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RW-1630 & RW-1630/50*

1. 3 6 2015 DMF Inc All Rights Reserved 3 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 3 1 Inspection and Maintenance If your Railgear vehicle is high use or operated under extreme conditions such as material handlers or weed spraying vehicles or 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 Railgear and that you abide by all local and national laws regarding Railgear maintenance and safety 3 1 1 Daily 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 Inspect wheel flanges for excessive wear primarily noting differences in wear between wheels on the same axle or diagonally If an abnormal pattern
2. 23 1 2 TO GROUND FROM BOTIOM SOLID SPACERS TO ACHIEVE OF BOX TO ACHIEVE 9 PROPER GROUND CLEARANCE OF GROUND CLEARANCE WHEN FULLY ASSEM BLED GROUND Figure 4 9 3 Behind Cab Installation Height The lower axle assembly complete with wheels and brakes is the remaining mechanical portion of the unit to be installed Position the 4 elastomer springs in their lower seats With the 4 lower axle straps removed raise the assembly up to the upper spring seats Install the 4 bolts through the springs and secure nylock nuts Next install the 4 axle straps and secure with the sixteen 5 8 11 bolts and lock washers 2015 DMF Inc All Rights Reserved 4 31 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 9 4 Completion Provided the frame brackets of the behind cab unit are properly centered on the truck no further adjustment to gauge is required Weld any shims and spacers to the inside of the frame brackets Finish installing the rear Railgear other applicable options hydraulic system pneumatic connections etc Continue on to Section 4 10 for Overall Alignment Procedure 4 10 OVERALL ALIGNMENT PROCEDURE 4 10 1 Overall Alignment Procedure and Final Weight Adjustment See next page for alignment and weight drawing Once you have completed the alignment procedure return to Section 4 11 for continued installation instructions With the front and rear Railgear both installed and each squ
3. CROSS TUBE FRAME RAIL 25 1 2 u FRONT MOUNTING PIN 12 3 4 REAR MOUNTING PIN Figure 4 5 4 B Between Frame Rail Bridge Kit 2015 DMF Inc All Rights Reserved 4 17 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 5 5 Front Mounting Dimensions FRAME en ENSEM SPACER TOP RUBBER SPACER MUST FRONTMOUNTING PIN EON TOPOF TRUCK FRAME pecu mm SPRING DISTANCE 4 MAX SPRING BRACKET SPRING BRACKET HEIGHT 25 1 2 2 O O Q i Sx LONG ARM 12 3 4 a2 REAR MOUNTING PIN Figure 4 5 5 Front Mounting Dimensions NOTE If the vehicle has been supplied with an integral extended front frame the Frame Extension will not be required The cross tubes can be brought up to the extended frame as shown in Figure 4 5 5 Follow all instructions for finding the Front Mounting Pin height with the Frame Extensions Solid or load bearing Spacers may be required between the cross tubes amp the bottom of the frame to obtain the desired 25 1 2 from ground to Front Mounting Pin 4 5 6 Mount Front Railgear Mounting spring bracket hangers 1 Remove the truck s front bumper 2 Slide the front Railgear under the truck frame positioning the spring bracket hangers as close as possible to the front truck axle Make sure at lea
4. mer 1 PUMP XSTING 5t07 gpm 2000 sc irme T 81029 NOTE DMF ONLY PROVIDES HYDRAULIC HOSES FROM FRONT 8 REAR CONTROL VALVES FITTING ELBOW 3 4 MPT x 08 JIC HYD CYL HOSES 96 qty 4 04 w 04JIC SWIVEL TO RAILGEAR CYLINDERS CUSTOMER IS RESPONSIBLE FOR ALL OTHER SYSTEM 4 51090 4 FITTING TEE 1 4 NPTx 04JICx 04JIC HYD CYL HOSES 38 qty 4 804 wi 04JIC SWIVEL COMPONENTS TANK DIVERTER PTO PUMP FILTER PRESSURE RELIEF VALVE ETC s 8950 6 FITTING ELBOW 1 2 werTxso4JIC HYD CYL HOSES 62 aty 4 04 w 04JIC SWIVEL L RS s 810204 VALVE ASSEMBLY FRONT VALVE wErras 16 2402586 7 8 810214 8 Al o sm REF VALVE HANDLE REPLACEMENT ASSEMBLY 79 VALVE ASSEMBLY FRONT WIS0deg FITTINGS LOCKING VALVE DPC1 10 P 6T NOTE ON THE FRONT VALVE THE RELIEF SETTING MAY BE LOCKING LOCATED IN DIFFERENT LOCATIONS DEPENDING THE MANUFACTURING BRAND ALL ELSE REMAINS THE SAME WE SHOW THE TWO MOST COMMON LOCATIONS BELOW FOR THE RELIEF SETTING FRONT TIRE DIVERTER ISOMETRIC OF FRONT VALVE ASSY J ens S Reni ewer Be TO OTHER EQUIPMENT CYLINDER BLIND ENDS N RELIEF SETTING 2500 psi MAX FROM DIVERTER TO
5. Alignment Procedure and Final Weight Adjustment 4 32 4 11 RALL TEST Z us E sai u A kuy sasa qS S Su Ra Za siku qap ER 4 34 4 12 FINAL WELD OUD 5406 astusausasusayauawsaqaskuskayiususpusakuyaaqasakuswunakuyaus 4 34 4 13 INSTAEE DECALS luu i lu aranana Kaanaa a aaan aat 4 36 4 14 VELCRO STEERING WHEEL LOCK ssssswssnnanaaananananana 4 38 4 15 INSTALLATION REVIEW 15 4 39 420 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 1 PRE INSTALL NOTE The proper installation of this equipment is solely the responsibility of you the installer When in doubt contact DMF for assistance NOTE During Railgear installation there are 3 different alignments front Railgear to truck frame rear Railgear to truck frame and a final procedure that aligns both sets of Railgear to each other 4 1 1 Safety Statements e Always block up gear before getting underneath e Always use jack stands when jacking up vehicle e Use personal protective equipment and clothing 4 1 2 Installation Order This manual presents the installation information in the order that we find to work best Your shop tools personnel or other factors may dictate a different order This is acceptable as long as the Rail T
6. 1 2 FILLET WELD ON BOTH SIDES TYP NO WELDS ON ENDS TYP E REVISED FRAME WIDTH TABLE ADDED ANGULAR REFERENCE 3 8 FILLET WELD OTHER PLACES TYP REV DATE DESCRIPTION APP TOLERANCES UNLESS SPECIFIED FRAC MACH t 1 32 FRAC OTHER 1 16 x DRILL SEES ANGULAR SURF FINISH TITLE REAR MOUNTING 12 FORMED BRACKET ASSY RW 1630 3 4 HEAVY DUTY PLATE DIVERSIFIED METAL FABRICATORS INC 404 875 1512 THREADS DRAWN BY APPD BY DATE DRAWING NUMBER 4 29 10 M1630117 RNSHED PART NUM BER 4 DESCRIPTION PARTNO DIMENSION 818225 REAR BRACKET 3 4 C RO SS PLATE 818793 10 3 4 REAR BRAC G USSETT SLO TIED PLATE FORMED 33 5 8 818228 REAR BRACKET C RO SS TUBE 2 1 2 X 8 15 16 818235 GREASE FITIING FOR REAR LINKS 1 8 819324 819317 34 1 8 819474 34 3 16 819315 34 1 4 819458 34 2 819312 34 7 8 819511 35 5 8 819313 36 11 16 Note These are the most commonly used Special widths are available please contact DMF 12 0 REF MUST ORDER COMPLETE BRACKET DIMENSION A SEE TABLE FRAME WIDTH 1 8 HALF A T lt 43 0 REF HOLD CENTER CENTER 1 563 REF 50 0 REF EE AEREN SIDES Ay 5716 12 ADDED
7. UNLESS SPECIFIED FRAC HACE EWS VARIOUS SPRING HANGER BRACKETS FRAC OTHER 1 16 x 063 X i 020 DIVERSIFIED METAL FABRIC ATO 404 875 1512 DRILL SIZES 015 DRAWING NUMBER ANGULAR 51 9 SPRING HANGER P N 818142 secos DARNOS 4 01 10 MGENN100 DIVERSIFIED METAL FABRICATORS INC RW 1630 DMF LIMITED WARRANTY POLICY 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 manufacture 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 replacing 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
8. 2 4 2 4 3 Lower Front Guide Wheels r 2 4 244 On The EUER inh asul hat DEEA E AREAN 2 5 2 5 OFF THE 2 5 2 5 1 Removing Truck from Track rr nnns 2 5 2015 DMF Inc All Rights Reserved 2 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 2 1 YOU OPERATE THE RAILGEAR 2 1 1 Familiarize Yourself with the Railgear Clearances amp Approach Angles The installation of Railgear typically reduces the ground clearance amp approach angle in the front and back In some installations the guide wheels extend slightly beyond the corners of the front bumper Operators should familiarize themselves with the modified clearance amp approach angles Pin off Systems and Locations Walk around vehicle and identify the location and type of pin off system s that are installed on this particular vehicle Please note that front and rear Railgear may have different types of pin off systems i e front may be manual while rear may be cable pin offs See section 5 0 for more information on pin offs DMF offers the following Pin Off options e Manual Pin Offs e Cable Remote Pin Offs e Air Remote Pin Offs NOTE DMF s Rear Cylinders are equipped with integral locking valves however pin offs are still r
9. Front Installation Rails 4 Rear Installation Rails 10 Figure 4 2 4 Installation Rails NOTE Inside to Inside measurement of 56 1 2 is the standard gage for the United States If your equipment is to be operated on any other gauge adjust measurements according 46 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 INSTALLATION OF REAR RAILGEAR NOTE Only use GRADE 5 bolts when attaching rear bracket on the truck frame The rear bracket should break away from the truck frame in an accident otherwise it will damage your truck frame 4 3 1 General Information There are several items to note before you begin the installation of the rear Railgear e Before you begin Railgear installation please read installation instructions for the options you have ordered Some options may affect the Railgear installation process e Itis important to note that there is difference between shims and spacers Shims are vertical fillers used to fill in the gaps between the truck frame and rear mounting bracket side plates Spacers are solid steel pieces varying in thickness used between the rear mounting bracket and the bottom of the truck frame to achieve proper weight settings between the truck tires and rail wheels while on rail e Spacers used in adjusting the height of the rear bracket must be solid steel pieces because they will experience the full structural load seen
10. PES 4 24 Recommended Tack Location for Front Stub Axle 4 25 Remote Air Pin Off Installation Under Cab 4 29 Behind Cab Installation Height 4 31 Overall Alignment Procedure and Final Weight Adj ustmeriE kana a a 4 33 Standard Front Railgear Final Weld out 4 34 Front Stub Axle Final Weld out 4 35 Rear Mounting Plate Weld off 4 35 Rear Spacer Welding 4 36 Install Decals 2 eie oat 4 37 Rail SWeeDS s aasma etel 5 2 Rail Sweep Position 5 2 Manual PIN OfFE aaa palu qa k a mene 5 4 Front Remote Pin Off 5 5 Rear Remote 5 6 Cobra Air Brake Location 5 7 Front Air Brake Installation 5 8 Rear Air Brake Installation 5 8 Cobra Air Brake Control System Assembly 5 10 Air Brake Control Kit for Behind Cab 5 11 Brake Inspection and Alignment 5 12 Cobra Air Brake Assembly 5 13 RW 1630 50 Insulated 2 Pc Wheel Assembl
