill 2 3 16 holes Using the 10 24 flat socket head screws and the 10 24 nuts attach the Lock Bracket Strap the Latch Weldment around the column and tighten until the clamp starts to grip With the latch in the down position move the Latch Pin into line with the Lock Bracket There should be a 1 2 gap between the Lock Bracket and the Latch Weldment Tighten the Latch Weldment hose clamp securely NOTE Check to be sure that nothing interferes with the normal operation of the steering wheel Check the operation of the latch for fit and operation with the Lock Bracket After making all necessary adjustments drill a 125 hole through the column strap at the loose end near the truck s turn signal Use a 1 8 x 3 4 pop rivet to secure the column strap and the Latch Weldment into place Replace steering wheel cover For more information see the Steering Wheel Lock Drawing
70. pace There should be enough space to maneuver the Railroader components into position and to safely work around other equipment Truck Condition Before installation the truck should be checked in some important areas e ires The tire pressure should be checked for the manufacturer s recommended inflation and for consistent pressure readings from all the tires This will ensure correct traction of the tires on the rails Also the condition of the rear tires needs to be determined If the rear tires are worn they should be replaced e Alignment Rear truck axle must be square with truck frame DMF recommends that a reputable alignment shop check this 0 degree thrust angle which can be different than the factory specification is required for proper Railroader operation e Frame amp Suspension On a new truck these should be in good condition On a used truck the frame should be inspected to insure that it has not been damaged or bent The suspension bushings should also be examined for excessive wear and replaced if necessary If any problems in these areas are not corrected it will cause difficulties aligning and operating the rail gear e Transverse Torque Rods On vehicles that will regularly experience high center of gravity loads on rail e g spray trucks material loaders it is advisable to install rear tandem control rods to limit transverse axle displacement This is also necessary of long wheel base vehicles to limit fro
71. placing at its factory or other location designated by us any part or parts there of which shall within 30 DAYS of the date of failure or notice of defect be returned and which upon examination shall appear to DMF s satisfaction to have been defective Such repair or replacement does not include the cost of installing the new part or any other expenses incident thereto however the outbound direct ground freight on the part will be prepaid to locations within the continental United States and Canada DMF shall not be liable for other loss damage or expense directly or indirectly arising from the use of its products Ordinary wear and tear abuse misuse neglect or alteration is not covered by this warranty DMF assumes no liability for expenses or repairs made outside its factory except by written consent Warranty is null and void if instructions and operating procedures specifically referring to warranty coverage are not followed Equipment or parts not manufactured by this company but which are furnished in connection with DMF products are covered directly and solely by the warranty of the manufacturer supplying them 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 All warranty claims must reference a serial number Returns must reference a RMA number m ten zr
72. revent any movement during the remaining installation Then raise the Rear Mounting Bracket with temporary 6 spacer and the truck frame and lift the truck wheels up off of the rear Installation Rails Measure the Gap from the top of the rear Installation Rails to the bottom of the tire with this 6 spacer in place as shown in Figure 4 2 The truck spring and tire deflection equals 6 0 minus the measured Gap To calculate the required Spacer thickness multiply the spring and tire deflection by 60 The formula is Calculated Spacer thickness 6 0 Gap x 60 The following table shows the calculated Spacer thickness given a certain Gap This table is given as an example Actual gaps may include fractions and the Spacer thickness will need to be calculated for that specific gap NOTE Some customers require a minimum 4 spacer for future adjustability Contact your customer to determine his requirements Spring amp Tire Deflection Calculated Spacer thickness 6 0 Gap 6 0 Gap x 60 Release the clamps holding the Rear Frame Bracket to the truck frame Collapse the Rear Railroader to the folded position which will lower the truck wheels back down on the Installation Rails Replace the temporary 6 spacers with the permanent Calculated Spacers and tack in place onto the Rear Frame Bracket These permanent Spacers should be solid steel pieces because they will experience the full structural load seen by the rear