11. Ll 5 7 5 3 2 Front Air Brake 01 2 1411 20202 4 4 0 4 20 0 5 8 5 3 3 Rear Air Brake Installation 1630 2 5 8 5 3 4 Air Brake Plumbing Installation 0004 4 4 0 7 0 5 9 5 3 5 Cobra Air Brake System Plumbing Overview 5 9 5 3 6 Inspection and emen e eene 5 12 5 3 7 Testing orrs DUE 5 12 5 3 8 Brake Parts momsen aaa aN soda a 5 12 5 4 TWO PI ECE WHEELS 5 14 2015 DMF Inc All Rights Reserved 5 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 5 1 RAIL SWEEPS The components that make up the standard Front and Rear Rail Sweeps for Railgear without any brakes are different than Rail Sweeps for Railgear with Cobra Air Brakes For Rail Sweeps provided with Cobra Air 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 For Rail Swee
12. re ple sere fatte Deed a eu sq EIE PRA rents 4 25 4 8 UNDER CAB FRONT UNIT INSTALLATION 4 26 4 8 1 Under Cab General Information 4 26 O 2015 DMF Inc All Rights Reserved 4 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 8 2 Disthantle cerei eer p mer rA E ha us vr n qa EN 4 27 4 8 3 MOUNTING 4 27 48 4 Axle AdJ stment etie brea SERIE RR Y DER 4 27 4 8 5 Welding eee xp pev p e eden decr e gne digne ee 4 27 4 8 6 Remote Air Pin Off HII HI IIa 4 28 4 8 7 Completion eter EH Iit RR Ir ren Ei 4 28 4 9 BEHIND CAB FRONT UNIT 5 4 30 4 9 1 Behind Cab General Information 1 2 110 0 6 4 30 2 6 ulus mim ettet tet de tete ome ec etre dea eodd 4 31 Z 9 3 I Wa oi R ua e 4 31 4 9 4 ComlpletlOty inet P ERVERE DU EU RE ERN ROCHE Ra ER Mi PER On EE DU ES 4 32 4 10 OVERALL ALIGNMENT PROCEDURE ssssssmnanananananaaaanaa 4 32 4 10 1
13. 7 10 7 9 RW 1630 Stub Axle Assembly Rear Double Insulated oorr Me LEGE EROS tas 7 11 7 10 RW 1650 Wheel amp Rear Axle Assembly Detail 7 12 7 11 RW 1650 Stub Axle Assembly Rear Double Insulated 7 13 7 12 Rear Mounting Bracket 12 7 14 7 13 Rear Mounting Bracket 10 3 4 7 15 SECTION 8 0 FRONT RAILGEAR PARTS 8 1 Before Ordering Parts Front Railgear 8 2 8 2 Front Parts Detail Drawing 8 3 8 3 Long Arm Variations 8 4 8 4 RW 1630 Wheel amp Front Axle Assembly 8 5 8 5 RW 1630 Stub Axle Assembly Front Double 8 6 8 6 RW 1630 Under Cab Front Railgear Assembly 8 7 8 7 RW 1650 Behind Cab Front Railgear Assembly 8 8 8 8 RW 1630 Mounting Tube Variations 8 9 8 9 RW 1630 Spring Hanger Variations 8 10 2015 DMF Inc All Rights Reserved Figure 1 2 1 Figure 1 3 1 Figure 3 2 Figure 4 1 4 Figure 4 2 4 Figure 4 3 2 Figure 4 3 4 Figure 4 3 7 Figure 4 3 9 Figure 4 3 10 Figure 4 5 2 Figure 4 5 3 Figure 4 5 4 A Figure 4 5 4 B Figure 4 5 5 Figure 4 5 7 Figure 4 6 2 Figure 4 7 1 A Figure 4 7 1 B Figure 4 8 6 Figure 4 9 3 Figure 4 10 1 Figure 4 12 A Figure 4 12 B Figure 4 12 C Figure 4 12 D Figure 4 13 Figure 5 1 A Figure 5 1 B
14. 8 16 13 REMOVED 818581 DISCONTINUED A 8 11 10 REMOVED NOTE 2 AND REMOTE RETRO KIT CHART 9 05 09 REVISED PER NEW BRAZIL MANUAL amp KIT S REV DATE DESCRIPTION TITLE INCLUDES 800136 DECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 818593 QTY 1 818596 QTY 2 818599 QTY 2 818765 QTY 2 amp LW5 16 QTY 2 RW 1630 REMOTE CABLE ASSY REAR NOTE 42 RETO FIT KIT GENERIC DRAWING DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER 10 05 58 M1630113 P N 818599 5 16 24 JAM HEX NUT P N LW5 16 LOCKWASHER 5 16 NOTE 1 SPECIFY THE CABLE THAT BEST FITS YOUR APPLICATION REPLACEMENT CABLES LENGTH 818577 818580 P N 818709 CABLE HANDLE MOUNT P N 818758 PIN OFF PIN 2 7 8 x 3 4 0 w 5 16 24 Note Remote Front Pin Offs ITEM PART NO DESCRIPTION There are two different types of remote pin offs available for both front and rear Railgear and they can be used in any 1 Nove 1 REF REMOTE PIN OFF CABLE MORSE combination The two different types are 2 818571 REMOTE T HANDLE MORSE Cable operated Air operated Remote pin offs are not installed at the factory to prevent damage during shipment Note Remote Front Pin Offs Shown w amp w o Air Cylinder Once cables are installed to pins route cables to easily accessible location for operator use preferably as n
15. 4 13 4 4 3 Mid Mount eme me he e ementi essere ete e nens 4 13 4 5 TRADITIONAL LONG ARM ASSEMBLY INSTALLATION 4 14 4 5 1 General Information esses me mense eme essehi eee 4 14 4 5 2 Diagram of Key hene 4 14 4 5 3 Frame Extension 1 lt m nee semen 4 15 4 5 4 Bridge Kit 2 2 7 7 7 7 4 42 0 0 e en nens 4 15 4 5 5 Front Mounting 1 ee eere rens 4 18 4 5 6 Mount Front Railgear esses ene eme sense emen 1 1010 4 18 4 5 7 Front Railgear Clearance esee memes eene 4 20 4 6 CARGO ARM FRONT ASSEMBLY INSTALLATION 4 21 46 1 pront Cargo AFMS QL S a teneor etre tete sn ode dd diete d eei Rd nite oae 4 21 4 6 2 Diagram of Key Components Front Mounting Dimensions 4 21 4 6 3 Mount Front 0 50 0 eme e mense eterne nnns 4 21 4 7 COMPLETING FRONT INSTALLATION 4 23 ATL Align Front Rallge ars sect arem a wk anam rade aae aaa qs 4 23 4 7 21 SE Mal Steps du eo tote ek
16. MUST BE WELDED IN RAIL POSITION NO WELDING ON AXLE 0 4 ONCE FINAL ALIG NM ENT amp WEIG HTS ARE SET IUBE OUTBOARD OF THE INBOARD SIDE OF THE OUTER PIVOTARMS SHUNT BOLT MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND MUSTBE WELDED IN RAIL POSITION SLEEVE MUST BE FULLY WELDED IN THE gt F OPENINGS ON BOTH SIDES OF THE TES RW 1630 FRONTRAILG EAR INSTALL GUIDE SLEEVE ONCE FINAL ALIGNMENT amp x He EC E DIVERSIFIED METAL FABRIC ATO RS INC 404 875 1512 WEIG HTS ARE SET a NE 7 FRONT STUB AXLE WELD OUT STANDARD FRONTAXLE WELD OUT i lt DVIE gt THREADS 2A AND J DI 8 1 14 M 1630139 4 HOLE MOUNTNG PLATE FOR ALL SIRUC TURAL WELDS EITHER LOW HYDRO GEN ROD OR DUAL SEDI SHIELD MIG WIRE SHOULD BE USED DO NOTATIACH THE WELDING MACHINE GROUND CLAMP ON RAILWHEELS THIS WILL CAUSE ARCING ACROSS THE BEARING S INSIDE THE WHEEL amp LEADTO PREMATURE BEARING FAILURE SPACERS MIN 1 2 MAX 3 IF OUTSIDE OF THIS RANGE ON FINAL INSTALLATIO N CONTACT DMF x HEX HEAD BOLT 4X 5 8 11 GRADE 5 TACKE WEI ENSURE NUTS amp BOLTS SEC URELY FASTENED TO 154 LB FT REAR FRAME BRACKET IF SHIMMING REQUIRED THICKNESS ENSURE ALL SPACERS ARE FIRMLY AGAINSTSIDE MUST BE EQUAL ON BOTH SIDES BRAC KET OR SHIMS amp ALIG NED WITH THE REAR MOUNTING B
17. 1630 STUB AXLE STUB AXLE DETAIL 1630 INSULATED INSULATOR DISC 1630 STUB AXLE 5 8 LOCK WASHER GRADE 8 5 5 8 11 UNC x4 GRADE 8 HHCS 5 8 11 UNC X 5 GRADE8 STUB AXLE SLEEVE 1630 FRONTPIVOTARM WELDMENT DRIVER SIDE OUTER FRONTPIVOTARM WELDMENT DRIVER SIDE INNER FRONTPIVOTARM WELDMENT PASSENG ER SIDE INNER FRONTPIVOTARM WELDMENT PASSENG ER SIDE OUTER BRAKE SADDLE WELDM ENT FRONT 1630 STUB AXLE GREASE FITTING 1 8 NPT STRAIGHT HHCS 1 4 20 UNC X 1 NYLON o o o INJI N2 N2 I 9 I9 i N2 NA NL NA N2 Q WELDING ON AXLE TUBE OUTBOARD OF SHUNT BOLT NYLON BOLTFACES REAR OF VEHIC LE APPLY SILIC ONE BEAD TO EDGE OF SPINDLE BEFO RE INSTALLING TORQUE BOLTS TO 120 FT LBS IN AXLE TUBE BO TH ENDS 6 4 2014 ADDED NOTE JDI REV DATE DESCRIPTION BY APP N TES TOLERANCES 1 INSTALL ALL INSULATORS ON STUB AXLE BEFO RE BE T1630 STUB AXLE ASSEMBLY FRONT DOUBLE PRESSING INTO AXLE TUBE RAC ONE uns RW 1630 INSULATED 2 C HEC K FO R ZERO C O NTIN UITY A FIER ASSEM BLY 5 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 pale 0 DATE DRAWING NUMBER 9 26 12 820605 ITEM PART NO DESCRIPTION 110400 UPPER ARM ASSEMBLY DRIVER S SIDE UPPER ARM ASSEMBLY PASSENGER S SIDE LOWER ARM ASSEMBLY HYDRAULIC CYLIND
18. 818445 AIR BRAKE PIVOT PIN w 2 ROLL PINS INCLUDES 5 818454 BRAKE SHOE PIVOT PIN QTY 1 amp 17 818509 ROLL PIN QTY 2 L A aie a EM 818513 WAS 818426 DESCRIPTION NOTE 2 Es TITLE Mon COBRA AIR BRAKE ASSEMBLY SEE NOTE 1 PART NO DESCRIPTION e DIVERSIFIED METAL FABRICATORS INC 404 875 1512 amu sz s 075 DRAWN BY APPD BY DATE DRAWING NUMBER REV sure Ns 125 wono Ty en 1 25 10 M1630101 A DIVERSIFIED METAL FABRICATORS INC RW 1630 5 4 TWO PIECE WHEELS DMF offers a two piece insulated wheel option for extreme applications such as material handlers If your material handler will be insulated then DMF requires the use of our two piece wheel DMF s two piece wheels require additional maintenance over and above our standard wheels so we only recommend them for use in heavy duty applications The additional maintenance procedures center around proper monitoring of the torque of the 8 bolts holding the tread and hub together To assist in monitoring the torque of these bolts DMF has provided Loose Wheel Nut Indicators also referred to as torque indicators on all 8 bolts See the following checklist for additional maintenance procedures Additional Checklist for Two Piece Wheels In addition to following the inspection and maintenance procedures as defined in Section 3 1 Two Piece Wheels require the following specific inspections e As previ
19. Another option would be to reinstall the tanks higher during re assembly Is there room to move the tanks higher 4 Do you have squared or cylindrical tanks This affects Rail wheel clearance between the bottom corner of the tank as it is deployed into the rail position a For cylindrical tanks nominally 26 dia spaced 2 from frame Mount the back edge of the frame mounting bracket behind and no closer than 3 from back edge of 13 1 4 G C tank 1 1 2 14 5 8 15 3 16 16 Table 4 8 1 A Cylindrical Tank Spacing b For squared step tanks mount the back edge of the frame mounting bracket behind and no closer than 5 from the back edge of 13 1 4 G C tank 2 7 8 14 1 5 8 15 3 4 16 Table 4 8 1 Squared Tank Spacing c The Railgear may be located further rearward than allowed above but you must contact DMF 5 The rail axle requires 24 of ground clearance to stow under the truck drive shaft The rail axle will stow 10 1 2 behind the back edge of the mounting bracket 6 Mark the location of the back of the frame mounting bracket on both sides as described above Measure forward from these marks 31 1 4 bracket length and mark frames again MOTOR TRANSMISSI ON PTO ARRANGEMENT The mounting shelf of each frame mounting bracket is 9 wide The inboard side of the frame mounting brackets can be spaced out to a maximum clearance of 41 3 8 The Railgear
20. Description REAR SPRING BRACKET SPACERS if Required SPACER Top Required RUBBER SPACER Required REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM 10 FRONT MOUNTING PIN 11 FRONT SPRING BRACKET amp PIN Figure 4 6 2 Diagram of Key Components Front Mounting Dimensions 4 6 3 Mount Front Railgear Mounting Rear Spring Bracket 1 Remove the truck s front bumper 2 Slide the front Railgear under the truck frame positioning the spring bracket hangers as close as possible to the front truck axle Make sure at least half of the spacer is seated on the leaf spring closest to the front truck axle If the spacer is not at least half seated move spring bracket hanger forward to next leaf spring The spring hanger can be moved 6 max from front truck axle 2015 DMF Inc All Rights Reserved 4 21 DIVERSIFIED METAL FABRICATORS INC RW 1630 3 Once positioned place a floor jack under the outboard and inboard long arm close to the spring hanger on the driver s side Using the jack raise the spring hanger up toward the truck s leaf springs You will raise and lower the long arms until the Rear Mounting Pin is 12 3 4 V2 from the floor See figure 4 5 5 4 Once you achieve the desired height insert 1 x2 flat bar spacers between spring hanger and leaf spring up to a maximum of 4 If you need more than 4 of spacers a change of spring brackets may be required see section 8 0 for spring b
21. I I i IS i 00 O9 oo I NS See Section 5 2 for detail 5 811 x 4 Grade 8 Bolts amp care for2 pc wheels Must only use once MUSTBE HARDENED WASHERS Must only use once TORQUE TO 120 FT LBS 5 8 11 Type C prevailing Torque Nut Must only use once IF A LOCK NUTBECOMES LOOSE RETIG HTEN TO TO RQ UE SPEC amp USE RED TO RQUE INDICATOR TO MARK THAT PARTIC ULAR NUT UNTIL NEXTINSPECTIO N In addition to following the inspection amp maintenance procedures as defined in Section 3 1 Two Piece Wheels require the following specific inspections As previously specified in Section 3 1 1 check the bolt torque indicators the tabsaround each bolt daily to ensure that they have not moved If torque indicators are missing or damaged please contact DMF for replacements If torque indicators have moved follow this procedure to remedy the situation 1 Remove the green torque indicator retorque the loose nut see torque specificationsabove and then replace with a red torque indicator DMF providesone red torque indicatorper wheel To install a torque indicator place it overthe nut withthe raised collarresting against the wheel Push with both thumbs ora socket flush to the wheel The next time that the vehicle a shop for service or repair disassemble the wheel and inspect all the componentsfordamage Replace damaged or wom components and re assemble the wheel with new bolts nu
22. Inc All Rights Reserved 5 7 DIVERSIFIED METAL FABRICATORS INC RW 1630 5 3 2 Front Air Brake Installation 44 1 2 Maximum widths of Long Arms clips 4 places each side NOTES Run the supplied hoses through the J clips with the spring guards located in the loops left at the Brake Assemblies The 75 Hose is for the passenger side amp the 62 Hose is for the driver side Mount Air Brake Valve Assembly to an appropriate place near the Front Railgear usually on the Front Valve Assembly Plate with supplied Relay Brake Hoses attach to the Front Valve Assembly Figure 5 3 2 Front Air Brake Installation 5 3 3 Rear Air Brake Installation RW 1630 J clips 4 places each side Run the supplied hoses through the J clips Rear Hoses 59 long Mount Air Brake valve Assembly to an appropriate place near the Rear Railgear usually on the Rear Frame Bracket with supplied Relay Mount Attach Brake Hoses to the Air Brake valve Assembly Figure 5 3 3 Rear Air Brake Installation 5 8 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 5 3 4 Air Brake Plumbing Installation An air toggle valve on a plate labeled brakes on off is to be located on the vehicle instrument panel This valve disconnects the guide wheel braking system from the vehicle airbrake system by interrupting the CONTROL line air pressure to the guide wheel system only On the Front
23. L o 2 REAR AXLE LOWER PIN SADDLE 4 9 2 REAR AXLE LOWER PIN SADDLE ROCK p 2 man AXLE LOWER PN SADDLE BLOCK s E j 8 REAR SCISSORS LINK MECHANISM 0 s HER SCISSORS LINK MECHANISM 0 s 8 rea SCISSORS LINK MECHANISM j 6 F 2 REAR CYLINDER ROD cross rS s F 2 REA CYLINDER ROD CROSS TUBES s F 2 REAR CYLINDER ROD cross TUBES 7 2 FRONT sre axle sr 7 6 sup ONLY APPLIES TO STUB AXLE RW 1630 50 RW 1630 50 RW 1630 50 FRONT MOUNT FRONT MOUNT FRONT MOUNT x NTN UNDER CAB UNDER UNDER M m mn2 A a i 7 RW 1630 RW 1630 RW 1630 oL Ap RW 1650 RW 1650 RW 1650 BEHIND CAB BEHIND CAB BEHIND CAB m a 9 amp 3 11 15 GREASE STANDARD CHANGED 6 24 14 ADDED STUB AXLE GREASE POINTS DESCRIPTION LUBRICATION SPECIFICATIONS mue WHEEL BEARING GREASE GREASE FITTINGS Y 1722 RW 1630 50 GREASE POINT LOCATIONS Factory Standard Citgo Syndurance Premium Synthetic 460 2 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent f or OATE DRAWING NUMBER DEDE LA AND za 10 14 98 11 M1630126 DIVERSIFIED METAL FABRICATORS INC RW 1630 3 3 Troubleshooting 3 3 1 Troublesh
24. PORT FROM FRONT VALVE 55 OUT PORT 90deg FITTINGS 1 IF HANDLE REVERSED FRONT VALVE PLUMBING MUST BE REVERSED sea CORRECTED SECTION REFERENCE DELETED P N S 810311 810312 amp 810313 amp ADDED 240258 910909 REVISED SCHEMATIC LAYOUT AND B O M PER AS BUILT NOW SEE SECTION 4 3 OF MANUAL WHICH SPECIFIES HYDRAULIC SYSTEM REQUIREMENTS LA REVISED BY REMOVING TYPE OF VALVES ENERGY GRESEN DATE DESCRIPTION TOLERANCES C C x LUBRICATION SPECIFICATIONS EE m TITLE HYDRAULIC OIL NAC Aa VALVE ASSEMBLIES amp HYDRAULIC SCHEMATIC ASTM D6158 HM UNAX RX 46 HYDRAULIC OIL SHELL TELLUS EE 46 OR EQUAL x N OR A fe DIVERSIFIED METAL FABRICATORS INC 404 875 1512 SOME CUSTOMERS OPERATE ON DEXRON III ATF DRAWN BY APPD BY DATE DRAWING NUMBER REV 10 07 98 M1630114 0 BREAK SHARP EDGES PART NO DESCRIPTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 DMF P N 240225 SEAL KIT SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WI
25. REMOVED 818581 DISCONTINUED 9 05 09 REVISED PER NEW BRAZIL MANUAL amp S DATE DESCRIPTION KIT P N 818774 FRONT REMOTE AIR KIT ASSY LESS PIN OFFS MUS CAO RENE GALE FRG INCLUDES 800136 DECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 818593 QTY 1 4 NOTE 2 RETO FIT KIT GENERIC DRAWING 818596 QTY 2 818599 QTY 2 818755 QTY 2 818758 QTY 2 amp FW1 4 QTY 2 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER 10 05 58 yl gt M1630112 DIVERSIFIED METAL FABRICATORS INC RW 1630 5 3 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 DMF s RW 1630 Railgear uses an optional air braking system The same Cobra air braking system is used for both the front and rear Railgear For a detailed drawing of the Cobra Air Brake Assembly section 5 3 8 While the Front and Rear Railgear is in the rail position the front Cobra Air Brake assembly should be located as shown below The rear Cobra Brake assembly is oriented at the factory and will not need to be changed 5 3 1 Cobra Air Brake Location Figure 5 3 1 Cobra Air Brake Location 2015 DMF
26. flat bar only to be welded to each frame mounting bracket shelf This sets the bracket shelf at 29 when installed 4 8 2 Dismantle Now that you have determined where the Under Cab Railgear will install strip the truck frame in the area between the frame marks After the Railgear mounting brackets have been installed onto the frame mounted truck equipment tanks air dryers etc may be remounted over the Railgear mounts or they may be relocated further down the truck frame 4 8 3 Mounting The Railgear frame mounting brackets attach to the truck frame using 8 5 8 11 grade 5 bolts on each side These bolts use the same 4 hole mounting plates as used on the rear equipment installation After bolting the mounting brackets to the truck frame the 4 hole plates should be temporarily tack welded to the frame mounting brackets to prevent them from slipping and to allow for further adjustment during overall alignment by grinding off tack welds Final welding of these plates will be performed in Section 4 12 4 8 4 Axle Adjustment The rail axle may now be centered under the truck frame by sliding it transversely in the lower arm weldments Follow the established procedure for aligning Standard Front Railgear see Section 4 7 After centering the rail axle rotate the axle tubes to align the front brake assemblies with the arm weldments In the rail position the brakes should be located behind the guidewheels and about 15 degrees up from hor
27. with 16 guide wheels GVWR Range 33 000 Ibs and above Approx Installed Weight Front 1385 Ibs Capacity 40 000 pounds per Railgear axle 9 20 MPH For parts drawings see Section 8 0 and for installation instructions see Section 4 0 TRUCK FRAME FRONT TRUCK 4 SPRING Item Description SPRING BRACKET SPACERS if required SPACER Top required AXLE RUBBER SPACER REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM FRONT MOUNTING PIN CROSS TUBE FRONT EXTENSION if required COBRA BRAKES if equipped Figure 1 2 1 Front Railgear Components o 0 M9 Q RON 2015 DMF Inc All Rights Reserved 1 3 DIVERSIFIED METAL FABRICATORS INC RW 1630 1 2 2 Behind Cab Front Railgear Components DMF Behind Cab Front Railgear uses the RW 1650 axle and wheels Front Railgear mounted to truck frame behind the vehicle cab with 16 guide wheels GVWR Range 33 000 Ibs and above for heavy load applications Approx Installed Weight Front 1800 Ibs Capacity 70 000 pounds per Railgear axle 9 20 MPH For parts drawings see Section 8 0 and for installation instructions see Section 4 0 1 2 3 Under Cab Front Railgear Components DMF Under Cab Front Railgear uses the RW 1630 axle and wheels Front Railgear mounted to truck frame underneath the vehicl
28. 1 4 o Minimum Truck Frame extension Single Axle 21 1 4 Tandem Axle 17 1 5 L Check overall measurements o Rear Truck Axle to Rear Railgear Axle straight A1 A2 within 1 8 o Rear Truck Axle to Rear Railgear Axle diagonal B1 B2 within 1 4 o Front Railgear to Rear Railgear straight C1 C2 within 1 8 o Front Railgear to Rear Railgear diagonal D1 D2 within 1 4 L Raise and lower Railgear and verify pin off at highway and rail positions L Verify that all bodywork is replaced and secure In a parking lot or open area verify that the truck tires and rims do not contact the Railgear in any bump droop or steering position Check for any rattles and vibration 2015 DMF Inc All Rights Reserved 4 39 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 44 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 5 0 RAILGEAR OPTIONS 5 1 RAIL 5 5 5 2 5 2 PIN OFF 5 5 3 5 3 BRAKES uu eens eens eens usa 5 7 5 3 1 Cobra Air Brake Location
29. 2 1 2 Grade 8 17 108264 12 MOUNTING HEX NUTS 5 8 11 ESNA 18 108266 16 STRAP MOUNTING BOLTS 5 5 8 11 x 1 1 4 Gr8 19 108268 16 LOCK WASHER 5 8 11 20 108045 2 PIN OFF ASSEMBLY AUXILIARY 21 108044 2 CHAN 3 16 x 12 22 78750 2 AIR BRAKE ASSEMBLY see PAGE 17 for MORE DETAILS 1650 amp BEHIND CAB WHEELS NON INSULATED 1650 WHEEL w RACES 800015 INSULATED 1650 WHEEL w RACES 800016 INSULATED 2 PIECE 1650 WHEEL w RACES 820496 NOTE SPECIAL PROFILE WHEELS PLEASE CALL 1650 amp BEHIND CAB BEARING RACE TIMKEN 6420 BEARING RACE 800125 SEE DRAWING M1630103 FOR REAR PARTS amp WHEEL ASSEMBLY PROCEDURES 1 108015 2 BEHIND CAB FRAME BOX ASSEMBLY o O 2 108056 4 UPPER CYLINDER PIN DETAIL 3 108060 8 BANJO PIN 1 4 x 3 REID ROD END FORGED 4 108062 8 HEX HEAD BOLT 5 5 16 18 x 1 5 108064 8 LOCK WASHER 5 16 18 6 108074 4 LOWER CYLINDER PIN DETAIL A 7 110804 2 1 5 8 ASSY W CHAIN 108080 2 SLIDE TUBE WELDMENT 9 108100 4 HYDRAULIC CYLINDER ASSEMBLY 10 10820 1 BEHIND CAB AXLE ASSEMBLY 11 108250 4 MARSHMALLOW SPRINGS CENTURY DM 0376 6 x 1 x 5 LOCATE HOLES TO CLEAR 9 9 IEEE OTHER HARDWARE ON FRAME H CHANGED ITEM 7 108042 TO P N 108041 5 24 10 ADDED ITEM 15 NOTES amp PAR