73. s Reserved Page 56 of 69 DI VERSI FI ED METAL FABRI CATORS I NC RW 1212 8 0 ENGAGI NG THE RAIL Lower rear guide wheels first At the track crossing drive past the track then back the vehicle onto the rails Engage the truck s parking brake to prevent the truck from rolling If the railgear has brakes turn brake switch on Engage the PTO Remove the safety pin off pins one each side Push Pull valve handle to lower wheels to engage rail When both wheels are fully down and properly engaging rail replace safety pin off pins NOTE Rear end can be articulated to facilitate alignment by operating one spool at a time Lower front guide wheels If necessary drive the truck into position to line up the front guide wheels with the rail e Engage the PTO Remove the safety pin off pins one each side and stow in provided storage tubes Check and make sure that the front guide wheels line up with the rail then engage wheels NOTE The front guide wheel assembly is an over center design and does not require safety pin off pins engaged in the rail mode On the tracks e Do not exceed 30 MPH while on the track All railroad speed rules should be observed e Be aware that some high rail gear is insulated and will not operate the crossing gate circuits e Reduce speed at all crossings curves branch lines switches and frogs e Traction is reduced on the track especially in wet conditions Tire damage may re
74. ssembly Ines 15 Drawing Valve Assemblies Hydraulic Schematnc cnn nnrrnnnn cnn 16 3 0 Front Railgear Installatlon irc Ee 17 3 1 FOR NG He 17 3 2 AN FONR NET 20 33 Fra Front Stata cio vera eee 22 Drawing Front Raligear Assembly wette geed u C C cal ERU PC CER UP Gen ad 23 Drawing Front Wheel Axle Assembly TI 24 Drawing Front Wheel amp Axle Assembly Exploded View eeeseee I 25 Drawing RW 1420 Wheels Identification Chart 26 Drawing Front Hydraulic CyliNderS occoocccccccccccoccccnnccnnnn nnnm heme nna 27 4 0 Rear Railgear Installation aia 28 4 1 Location of Rear Ral Caida 28 4 2 Spacer Instalaci n ariadna S oa dr a cdd a x b d RR Pip adea teh oa pte upya abu haba 30 4 3 Square Rear Railroader with Truck Axle cesse Hm 32 44 Final Rear TnstallatiOD saa dor viec tev cdi e RO ORE sien pl o Ov o e ar PE HERO GER Rr PEE GN 33 Drawing Rear Railgear Assembly with Manual Pin offs 34 Drawing Rear Railgear Assembly with Remote Pin OffS 35 Drawing Rear Mounting Brackete nennen eaae na nn a 36 Drawing Manual amp Remote Pin offs and CableS emnes 37 Drawing Rear Wheel and Axle Assembly Exploded View 38 Drawing Rear Hydraulic Cylinders l oooocccccccccccccnonccnncncnnn nro rr meme e enn 39 Drawing Rear Hydraulic Cylinders II 40 4 5
75. sult from spinning wheels on track e Braking distance is increased on the track especially in wet conditions Do not slide tires or guide wheels on the tracks e Do not exceed the maximum rated capacity of the equipment e On newer trucks with Anti Lock braking systems the amber ABS dash light may remain on with the front wheels elevated This will not effect rear truck braking or rail wheel braking 8 2 Getting Off the Rail Removing truck from track Engage the PTO and the truck parking brakes Leave the truck running and the transmission in neutral gear Lift both sets of railgear there is no preference for removal order Engage the safety pin off pins in highway position Disengage the switch that controls the railgear brakes if applicable Disengage the PTO before moving the truck e f the amber ABS dash light remains on during rail operation the truck engine must be turned off and restarted after returning to highway operation This will clear the ABS after a few seconds If the amber light remains on during road operation the truck s brake O 2015 DMF Inc All Rights Reserved Page 57 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 system may have an active fault and should be checked out Please refer to the truck s operation manual O 2015 DMF Inc All Rights Reserved Page 58 of 69 DI VERSI FIED METAL FABRICATORS I NC RW 1212 9 0 ROUTINE MAINTENANCE 9 1 Inspection amp Maintena
76. u 1 IV Lea AO du x Q in Cyl IC 9 p AN IUE9 BI 91 6 X 2IF r T ADE NIL 2 ops EI ldN 8 T ONILLIJ asy 1 eme Tat 22 Ad8W3SSV CON T Dere T C3UIS SMIDNISSYD Z 1 F IATENISSY Taava T crore GUS S MJAIMDD 2 1 IATENISSY T3MNYE vo T Ornor2z oF 9 E 8 IdN A0YE DK DNRI O T 602 6 9 E 2 UNID ONIN O T Bomrg B tie 2 NOLSId ONO 1 Zooe Z amp 8 B S r 93 NAL SSITTONI LD Twas 12 686 mM 43dI 1 somre 9 LD WaS SZZ N d ANG 0002 0626 oN was T cora S TION G 8E 0Z7E NOLSId Was 3 Fromr2z FL MODAN INN T eptpks MIND 7T OTOH 2 82 14 NOISId 7 ms 7 oo S S Mt lie O AID ON Lard NELT Front Hydraul Drawing Page 27 of 69 O 2015 DMF Inc All Rights Reserved DI VERSI FIED METAL FABRICATORS I NC RW 1212 4 0 REAR RAI LGEAR I NSTALLATI ON 4 1 Location of Rear Railgear NOTE It is important that the truck tire pressure especially the rear tires be checked and brought to the manufacturers recommended level With the truck on the rear Installation Rails position the Rear Railgear as close to the rear tires as practical allowing clearance for mud flaps The following table gives standard location and clearance guidelines for the rear rail gear and these dimensions are shown in Figure 4 1 Generally leave a minimum of 2 clearance to any tire

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