30. 2x KIT 818441 INCLUDE ITEMS 19 20 2x amp 21 2x KIT 818437 OPTIONAL MOUNTING 2x HEX HEAD 5 16 18 X 1 1 4 10 LOCK WASHER LW 10 RD HEAD MACHINE SCREW 10 24 X 1 00 KIT 818437 Note Items 5 6 7 8 amp 13 shipped assembled Rear Kit p n 818415 ape tmt ae KIT 818441 INSTALLER S SUPPLY LINE I EB I INCLUDED WITH REAR AXLE KIT ONLY CORRECTED HARDWARE PART 5 REVISED ITEM 1 TO QTY 1 AND ADDED NOTES ADDED TANKS REV DATE TOLERANCES cd NLESS SPECIFIED COMMO NONSE PREVAILS MACH 1 FRAC OTHER x DESCRIPTION APPD BY DATE 05 17 92 lt XXX OR XXXX DRILL SIZES ANGULAR DRAWN BY SURF FINISH THREADS 1 125 MICRO AND TSH
31. 3 4 NPT 1 one 1 2 NPT return and a tank filler breather Fill the tank with Unax RX 46 hydraulic oil or equivalent If other equipment is to be installed in addition to your DMF Railgear you will need to adjust your tank specifications accordingly Once your new hydraulic system is installed if your vehicle is going to have multiple applications for the hydraulic system please proceed to Section 6 1 2 for instructions on installing a diverter valve 6 1 2 Hydraulic System for Multiple Uses Railgear and other application s If the truck has an existing hydraulic system you must first install an appropriately sized pressure relief valve in the pressure line after the pump Install an appropriate sized diverter valve depending on pump volume in the pressure line after the pressure relief valve and before any existing equipment One diverter outlet routes to the existing equipment s valves the other diverter outlet routes to the front Railgear See Section 6 2 for additional information on installation of the pressure relief valve and diverter valve Railgear control valves have built in pressure reliefs and the hydraulic working pressure of the system is 2500 psi The front valve should be set to 2250 psi at the relief The rear valves should be set to 2000 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 relie
32. 4 3 3 Location of Rear Railgear Position the rear Railgear as close to the rear tires as practical allowing clearance for mud flaps Table 4 3 3 gives standard location and clearance guidelines for the rear Railgear and these dimensions are shown in Figure 4 3 4 Generally leave a minimum of 2 clearance to any tire spring or suspension components Minimum Distance from Single Axle Tandem Axle Rear Tire to Rail Wheel Center 15 1 4 11 1 4 Min Truck Frame Extension 21 1 4 17 1 4 from rear edge of tire Minimum clearance area 24 1 4 x 19 20 1 4 x 19 from rear edge of tire Table 4 3 3 Location of Rear Railgear 4 3 4 Location and Clearance of Railgear The Railgear 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 3 4 It is important that nothing encroach upon this space e g outriggers lift gates and body tie down bolts SINGLE Figure 4 3 4 Location and Clearance of Railgear 2015 DMF Inc All Rights Reserved 4 9 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 5 Shimming and Temporarily Spacing Rear Bracket Once Railgear is correctly located on rear frame as above if more th
33. 428 O 2015 DMF Inc All Rights Reserved REMOTE AIR PIN OFF OPERATION PIN ENGAGE PUSH TO PIN DIS ENGAGE RED LIGHT ENGAGE GREEN LIGHT ps O C ps PULL TO PIS O DIS ENGAGE Ps 818754 FRONT VIEW OF LEGEND PLATE APPLY ANTI SEIZE TO LOCK PIN SEE INSTALLATION NOTE ADJUST TO i HU SENSOR WIRING DIAGRAM EACH SIDE NOTE EACH SIDE MUST BE INDEPENDENT OF THE OTHER IN ORDER TO FUNCTION PROPERLY DO NOT WIRE IN SERIES ITEM PART NO DESCRIPTION A 1 81873 2 HOUSING WELDMENT AIR PIN OFF 2 sz 2 PworeNvO 0 3 2 TRAVELSTOPRJAMNUT CRR2O o par T ce ee O s smrss 2 NRCYUNDER I amp BORExT STROK 6 str 4 PROXIMITY SWITCH T summo 2 romo 7771 s stra 2 s sura 1 lEGENDPLAIE C S E 1 sie 2 AIR PIN OFF FITTINGS 269PMT 4 2 1869x4S 12 818591 4 AIRLINE FOR REMOTE PIN OFF 1 4 SYNFLEX 04 5 1 ARCONTROLVALVE BUYERSVALVE NOT SHOWN APPLY LOCKTIGHT TO THREADS OF CYLINDER ROD BEFORE INSERTING INTO ITEMS 2 amp 3 THIS SENSOR CONNECTS TO THE GREEN LED ADJUST SWITCH TO GAP SHOWN THIS SENSOR CONNECTS TO THE RED LED INSTALLATION NOTE INSTALL LED S AND PIN OFF AIR VALVE IN LEGEND PLATE ON OUTSIDE OF FRAME WELDING TO RAILGEAR FRAME APPLY 2 1 2 PASSES ON EACH VERTICAL EDGE OF PIN OFF TUBE DO NOT WELD ACROSS TOP amp BOTTOM
34. 7 2 4 3 240103 1 Nu t 14 8 O 5 240105 1 SEAL ROD 3750 2000 6 240106 1 WIPER ROD 959 21 7 240107 1 O RING PISTON 2 214 8 240108 1 O RING GLAND 2 346 9 240109 1 O RING GLAND BACK UP 8 346 10 240110 1 or BARREL ASSEMBLY 4 1 2 DRIVER S SIDE 240115 1 BARREL ASSEMBLY 4 1 2 PASSENGER S SIDE 11 240120 1 ROD ASSEMBLY 2 12 818235 1 GREASE FITTING 1 8 FITTING ELBOW 1 4 JIC x 9 16 18 6801 NW 4 6 Eh ENSS 7 S REF CLOSED 20 tbe OPEN _Al 41630 1420 1212 1019 FRONT CYLINDER A 7 25 13 SWAPPED PASSENGER DRIVER SIDE A 2 17 12 818235 WAS 240123 JT DATE DESCRIPTION S SPECFED TITLE rea gu oN ENSE PR XEVAILS RW 1630 FRONT HYDRAULIC CYLINDER ASSEMBLY i 4 1 2 BORE x 2 ROD x 9 11 16 STROKE DIVERSIFIED lt gt FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV 240099 DS 11 10 92 240100 PS TITLE Cylinder Assembly PURPOSE To Establish Production Methods For The Assembly Of Cylinders COMMON USAGE All Models PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE D M F Manufactured Hydraulic Cylinders With PolyPack Piston Seals ASSEMBLY PROCEDURE PISTON A Inspect for sharp edges Deburr as neccessary B Clean and blow off with shop air Use Blue Assemblee Goo 19260 to aid assembly D Install two 2 seals wit
35. ADJUSTMENT IS NECESSARY EXCEPT HUBCAP P N 800301 KIT 2 PC WHL TORQUE INDICATORS J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE Se as ye See See 1630 amp UNDER CAB REAR AXL ADJUST INNER WHEEL NUT 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 L INSTALL TAB WASHER ITEM 7 mamas M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND F N SELECT THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS O FILL OUTBOARD CAVITY COMPLETELY P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N 800020 ALL HARDWARE KIT FOR RW 1630 amp UNDER CAB WHEEL Does not include silicon for hubcap or wheel grease or bearing race PARTNUMBER 820700 820603 820604 820602 108268 820486 605120 820701 820702 605139 820601 lt DESCRIPTION AXLE TUBE WELDMENT 1630 REAR STUB AXLE SIANDARD GAUGE INSULA TO R TUBE 1630 STUB AXLE BOLTINSULATOR 1630 STUB AXLE INSULATOR DISC 1630 STUB AXLE 5 8 LOCKWASHER GRADE 8 HHC 5 5 8 11 UNC x4 GRADE 8 HHC S 5 8 11 UNC X 5 GRADE 8 BRAKE SADDLE WELDM ENT REAR PASSENG ER SIDE 1630 STUB AXLE BRAKE SADDLE WELDM ENT REAR DRIVER SIDE 1630 STUB AXLE HHCS 1 4 20 UNC X 1 NYLON SIUB AXLE DETAIL 1630 INSULATED N
36. Inspection and Maintenance 3 2 3 2 Lubrication Specification 3 3 3 3 Troubleshooting 3 5 3 4 Derailment 3 6 RAI LGEAR INSTALLATION 4 1 Pre Install 4 3 4 2 Initial Instructions 4 5 4 3 Installation of Rear Railgear 4 7 4 4 Varying Front Railgear Configurations 4 13 4 5 Traditional Long Arm Assembly Installation 4 14 4 6 Cargo Arm Front Assembly Installations 4 21 4 7 Completing Front Installation 4 23 4 8 Under Cab Front Unit Installation 4 26 4 9 Behind Cab Front Unit Installation 4 30 4 10 Overall Alignment Procedure 4 32 ATI Rail TeSt ai 4 34 4 12 Final Weld Out 4 34 4 13 Install Decals sese 4 36 4 14 Velcro Steering Wheel Lock 4 38 4 15 Installation Review Checklist 4 39 RAILGEAR OPTI ONS 5 2 Ralli Sweeps i dtes dades 5 2 5 2 Pin Off 2 2 5 3 5 3 Brakes yaa eR DEEP Ag 5 7 5
37. Once centered over tracks remove front and rear safety pins 3 Lower rear wheels first A If rear is not completely centered within 4 rear rail wheels will center truck on rail B With rear wheels fully extended and properly seated on rail install safety pin into lower hole on both sides 4 Center front rail wheels over rail A If front is not completely centered over rail maneuver truck so that it is B Front vehicle wheels must be straight ahead C Lower front rail wheels until cylinders are fully retracted Front rail wheels incorporate over center design and do not require safety pins in rail position 5 Double check all flanges to assure they are seated properly on rail and safety pins are installed 6 Engage steering wheel lock if equipped Safe operating speeds on rail will be governed by track conditions and existing railroad rules and regulations Under no conditions should vehicle be operated over 30 MPH on track DIVERSIFIED METAL FABRICATORS 404 875 1512 TO REMOVE VEHICLE FROM RAIL 1 Drive vehicle over road crossing 2 Either front or rear wheels may be activated first 3 Front rail wheels A Retract front rail wheels completely B Once retracted install safety pins 4 Rear rail wheels A Remove safety pins B Fully retract rear rail wheels C Re Install rear safety pins 5 Double check all safety pins are in proper location 6 Disengage steering wheel lock if equipped AT
38. TOLERANCES TITLE aaa CYLINDER REAR SAE PORT L VLV 3 1 2 BORE x OTHER re 9 1 2 STROKE RH PASSENGER SIDE x on DIVERSIFIED METAL FABRICATORS INC 404 875 1512 GUAE ie DRAWN BY APPD BY DATE DRAWING NUMBER SURF FINISH 125 MICRO THREADS 2A AND 28 BJF 10 7 09 240257 PARTNUMBER DESCRIPTION 240246 DETAIL 3 1 2 HYD CYLINDER PISTON LVL 240202 HYD CYL GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 240208 O RING GLAND 2 338 240209 O RING GLAND BAC K UP 8 338 241319 ASSY 3 1 2 TUBE LVLV REAR DRIVER SIDE 240229 HYDRAULIC CYLINDER REAR ROD ASSY LV 818235 GREASE FITTING 1 8 NPT STRAIGHT 241016 VALVE LOCKING CPD 084P PARKER 241335 FITTING 06 MJ IC X 04 MJ IC X 90 DEGREE 108129 TUBE NUT 3 8 108130 TUBE FERRULE 3 8 DMF P N 240225 SEAL KIT SEAL KITINC LUDES 5 4 5 6 7 8 amp 9 ox o u 5 w N m o m m N m w m m a m o 3 TORQUE 300 FT LBS OPEN 20 908 CLOSED 13 633 Cc 10 3 14 REDRAWN OPEN 20 908 WAS OPEN 21 068 JDI B 4 6 12 818235 WAS 24
39. WASHER SEAL 5 8 C HEX END CAP 818587 REM AIR P O FITTING 818593 REM P O AIR CTRL ver a Truck STAR P N 818596 5 87 18 JAM NUT P N 818765 AIR CYLINDER P N 818528 TEE 1 2 13 HEX NUT 4 PLCS 1 2 LOCKWASHER 2 PLCS P N 818595 MOUNTING PLATE KIT P N 818613 AIR REMOTE KIT ASSY LESS PIN OFFS 1 Nor 1 REF 2 88563 REF 3 _ REF 88551 REF 5 818571 1 27 13 HEX NUT 7 16 LOCK WASHER 7 16 FLAT WASHER 7 16 C HEX JAM NUT SEAL 7 16 INTERNAL LOCK WASHER 7 16 C HEX END CAP 1 27 13 HEX NUT TRUCK SUPPLY 818591 1 4 TUBE DESCRIPTION REMOTE PIN OFF CABLE MORSE REMOTE MOUNTING PLATE REMOTE PIN OFF ASSY for w LONG LINKS 7 3 4 C to C REMOTE PIN OFF ASSY for w SHORT LINKS 5 3 4 C to C REMOTE T HANDLE MORSI SS 1 27 13 x 5 1 2 HEX HEAD BOLT 1 4 20 HEX NUT 55555555 4 m paH N UPPER REAR UNK D INSTALLATION NOTES INSERT AIR CYLINDER THROUGH PLATE AND SCREW INTO P O SLIDE WELDMENT P O ASSEMBLY MUST BE PARALLEL TO LINK AND STUDS SHOULD BE FLUSH WITH THE OUTER HEX NUTS LOCATE AIR CONTRL VALVE P N 818593 FOR CONVENIENCE AND CONNECT TO A PROTECTED AIR SUPPLY CONNECT LEFT VAVLE TO THE LEFT P O CYLINDER WITH TWO OF THE HOSES AND FITTINGS SUPPLIED REPEAT THE SAME PROCEDURE FOR THE RIGHT P O ASSEMBLY P O SHOULD DISENGAGE WHEN VAVLE IS PULLED
40. by the rear frame e When setting the height of the rear bracket using spacers you must be within the range of 1 minimum to 3 of spacers maximum If you are outside of this range it may be necessary to change out your links See Section 7 0 for different link measurements and contact DMF for final consultation before ordering a different set of links DMF will not be responsible if the links are changed from the initial order without consulting with DMF e Before permanently affixing your rear bracket to the truck frame including welding or drilling holes be aware that during the locating shimming if necessary spacing squaring and weight setting procedures your rear bracket will be making slight movements during each of these steps So you will want to only TEMPORARILY secure Railgear using clamps chains fork lift etc after each procedure e The rear Railgear is usually installed with the Safety Pin Offs manual cable or air operated facing towards the rear of the truck However truck work body may dictate locating the Safety 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 see Section 7 3 The insulated Rail Wheels should always be on the driver s side of the Railgear e It 15 important that the truck tire pressure especially the rear tires be checked and brought to the tire manufactur
41. downward pressure Caution Do not over tighten Repeat process on passenger side Route Hydraulic lines 1 2 3 Route all hydraulic lines as shown in Section 6 0 Engage the PTO and allow hydraulic circuit to self bleed Inspect all connections for leaks and tighten as necessary Mounting Front Cross Tubes 1 2 Ensure that both spring bracket hangers properly installed before attempting to install front cross tubes 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 see Figure 4 5 5 The cross tubes only need to be brought up to where they touch 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 Railgear at the correct height the center of the Front Mounting Pins must be located at 25 1 2 1 from the ground with the truck tires on the ground as shown in Figure 4 5 5 If required shim the cross tubes to obtain this 25 1 2 Any shims used should be load bearing members no thin wall tubing If necessary a different cross tube can be used to obtain the desired height of the Front Mounting Pin up to a maximum of 3 of shims If you need more than 3 of shims a change of cross tubes mounting block may be required see section 8 0 for information Contact DMF f
42. for knowing if your Railgear equipped vehicle has insulated or non insulated wheels To assist in identifying insulated rail wheels a grooved ring is machined around the inside of the front and rear driver s side wheels All railroad rules and safety guidelines should be observed Reduce speed while in reverse and or at all crossings curves branch lines switches and frogs no more than a slow walking pace is recommended Traction is reduced on the track especially in wet conditions Braking distance is increased on the track especially in wet conditions Do not slide tires or guide wheels on the tracks as this will cause premature wear Do not exceed the maximum rated capacity of the equipment On newer trucks with Anti Lock braking systems the amber ABS dash light may remain on with the front wheels elevated This will not affect rear truck braking or rail wheel braking 2 5 GETTING OFF THE RAIL 2 5 1 Removing Truck from Track Ur dor NL TES e Safely pull onto the track crossing paying attention to traffic and other obstacles Set the truck parking brakes and engage the PTO Leave the truck running and the transmission in neutral gear Lift both sets of Railgear there is no preference for removal order Engage all 4 safety pin off pins in highway position passenger and driver side for both front and rear Railgear Disengage the switch that controls the Railgear brakes if applicable Disengage the PTO and the pa
43. frame mounting brackets is 34 7 8 To determine the amount of space required between the truck frame and Railgear each side measure the outside width of the truck frame and subtract that distance from 34 7 8 This amount divided by 2 will space both sides out equally Flat bar shims are furnished to use as Spacers If additional shims are necessary they must conform to the shape of the furnished part except for required thickness These shims are to be securely welded to the inside of the frame mounting brackets Depending on truck frame depth and vertical spacing required to achieve the proper height for 9 of ground clearance the frame mounting brackets may protrude above the top of the truck frame by as much as 8 inches This must be taken into consideration if the unit is installed on a flat bed truck where crossmembers span the truck width over the frame Also space above the frame brackets needs to be maintained in order to provide access for hydraulic hose routing to the Railgear cylinders 4 30 11 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 9 2 Dismantle Now that it has been determined where the behind cab unit will be installed strip the frame in the area between the frame marks It may also be necessary to remove one or two rows of truck crossmember bolts in order for the frame brackets to fit flush against the truck frame The Railgear attaching hardware will replace the crossmember bol
44. is designed to fit a truck frame with as little as 29 G C 1 Measure from ground to 29 height between the frame marks on each side Determine what machinery probably transmission or plumbing is closest to the outside of the 4 06 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 frame along this horizontal 29 plane Measure on each side to determine what the closest distance is to the outside of the frame 2 Ifthe nearest obstruction is more than 9 from the frame proceed to step 5 And use the truck frame width 3 Subtract the closest distance from the 9 shelf width This is how far you would space the frame mounting bracket out on that side to clear the obstruction 4 Add to the frame width of the truck twice the distance you figured for step 3 This will space both sides out equally 5 15 the distance from step 2 or step 4 less than 41 3 8 If not you move Railgear to clear the obstruction Consult with DMF 6 The spacer distance found in step 3 will be added to the inboard side of each frame mounting bracket These spacers should be flat bar welded to the frame mounting bracket at each of the 4 vertical slots on each bracket Later you will drill through the slots spacers and truck frame to attach each bracket to the frame 7 Measure from the ground to under the truck frame between the frame marks Subtract 29 from this measurement This is the amount of solid spacer
45. is noted check Railgear alignment see alignment procedure in Section 4 10 e Inspect wheel end play Placing one hand at the 9 o clock position and your other hand at the 3 o clock position firmly grab the wheel and push and pull it a few times There should be no discernable movement in and out and the wheel should rotate freely If you feel there is too much movement in and out or if the wheel does not rotate freely a detailed inspection should be performed See Sections 7 0 amp 8 0 for appropriate axle assembly drawings e Throughout the day inspect wheel temperature If extremely hot this could indicate bearing adjustment is too tight For adjustment information see Section 7 0 amp 8 0 for appropriate axle assembly drawings e f your vehicle is equipped with DMF two piece wheels check the bolt torque indicators the tabs around each bolt to ensure that they have not moved If torque indicators are missing or damaged please contact DMF for replacements If torque indicators have moved you must check bolt torque see Section 5 4 for additional information 3 1 2 Weekly Perform standard daily inspection points as listed above and then check the following e Grease and lubricate all grease fittings on front and rear Railgear and guide wheel assemblies NOTE There are six 6 locations on front assembly and fourteen 14 locations on rear assembly Stub axles will have an addition 2 grease fittings in the axle sleeve
46. 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 RA number 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 FOR ALL STRUC TURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL GRADE 8 BOLTS MUST BE USED WHEN ONCE SPRING BRAC KET IS FINALLY SET WHERE SHIELD MIG WIRE SHOULD BE USED MOUNTING FRAME EXTENSIONS TO TRUCK FRAME CLEARANCE ALLOWS LEAVE 1 OF THREADED ROD SPACER TOP RUBBER SPAC ER MUST EXPOSED ABOVE NUT 2 THREAD MIN BE DIRECTLY ON TOP OF DO NOTATTIACH THE
47. on the front axle See Drawing in Section 3 2 for details e Check level of hydraulic oil and all other fluids e Check air pressure in tires and inflate to proper inflation pressure if necessary e Inspect brakes and adjust if necessary Refer to Section 5 3 6 amp 5 3 7 e Brake Testing Operate the vehicle on a test track With the on off toggle valve on and the ball valve s open check that 1 When the vehicle brake pedal is depressed the guide wheel brakes clamp the Rail wheel enough to begin slowing its rotation but not enough to totally lock the Rail 3 2 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 Wheel The Rail Wheels should not be allowed to lock up since that will cause a flat spot on the wheel due to the sliding action on the rail 2 The brakes properly release when the brake pedal is released If brakes do not function properly contact a Service Representative at DMF 3 1 3 Bi annually Perform standard daily and weekly inspection points as listed above and then check the following e Remove the hubcaps from the Rail wheels 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 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
48. section 5 1 If multiple spacers are used remember to weld spacers to one another METHOD 2 Note Method 2 distributes the vehicles rear axle s weight s equally over all rear axles including the Railgear 1 If truck scales are available weigh the vehicle s rear axle if tandem weigh both 2 With front and rear Railgear in the rail position add or remove shims until rear Railgear axle weight is distributed equally between rear truck axle amp Railgear If truck has tandem axle the weight should be equally distributed over all 3 axles tandem amp railgear axle 1 3 1 3 1 3 3 Once weight is equally distributed then raise Railgear to the highway position 4 Re tighten the rear mounting bracket bolts to 154 ft Ib torque and re weld the mounting plates and shims to the bracket per rear install detail in section 5 1 If have multiple spacers remember to weld spacers to one another INSPECTOR DATE SPECIFICATION SPECIFICATION FRONT REAR GUIDE GUIDE WHEELS WHEELS INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE Note Install shims on both pivot arms per side of truck not just outboard Frame Set OK Frame Too High Frame Too Low A n2 UPDATED AS PER 1630 MANUAL CHANGES A 9 14 09 UPDATED AS PER 1630 MANUAL CHANGES DATE DESCRIPTION TOLERANCES TITLE UNLESS SPECIFIED COMMON SENSE PREVALE ALIGNMENT PROCEDURE amp TEAR SHEET FRAC OTHER tnos amp TRACTION ADJUS
49. the handle facing forward and weld in place If this is not possible mount Valve Assembly in the most appropriate and easily accessible location 4 5 4 Bridge Kit Information In some instances the frame rails are wider than normal to clear vehicle components such as the radiator When this occurs the frame rail is too wide and the cross tube falls in between the frame rails and a bridge kit is needed There are two different types of bridge kits below frame rails Figure 4 5 4 A and between frame rails Figure 4 5 4 B If the correct front mounting pin height can be achieved with a heavy walled square tube below the frame rail as shown in Figure 4 5 4 A that is recommended However if the correct front mounting pin height cannot be achieved because the below frame rail bridge will cause the front mounting pin to be too low it is recommended to use a between the frame rail bridge with gussets Figure 4 5 4 B 2015 DMF Inc All Rights Reserved 4 15 DIVERSIFIED METAL FABRICATORS INC RW 1630 FRAME RAIL BRIDGE TUBE CROSS TUBE 25 1 2 12 3 4 REAR MOUNTING PIN FRONT MOUNTING PIN Figure 4 5 4 A Below Frame Rail Bridge Kit 416 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 FRAME RAIL BRIDGE GUSSET BRIDGE TUBE
50. to slide the front Installation Rails into place under the Rail Wheels Because the Railgear Axle assembly is not fixed to the Pivot Arms outside pivot arms will be completely welded to at final weld out 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 Railgear components in the right position The possible configurations are Without Brakes If the Railgear is not supplied with any brakes the Steering Wheel Locks must be aligned When the front Railgear is in the rail position these Steering Wheel Locks prevent the front truck wheels from interfering with the Railgear operation With Cobra Brakes If the Railgear is supplied with Cobra Brakes factory installed then they need to be rotated around so that they are oriented in the correct position see Section 5 3 1 For the rest of the brake installation see Section 5 3 With the Axle Tubes now centered and brake configuration determined the Axle Tubes should be temporarily tacked at final adjustment the tacks can be ground off and the axle re 2015 DMF Inc All Rights Reserved 4 23 DIVERSIFIED METAL FABRICATORS INC RW 1630 adjusted if necessary Se
51. unit tank e Rail test for proper traction and adjust as appropriate see Section 4 10 e Rail test for proper braking and adjust as appropriate see Section 5 3 e Check Railgear alignment see Section 4 10 3 1 4 Annual Maintenance or as required In addition to the items listed in 3 1 1 Daily Maintenance 3 1 2 Weekly Maintenance and 3 1 3 Bi annual Maintenance perform the following Disassemble inspect repack and reassemble Rail Wheel Bearings as shown in Sections 7 0 amp 8 0 3 2 Lubrication Specification Hydraulic Oil e ASTM D6158 HM Unax RX 46 Hydraulic Oil Shell Tellus EE 46 or equal OR e Some customers operate on Dexron ATF Wheel Bearing Grease Grease Fittings e Factory Standard Citgo Syndurance Premium Synthetic 460 2 e Warm Climates Mystik T 6 Hi Temp Multi Purpose Grease 2 or equivalent 2015 DMF Inc All Rights Reserved 3 3 ITEM GREASE PLCS DESCRIPTION UNDER CAB RAILGEAR j 1 A 4 FRONT PIVOT ARM PIVOT PINS CENTER OF THE PIN HEAD 1 4 FRONT CYLINDER ROD CROSS TUES 1 4 UPPER CYLINDER ROD CROSS TUBES 2 B j 2 rmwrcumoR roo cross uses 5 2 4 PNOT ARM cross TUBES UPPER amp Lower 2 4 LOWER CYLINDER ROD CROSS TUBES 8 3 c 2 REAR BRACKET UPPER PIN CROSS TUBES s c 2 REAR BRACKET UPPER PN cross tuses 51 2 men BRACKET UPPER PIN CROSS TUBES
52. white lead are applied 12 2999 ADDED RECOMMENDED TORQUE CHART D ultiply the torque values in charts by 0 90 The use of Loctite does not affect the DESCRIPTION BY APP values in charts All values in Foot Pounds FTLB Multiply by 12 for Inch Pounds PO Rr DUIS ii ib pe ig OTHER FASTENER TORQUE SPECIFICATION C Flat washers of equal strength must be used x D Bolt manufacturer s specs should be used when available k 2000 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 E Plated values in charts are for Cadmium Multiply by 1 87 for Zinc ANGUUR l T DATE DRAWING NUMBER REV F Never re use a highly stressed torqued fastener IT MAY FAIL READS 06 02 94 Ty PPoo6 A MATCHING HEX NUTS DIVERSIFIED METAL FABRICATORS INC RW 1630 4 1 5 Welding Information Dual Shield Wire spec gt AWS E71T 1 Low Hydrogen spec gt AWS E 7018 Low Hydrogen Electrodes AWS E 7018 Manufacturer Equivalent Rod Air Products AP 7018 7018IP Airco 7018C 7018 A1 Arcos Ductilend 70 Air Products 170 LA SW 47 616 Chemtron 170 LA SW 47 616 Hobart 718 718 SR Marquette 7018 McKay Co 7018 Reid Avery 7018 Uniblaze 7018 Westinghouse Wiz 18 Lincoln Jetweld LH 70 Table 4 1 5 Manufacturer Equivalent Welding Rod 4 2 INITIAL INSTRUCTIONS 4 2 1 Work Area The area in which the Railgear ins
53. 0111 X SHORT LINKS Note Links are sold individually unless you want a lull set of all 8 Please refer to full set p n s shown below The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same for x short links no matter what pin off option you have MANUAL XSHORT P N 819220 X SHORT SLOTTED LINKS 818661 Truck Front 81 662 lt Truck Rear 818661 818666 Truck Front bs Truck Rear AIR REMOTE XSHORT SLOTTED AIR REMOTE XSHORT P N 819225 P N 819224 Truck Front i Truck Rear CABLE REMOTE XSHORT SLOTTED P N 819223 CABLE REMOTE XSHORT P N 819221 X SHORT STANDARD amp SLO TIED LINKS DIVERSIFIED METAL FABRIC ATO RSINC 404 875 1512 DRAWING NUMBER M1630107 818670 Truck Front per Truck Rear 818285 Truck Front is Truck Rear Note Links are sold individually unless you want a full set of all 8 Please refer to full set p n s shown below The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same for short links no matter what pin off option you have MANUAL SHORT SLOTTED MANUAL SHORT i PIN 319202 P N 819200 SHORT SLOTTED LINKS 818264 818243 Truck Front Truck Front k Truck Rear AIR REMOTE SHORT AIR REMOTE
54. 0123 12 1 11 241016 WAS 241013 JDI REV DATE DESCRIPTION BY APP TOLERANCES UNLESS SPEC IFIED REAR EXTRA SHORTL VLV CYLINDER ASSEMBLY FAC OHER RW 1630 50 3 1 2 BORE X 2 ROD DRIVER SIDE 063 020 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 SEE PPO08 FOR CYLINDER DATE DRAWING NUMBER ASSEMBLY amp TEST PROCEDURE Teos 9 11 09 241304 240125 SEAL KIT SEAL KIT INCLUDES ITEMI s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER WITH FITTINGS POINTED TOWARDS YOU AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE ACTUAL FITTING ON THE BASE END SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE IF THE BASE FITTING IS TO THE RIGHT THEN IT IS A iP nbi SIDE CYLINDER PS PART 240100 F THE BASE FITTING IS TO THE LEFT THEN IT IS A DRIVER SIDE CYLINDER DS PART 240099 OG 0 ENS SS S Z 2 WK Y NS 2 NG 00 I 6 3 16 ROD END BASE END BASE END ROD END PORT PORT PORT PORT DETAIL DETAIL P N 240100 P N 240099 PASSENGER S SIDE DRIVER S SIDE 1 240101 1 PISTON 4 1 2 2 2400102 1 GLAND 4
55. 04JIC SWIVEL TO RAILGEAR CYLINDERS CUSTOMER IS RESPONSIBLE FOR ALL OTHER SYSTEM FITTING TEE 1 4 NPT x 04 JIC x 04 JIC HYD CYL HOSES 38 qty 4 04 wi 04JIC SWIVEL COMPONENTS TANK DIVERTER PTO PUMP FILTER PRESSURE RELIEF VALVE ETC 5 810310 6 FITTING ELBOW 1 2 MPT x 04 JIC HYD CYL HOSES 62 qty 4 04 w 04JIC SWIVEL NOTE ON THE FRONT VALVE THE RELIEF SETTING MAY BE LOCATED IN DIFFERENT LOCATIONS DEPENDING ON THE MANUFACTURING BRAND ALL ELSE REMAINS THE SAME WE SHOW THE TWO MOST COMMON LOCATIONS BELOW FOR THE RELIEF SETTING ISOMETRIC VIEW OF FRONT VALVE ASSY UN ENDS CYLINDER BLIND ENDS FROM DIVERTER INLET RELIEF SETTING 2500 psi MAX VALVE ASSY FRONT VALVE NOTE DEPENDING ON DIRECTION OF HANDLE UP DOWN YOU MUST RE PLUMB YOUR HOSES OPPOSITE FROM ABOVE SEE DIAGRAM BELOW EROM FRONT VALVE ASSY OUT PORT PULL TO RAISE PUSH TO LOWER PLUMBING FOR REVERSED HANDLE ONLY ISOMETRIC VIEW OF FRONT VALVE ASSY 9 2 FROM DIVERTER INLET CYLINDER BLIND ENDS CYLINDER ROD ENDS RELIEF SETTING 2500 psi MAX REAR VALVE TO FRONT VALVE ASSY IN PORT RELIEF SETTING 2500 psi MAX FRONT VALVE ASSY IF HANDLE REVERSED FRONT VALVE PLUMBING erone MUST BE REVERSED e 810204 EFJ 4 X 8 MORB 90 DEG ELBOW 6801 0403 NWOFG 7 e 610214 Er VALVEHANDLE REPLACEMENT wUNK
56. 1630 50 DRIVER SIDE REAR LOCKING VALVE CYLINDER ASSEMBLY 6 5 6 4 RW 1630 50 PASSENGER SIDE REAR LOCKING VALVE CYLINDER ASSEMBLY 6 6 6 5 RW 1630 DRIVER SIDE REAR LOCKING VALVE CYLINDER EXTRA SHORT 6 7 6 6 RW 1630 PASSENGER SIDE REAR LOCKING VALVE CYLINDER EXTRA SHORT 6 8 6 7 RW 1630 FRONT HYDRAULIC CYLINDER ASSEMBLY 6 9 6 8 CYLINDER ASSEMBLY PROCEDURES 6 10 6 9 JIC FITTING 6 11 6 10 O RING FITTING INSTALLATION 6 12 6 11 PIPE FITTING INSTALLATION 6 13 2015 DMF Inc All Rights Reserved 6 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 6 1 HYDRAULIC SYSTEM NOTE DMF only provides hydraulic hoses from front and rear control valves to Railgear cylinders Customer is responsible for all other system components tank diverter PTO pump filter pressure relief valve etc 6 1 1 New Hydraulic System for Vehicle without Hydraulic System If only DMF Railgear is to be installed and there is not an existing hydraulic system outfit the truck with a 5 to 7 GPM 2500 psi pump suction filter such as a Vickers OFSS 10 with an appropriate sized reservoir The tank should have a minimum of 1 one suction port
57. 4 Two Piece Wheels 5 14 HYDRAULIC SYSTEM 6 1 Hydraulic System 6 2 6 2 Valve Assemblies and Hydrualic Schematic 6 4 6 3 RW 1630 50 Driver Side Rear Locking Valve Cylinder Assembly doces a E uto TERN n 6 5 6 4 RW 1630 50 Passenger Side Rear Locking Valve Cylinder Assembly 6 6 6 5 RW 1630 Rear Locking Valve Cylinder Extra Short B cR DC aqa Sau 6 7 6 6 RW 1630 Front Hydraulic Cylinder Assembly 6 8 6 7 Cylinder Assembly Procedures 6 9 2015 DMF Inc All Rights Reserved RW 1630 DIVERSIFIED METAL FABRICATORS INC RW 1630 6 8 JIC Fitting Installation 6 10 6 9 O Ring Fitting Installation 6 11 6 10 Pipe Fitting Installation 6 12 SECTION 7 0 REAR RAILGEAR PARTS 7 1 Before Ordering Parts Rear Railgear 7 2 7 2 Rear Parts Detail Drawing 7 4 7 3 RW 1630 Pin Off Orientation 7 5 7 4 Link Dimensions 7 6 7 5 Extra Short 2 2 7 7 TOSNO LINKS osare au aaa ERU IER 7 8 kong INKS iis u eea aE Er ai 7 9 7 8 RW 1630 Wheel amp Rear Axle Assembly Detail
58. 5 1 VALVE TOGGLE AIR VEO32037 4 818486 1 LEGEND PLATE ON OFF FOR TOGGLE AIR VALVE 5 818488 2 VALVE BRASS BALL 3 8 PBV500P 6 6 818498 4 FHTING NIPPLE 215 6 7 818489 2 REGULATOR AIR MIDLAND KN31070 8 818490 2 VALVE AIR RELAY MIDLAND KN28500 9 818492 1 HOSE AIR LINE FRONT LH w SPRING GUARD 06906 x 62 10 818494 1 HOSE AIR LINE FRONT RH w SPRING GUARD 06906 x 75 11 818496 2 HOSE AIR LINE REAR 06906 x 59 12 818497 2 FITTING STRAIGHT 0104 6 6 SAE 13 818499 6 FITTING 900 2104 6 6 14 818458 1 AIR BRAKE CHAMBER FRONT DRIVER S SIDE 15 818459 1 AIR BRAKE CHAMBER FRONT PASSENGER S SIDE Note Items 5 6 7 8 amp 13 shipped assembled Front Kit p n 818413 CONTROL CIRCUIT FRONT AXLE FROM VEHICLE AIR BRAKE item 1 p n 818483 only qty 1 included w front brakes KIT 818437 KIT 818437 OPTIONAL MOUNTING KIT 818413 FRONT INCLUDE ITEMS 5 6 7 8 amp 13 KIT 818415 REAR INCLUDE ITEMS 5 6 7 8 amp 13 KIT 818437 INCLUDE ITEMS KIT 818438 INCLUDE ITEMS KIT 818441 INCLUDE ITEMS 2 3 4 22 23 24 25 amp 26 18 20 2x amp 21 2x 19 20 2x amp 21 2x KIT 818441 PART QTY 16 818460 1 AR BRAKE CHAMBER REAR DRIVER S SDE 17 818461 1 AR BRAKE CHAMBER REAR
59. 650 800261 INSULATOR KIT W BOLTS amp NUTS 820479 RW 1650 AXLE HD 4 X 64 BOLTS amp NUTKIT 820539 HUBCAP 1650 7 B C FLAT NOTE SPECIAL PROFILE WHEELS PLEASE CALL 800131 820401 820441 WHEEL BEARING GREASE Factory Standard Citgo Syndurance Premium Synthetic 460 2 Warm Climates Mystik J T 6 Hi Temp Multi Purpose Grease 2 or equivalent m oun sull o NIHIN SNN 3 RW 1650 2 PC WHEEL OPTION SEE RAILGEAR OPTIONS SECTION OF MANUAL FOR DETAILS amp CARE FOR 2 PC WHEELS 5 8 11 X 4 GRADE 8 BOLTS MUSTONLY USE ONCE P N 820496 2 PC INSULATED 1650 WHEEL W RACES REPLACES ITEMS 4 amp 5 BELOW KEEP ALL O THER PARTS MUSTBE HARDENED WASHER MUSTONLY USE ONCE TORQUE TO 120 FF LBS 5 8 11 TYPE C PREVAILING TORQUE NUT MUSTONLY USE ONCE DECAL 800300 APPLY TO HUCAP COVER WHEN USING 2 PC WHEEL AXLE SADDLE PART OF TUBE WELDMENT P N 800300 DECAL 2 PC WHL INSPECTION P N 800301 KIT 2 PC WHL TORQUE INDICATORS BRAKE SADDLES NEVER RE USE PREVIOUSLY BENT TABS EEL ASSEMBLY PROC EDURE J PACK ALL BEARING S COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB PLACE WHEEL ON AXLE FILL CAVITY BETWEEN BEARING S AND AROUND AXLE UN
60. 74 DRIVER SIDE INNER PASSENGER SIDE INNER DRIVER SIDE OUTER PASSENGER SIDE OUTER 808178 PASSENGER SIDE INNER 808179 DRIVER SIDE INNER 818196 DRIVER SIDE OUTER 818197 PASSENGER SIDE OUTER 818198 INNER 808146 SET SNUB NOSE LONG ARM 808117 PASSENGER SIDE OUTER 808118 DRIVER SIDE OUTER 808152 PASSENGER SIDE INNER 808153 DRIVER SIDE INNER 808154 INNER OUTER SET INNER LONG ARM 08 VOLVO VHD64B 808183 PASSENGER SIDE INNER 808184 DRIVER SIDE INNER XTRA CLEARANCE EXT NOTCHED INNER ONLY 808186 LH ASSY 808187 RH ASSY USED WITH PIVOT ARMS 810066 amp 810067 EXTENDED CARGO ARM STERLING W O FRAME EXT NOTE IF ORDERING DRIVER S SIDE OUTER ARM MUST HAVE SERIAL FOR A REPLACEMENT SERIAL TAG LONG ARM WILL SHIP WITH TAG ATTACHED A 116 12 AN 5 26 11 REV DATE UPDATED EXTCARGO ARM ADDED NOTES FOR T 800 CARGO LONG ARM AND EXTCARGO ARM ADDED PART 5 FOR EXTENDED CARGO ARM DESCRIPTION TE CES JUNLESSPECTES VARIOUS RW 1630 LONG ARMS DIVERSIFIED METAL FABRICA TORSINC 404 875 1512 DATE DRAWING NUMBER 3 16 10 M1630116 ITEM N0 PART NUMBER DESCRIPTION rg Wheel Bearing Grease 300100 vt DE CONE MENA 3 1800102 12 CR 39954 T WH WH SY NON INSUIA RW 0 ANDER 11 1818104 2 12 INNER PIVOT ARM 1 15 UTER POT A
61. 819511 33 5 8 WAS 34 5 8 JDI 3 8 FILLET WELD OTHER PLACES TYP EN REVISED REFERENCE TOLERANC ES TLE REAR MOUNTING 10 3 4 FORMED BRACKETASSY mac ome un RW 1630 3 4 HEAVY DUTY PLATE X 063 p 7 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SZES DRAWING NUMBER ANGULAR 9 TREADS o 4 29 10 1630118 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 7 16 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 8 0 FRONT RAILGEAR PARTS 8 1 BEFORE ORDERING PARTS FRONT RAILGEAR 8 2 8 2 FRONT PARTS DETAIL 8 3 8 3 LONG ARM VARIATIONS 8 4 8 4 RW 1630 WHEEL amp FRONT AXLE ASSEMBLY 8 5 8 5 RW 1630 STUB AXLE ASSEMBLY FRONT DOUBLE INSULATED 8 6 8 6 RW 1630 UNDER CAB FRONT RAI LGEAR 55 8 7 8 7 RW 1650 BEHIND CAB FRONT RAI LGEAR ASSEMBLY 8 8 8 8 RW 1630 MOUNTING TUBE VARIATIONS 8 9 8 9 RW 1630 SPRING HANGER VARIATIONS 8 10 2015 DMF Inc All R
62. ACER S IF REQUIRED J REAR UPPER MOUNTING PINS D REAR HYDRAULIC VALVE ASSEMBLY K REAR LOWER MOUNTING PINS E REAR UPPER LINKS 4 L REAR CYLINDER PINS F REAR LOWER LINKS 4 M REAR BRACKET SHIM S PLATE G REAR LIFT CYLINDERS 2 N SIDE PLATE Figure 1 3 1 Rear Railgear Components For parts drawings see Section 7 0 and for installation instructions see Section 4 0 2015 DMF Inc All Rights Reserved 1 5 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 1 6 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 2 0 OPERATIONS 2 1 BEFORE YOU OPERATE THE RAILGEAR 2 2 2 1 1 Familiarize Yourself with the HH 2 2 2 1 2 expen x dixe ERR E 2 2 2 2 ANTI LOCK BRAKE SYSTEM ABS 2 3 2 2 1 Trucks Equipped with 5 05000 2 3 2 2 2 Rail Operation of Trucks with ABS r 2 3 2 3 HIGHWAY 2 4 2 4 GETTING ON THE RAIL 2 4 2 4 1 Getting onto the 00005 001 messen seen mese 2 4 2 4 2 Lower Rear Guide 10
63. C FITTING INSTALLATION TOLERANCES UNLESS SPECIFIED COMMON SENSE PREVAILS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 20 OR oot 005 ANGULAR T DRAWN BY APPD BY DATE DRAWING NUMBER REV BREAK SHARP EDGES mH DX CD s joa MM a TITLE SAE O Ring Fitting Installation PURPOSE To Establish Production Methods For The Installation Of O Ring Medium And High Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 4000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With O Ring Seals And SAE Straight Threads PROCEDURE A Inspect to ensure that both mating parts are free of burrs nicks scratches or any foreign particles B Lubricate O Ring with light coat of system fluid or compatible oil C For adjustable fittings back off lock nut as far as possible Make sure back up washer is not loose and is pushed up to nut D Screw fitting into port until finger tight Back up washer adjustable or hex face non adj should contact port face Light wrenching may be necessary E To align an adjustable fitting unscrew by desired amount but not more than one full turn Use wrench to hold in position Screw nut down to port face until finger tight F Tighten lock nut adjustable or fitting non adj the indicated Flats From Finger Tight F F F T in either the Adjustable char
64. CH IS USUALLY DONE TO ACCOMMODATE THE CLEARANCE ISSUES WHEN INSTALLING AIR REMOTE PIN OFFS IE THE DRIVER S SIDE CYLINDER IS ACTUALLY ON THE PASSENGER S SIDE OF THE VEHICLE amp SHOULD BE ORDERED AS THE DRIVER S SIDE THE REVERSE APPLIES FOR THE OTHER SIDE OF THE VEHICLE NOTE ALL OTHER REAR PARTS ARE NOT DS DRIVER SIDE OR PS PASSENGER SIDE SPECIFIC PLEASE NOTE THAT IF YOU HAVE INSULATED RAILGEAR amp YOU MOUNT THE GEAR BACKWARDS YOU MUST SWAP THE WHEELS INSULATED WHEEL SHOULD ALWAYS BE ON THE ACTUAL DRIVER S SIDE OF THE TRUCK PASSENGER SIDE OF TRUCK PIN OFFS TO FRONT OF TRUCK DRIVER SIDE OF RAILGEAR TRUCK REAR CORRECTRAILG EAR ORIENTATION DESCRIPTION TLE RANCES UNLESS SPECIFIED FRAC MACTE _ PIN OFFS TO FRONT REAR OF TRUCK FRAC OTHER x p E DIVERSIFIED METAL FABRICATORS INC 404 875 1512 B DRAWING NUMBER M1630110 SLOTTED 11 75 X SHORT STANDARD SHORT sP DESCRIPTION BY APP NOTE DMF LINKS COME IN 3 SIZES X SHO RT SID SHO RT amp LONG eee m in RW 1630 50 REAR LINK OPTIONS amp DIMENSIONS THE SIZES CAN NO T BE MIXED BETWEEN UPPER amp LOWER LINKS d es o EXAMPLE LONG UPPER LINK CAN ONLY BE USED WITH LONG LOWER mens m T RNC NUS LINK EACH LINK HAS A SLOTTED VERSION dc 9 18 09 163
65. CK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 240208 O RING GLAND 2 338 240209 BACKUP RING GLAND 8 338 240255 WELD ASSY 3 1 2 TUBE SAE PORT LOCKING VALVE RR RH 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 NPT STRAIGHT 240258 90 DEGREE ELBOW 4 MJIC x 3 SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 DMF P N 240225 SEAL KIT TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO BASE OF CYLINDER IF THE TUBES ARE FACING YOU SR CLOSEST TO YOU THEN IT IS A DRIVER SIDE CYLINDER DS PART 240232 IF THE TUBES ARE FACING AWAY FROM YOU THEN IT IS PASSENGER SIDE CYLINDER PS PART 240231 SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE o o o s o m o N x Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123 A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP
66. COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE Must be hardened C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING P Must on D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB y 5 8 11 Type C prevailing Torque Nut E PLACE WHEEL ON AXLE f J Must only use once 2 pc wheel uses F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE 1650 hubcap 820441 G INSERT BEARING OUTBOARD SIDE OF WHEEL Decal 800300 H INSTALL INNER WHEEL NUT ITEM 5 ppb ADJUST BEARING 1 when using 2 wheel 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft lb 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS P N 820494 2 INSULATED A PROPERLY ADJUSTED WHEEL Torque to 120 ft Ibs 1630 WHEEL W RACES REPLACES ITEMS WILL SPIN FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 4 amp 12 ABOVE KEEP ALL OTHER PARTS PN DECAL 2 WHE INSPECTION 6 REPEAT IF
67. DING ON TRUCK SPECS LONG ARMS VARY DEPENDING ON TRUCK REV DATE DESCRIPTION BY p TE JUNLESSPECTES RW 1630 FRONT EAR ASSEMBLY FRAC HACE FRAC OHER x Drawing is for illustrative purposes Your 1 993 DRAWING NUMBER parts may not be exactly as pictured M1630136 P N 808119 REPLACED BY P N 808151 808120 PASSENGER SIDE INNER OBSOLETE 808121 DRIVER SIDE INNER OBSOLETE REPLACED BY P N s 808152 amp 153 EXTENDED LONG ARM 808140 DRIVER SIDE OUTER 808141 PASSENGER SIDE OUTER 808142 DRIVER SIDE INNER 808143 PASSENGER SIDE INNER 808144 SET SHORT EXTENDED LONG ARM 808160 INNER 808164 DRIVER SIDE OUTER 808165 PASSENGER SIDE OUTER USED WITH PIVOT ARMS 810066 amp 810067 LONG ARM KENWORTH T 800 REPLACED BY P N 808151 808136 PASSENGER SIDE INNER 808137 DRIVER SIDE INNER 808133 SET 808117 118 136 amp 137 EXT LONG ARM NOTCHED FOR 2 FREIGHTLINER 818117 PASSENGER SIDE OUTER 818118 DRIVER SIDE OUTER 818119 INNER 808145 SET STANDARD LONG ARM 810144 FRONT DETAIL CARGO ARM USED WITH PIVOT ARMS 810066 amp 810067 CARGO LONG ARM 808157 808158 808159 808161 PASSENGER SIDE OUTER DRIVER SIDE OUTER PASSENGER SIDE INNER DRIVER SIDE INNER EXTRA CLEARANCE EXTENDED LONG ARM LONG ARM 08VWCONST BZL 808171 808172 808173 8081
68. DIVERSIFIED METAL FABRICATORS INC Parts amp Service Manual RW 1630 amp RW 1630 50 ATLANTA March 2015 SERIAL NUMBER FRONT SERIAL NUMBER REAR NOTE Please refer to the serial numbers when ordering parts or inquiring about warranty items This manual applies to both DMF s RW 1630 Railgear and DMF s higher capacity RW 1630 50 Railgear including all configurations standard behind cab and under cab 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 infogdmfatlanta com http www dmfatlanta com DIVERSIFIED METAL FABRICATORS INC RW 1630 Message from DMF No matter what your job function is Operation Installation Maintenance or Repair it is your responsibility to familiarize yourself with the entire manual Once you have read the entire manual there are some specific sections that you will want to pay special attention to depending on your role For purposes of this manual we will refer to RW 1630 when discussing either RW 1630 or RW1630 50 and we will explicitly call out any differences when appropriate If you find anything missing incorrect or unclear in this manual please contact us We are always trying to improve our manuals Manuals service bulletins and general information are available on our we
69. E WELDED IN RAIL POSITION SLEEVE MUST BE FULLY WELDED IN THE OPENING S ON BOTH SIDES OF THE SLEEVE ONCE FINAL ALIGNMENTAND WEIG HTS ARE SET Figure 4 12 B Stub Axle Final Weld out e Fully weld on all sides front mounting blocks cross tubes to truck frame e fshims were required fully weld shims into place on all sides for each shim location Rear Railgear e Weld 4 hole mounting plate to rear frame bracket as shown in figure 4 12 C 4 HOLE MOUNTING PLATE ONCE FINAL ALIG NM ENT amp WEIG HTS ARE SET 2 WELD ATTOP CENTER 5 8 11 GRADE 5 ENSURE NUTS amp BO LTS SECURELY FASTENED TO 154 LE FT Figure 4 12 C Mounting Plate Weld Off e Ensure all spacers are firmly against side bracket and aligned with the rear mounting bracket then fully weld spacer to mounting bracket as shown in figure 4 12 D e f multiple spacers are used spacers must be fully welded to one another on the rear and tack welded on the sides as shown in figure 4 12 D 2015 DMF Inc All Rights Reserved 4 35 DIVERSIFIED METAL FABRICATORS INC RW 1630 TACK WELD REAR FRAME BRACKET ENSURE ALL SPACERS ARE FIRM LY AGAINST SIDE BRACKET OR SHIMS amp ALIGNED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO MOUNTING BRACKETAS SHOWN IF MULTIPLE SPAC ERS ARE USED SPAC ERS NEED TO BE WELDED TO ONE ANOTHER AT THE REAR amp TACKED ON THE SIDES IF PO SSIBLE Figure 4 12 D Welding of
70. ER ASSEMBLY 4 1 2 WHEEL amp AXLE ASSY w COBRA AIR BRAKES COBRA AIR BRAKE ASSEMBLY DRIVER S SIDE COBRA AIR BRAKE ASSEMBLY PASSENGER S SIDE NUT SLOTTED HEX 1 8 NUT SLOTTED HEX 1 1 4 7 COTTER 3 16 x 2 COTTER PIN 1 4 x 2 1 2 AIR REMOTE PIN OFF ASSEMBLY SEE PAGE 16 UNDER CAB AXLE ASSEMBLY ONLY NON INSULATED WITH BRAKES 110510 INSULATED WITH BRAKES 110513 SEE DRAWING M1630102 amp M1630103 IN SECTON 5 FOR AXLE amp WHEEL ASSEMBLY PARTS 1 tooo 4 2 5 7 1 2 FRAC MACH g FRAC OTHER x xx XXX OR DESCRIPTION PIN ASSEMBLY HOUSING PIN ASSEMBLY ROD END PIN ASSEMBLY CYLINDER TUBE END SPRING CENTURY DM0376 BOLT SPRING 1 8x 9 Gr8 NUT SPRING 1 8 TYPE C BOLT FRAME MOUNTING 5 8 11 x 2 1 2 Gr5 NUT FRAME MOUNTING 5 8 11 TYPE C LOCK WASHER FRAME MOUNTING 5 8 PLATE FRAME BACKING FRAME BOX ASSEMBLY DRIVER S SIDE FRAME BOX ASSEMBLY PASSENGER S SIDE DESCRIPTION TITLE RW 1630 UNDER CAB FRONT RAILGEAR ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES to hs E ANGULAR e DRAWN BY APPD BY DATE SURF FINISH 125 MICRO THREADS KLC 10 09 01 DRAWING NUMBER UC110005 15 108200 1 RW 1650 BEHIND NON INSULATED AXLE ASSEMBLY 108231 1 BC FRONT AXLE TUBE WELDMENT ASSEMBLY 820401 1 Rw 1650 AXLE 4 X 64 AXLE ONLY 16 108262 12 MOUNTING BOLTS 5 8 11 x
71. Fastener Size Diameter And Threads Per Inch Select The Appropriate Row In The Chart Selected C Identify Grade Of The Bolt D Identify Whether The Bolt Is Plated Or Plain E Read Across The Size Row And Down The Grade And Plain Or Plated Column The Intersection Of Row And Column Gives Torque FINE THREAD BOLTS COARSE THREAD BOLTS RECOMMENDED TORQUE SAE J429 SAE J429 ASTM A574 FOR GR 8 W SAE J429 SAE J429 ASTM 574 GRADE 5 GRADE 8 ALLOY PREVAILING TORQUE NUT GRADE 5 GRADE 8 ALLOY 8 MARKS 6 MARKS KNURLED OD 3 MARKS 6 MARKS KNURLED OD SIZE RUN PLATED a PLAIN is aa PLAIN DIA TPI FTLB FTLB ea fa ta Ta Ta mem se e P gt gt T gt wa s _ gt Fc 5 F m Emma su m mes e oee m ww m o HAH e 2 um x ZE m mi mk RE pes qe ps eo lt pa epe a e p pe m s pu EON ere es EUN 2 esee v COMMENTS A Ere values specified are for bolts with residual oils or no special lubricants pplied If special lubricants of high stress capacity such as Never Seez 2a d e eo graphite and oil molybdenum disulphite colloidal copper or
72. Figure 5 2 A Figure 5 2 B Figure 5 2 C Figure 5 3 1 Figure 5 3 2 Figure 5 3 3 Figure 5 3 5 A Figure 5 3 5 B Figure 5 3 6 Figure 5 3 8 Figure 5 4 DIVERSIFIED METAL FABRICATORS INC LIST OF FIGURES TABLES Front Railgear Components 1 3 Rear Railgear Components 2 1 5 Railgear Grease Locations 3 4 Bolt Torque Specifications 4 4 Installation RailsS 4 6 Diagram of Key Rear Components 4 8 Location and Clearance of Rear Railgear 4 9 Squaring Rear Railgear 4 11 Rear Mounting Plate Installation 4 12 Tack Welding of Rear Spacer 4 12 Diagram of Key Front Components 4 14 Bolted Joint Cross Section 4 15 Below Frame Rail Bridge Kit 4 16 Between Frame Rail Bridge Kit 4 17 Front Railgear Mounting Dimensions 4 18 Front Railgear Clearance 4 20 Diagram of Key Cargo Arm Components amp Front Mounting Dimensions 4 21 Recommended Tack Location for Standard Front
73. IN OPENING ON DRIVER SIDE SLEEVE FOR FRONT STUB AXLE Figure 4 7 1 B Recommended Tack Location for Front Stub Axle 4 7 2 Final Steps If the Spring Bracket location had to be adjusted make sure that the hex nuts two per stud on both Spring 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 4 5 7 NOTE Remount the truck front bumper or use 8 standard channel welded onto the ends of the Frame Extensions 2015 DMF Inc All Rights Reserved 4 25 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 8 UNDER CAB FRONT UNIT INSTALLATION Part Drawings are available in Section 8 0 NOTE Two factors control the installation of the Under cab front unit A Fuel Tanks and B Motor Transmission PTO Arrangement Read Section 4 8 1 before dismantling any equipment 4 8 1 Under Cab General Information FUEL TANKS 1 Are cab steps part of the tank or tank brackets You can either leave tanks in location or relocate tanks and add new Under Cab steps 2 Can tanks be relocated Do you have room down the frame 3 What is the Ground Clearance under tanks You need a minimum of 13 1 4 under tank and or tank brackets to maintain an 11 Rail wheel G C in Highway mode This can be reduced for fitting under lower tanks but you must contact DMF
74. ING RACE 5 NOTE DRAWING amp PARTNUMBERS ARE APPLICABLE FOR BOTH 1650 AND BEHIND CAB FOR BEHIND CAB AXLE PARIS SEE FRONTRAILGEAR PARIS SECTION OF MANUA JUNLESSPECTES RW 1650 REAR WHEEL amp AXLE ASSY FRAC ACE Fac omen V x M1650103 FINSHED PART NO A DIMENSION 19442 33 1 2 19444 33 5 8 19446 33 3 4 19448 33 7 8 19450 34 19501 34 1 8 19454 34 1 4 19455 34 5 16 19456 34 3 8 19503 34 1 2 9460 34 5 8 19462 34 3 4 19464 34 7 8 19466 35 19468 35 1 8 19469 35 1 4 19471 35 5 8 19487 35 3 4 19484 36 19491 36 1 2 8 8 8 8 8 8 8 8 8 8 81 8 8 8 8 8 8 8 8 8 8 19482 43 1 8 PART NUMBER DESCRIPTION 818225 REAR BRACKET 3 4 CROSS PLATE 818792 12 REAR BRACKET GUSSETT SLOTTED PLATE FORMED 818228 REAR BRACKET CROSS TUBE 2 1 2 X 8 15 16 818235 GREASE FITTING FOR REAR LINKS 1 8 NPT 12 0 REF MUST ORDER CONPLETE BRACKET DIMENSION A SEE TABLE FRAME WIDTH 1 8 HALF A 21 5 REF _ Y 43 0 REF HOLD CENTER TO CENTER 50 0 REF Ls 1 563 REF
75. KT 78 A s 610215 REF VALVE HANDLE REPLACEMENT ASSEMBLY 19 51028 1 VALVE ASSEMBLY FRONT W 30deg FITTINGS VALVE HANDLE REPLACEMENT HANDLE ONLY LOCKING VALVE DPC1 10 P 6T 21 21 600606 REF LOCKING VALVE WI FITTINGS DIVERTER lt 3 i I L i OTHER EQUIPMENT im ee PRESSURE RELIEF VALVE RETURN TO TANK W N TRUCTI FILTER RETURN TO TANK ETURN TO 1 NO OBSTRUCTION OR FILTERS 25 2 a i De TO HYDRAULIC PTO PUMP FILTER O RELIEF SETTING x 1 2000 psi REAR VALVE NOTE DOES NOT HAVE TO BE RE PLUMBED DEPENDING ON foem m DIRECTION OF HANDLES UP DOWN PLUMBING FOR EXTERNAL LOCKING VALVE PLUMBING FOR EXTERNAL LOCKING VALVE WITH T FITTINGS ON FRONT VALVE STD HANDLE W 90deg FITTINGS ON FRONT VALVE STD HANDLE TO FRONT VALVE ASSY IN PORT TO FRONT VALVE ASSY IN PORT f OUT VALVE ASSY VALVE ASSY OR REPLACE T FITTINGS W FROM FRONT VALVE ASSY OUT PORT 90460 FITTINGS FRONT TIRE A TP 5 9 11 CORRECTED SECTION REFERENCE 9 20 10 DELETED P N S 810311 810312 amp 810313 amp ADDED 240258 9 09 09 REVISED SCHEMATIC LAYOUT AND B O M PER AS BUILT NOW SEE SECTION 4 3 OF MANUAL WHICH SPECIFIES HYDRAULIC SYSTEM REQUIREMENTS REVISED BY REMOVING TYPE OF VALVES ENERGY GRESEN LUBRICATION SPECIFICATIONS HYDRAULIC ASTM D6158 HM UNAX RX 46 HYDRAULIC OIL SHELL TELLUS EE 46 OR EQUA
76. L OR SOME CUSTOMERS OPERATE DEXRON ATF DESCRIPTION FRAG MACH EIRA VALVE ASSEMBLIES amp HYDRAULIC SCHEMATIC FRAC OTHER x T Sox OR 10006 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES E ANGULAR DRAWN BY APPD BY DATE DRAWING NUMBER 1 SURF FINISH 125 MICRO KLC 10 07 98 M1630114 VALVE PRESSURE PROTECTION BW103976 SPL PR 4 VALVE BRASS BALL 3 8 5 6 6 818498 4 FITTING NIPPLE 215PN 6 lt gt REGULATOR AIR MIDLAND KN31070 RAIL GEAR AIR BRAKES 818490 2 VALVE AIR RELAY MIDLAND KN28500 9 818492 1 HOSE AIR LINE FRONT LH w SPRING GUARD H06906 x 62 HOSE AIR LINE FRONT RH w SPRING GUARD H06906 x 75 HOSE AIR LINE REAR 06906 x 59 FITTING STRAIGHT 0104 6 6B SAE 13 818499 6 FITTING 909 2104 6 6 AIR BRAKE CHAMBER FRONT DRIVER S SIDE AIR BRAKE CHAMBER FRONT PASSENGER S SIDE Note Items 5 6 7 8 i nn FROM VEHICLE AIR BRAKE CONTROL CIRCUIT uot I amp 15 shipped assembled Front Kit p n 818413 FRONT AXLE Item 1 p n 818483 only qty 1 included w front brakes KIT 818413 FRONT INCLUDE ITEMS 5 6 7 8 amp 13 KIT 818415 REAR INCLUDE ITEMS 5 6 7 8 amp 13 KIT 818437 INCLUDE ITEMS 2 3 4 22 23 24 25 amp 26 KIT 818438 INCLUDE ITEMS 18 20 2x amp 21
77. LANTA GA 800116 SAFETY INSTRUCTIONS Lock front wheels straight ahead for on rail travel 800119 N CAUTION N RELIEF VALVE SETTINGS 2000 PSI FRONT 1500 PSI REAR DO NOT EXCEED 2500 PSI FRONT VALVE DO NOT EXCEED 2000 PSI REAR VALVE DO NOT BOTTOM OUT RELIEFS IF ADJUSTED 800135 INSTRUCTIONS 1 REMOVE SAFETY PINS 2 ACTIVATE VALVE A PUSH RAIL POSITION B PULL HIGHWAY POSITION 3 REPLACE SAFETY PINS IN PROPER LOCATION 800117 die CAREFUL WORKER IS THE HI RAIL VEHICLE COMPLETED BY WITH APPLICATION OF HI RAIL AND FINISHED BODY THIS VEHICLE HAS POUNDS OF AVAILABLE PAYLOAD DATE OF COMPLETION OF HI RAIL EQUIPPED VEHICLE mo yr CAUTION ruis MUTIPURPOSE VEHICLE HAS SPECIAL DESIGN AND EQUIPMENT FEATURES FOR OFF ROAD USE HANDLES DIFFERENTLY FROM AN ORDINARY PASSENGER CAR IN DRIVING CONDITIONS WHICH MAY OCCUR ON STREETS HIGHWAYS AND OFF ROAD WEIGHT AND LOCATIONS OF AVAILABLE PAYLOAD MAY ALSO AFFECT THE HANDLING OF THIS VEHICLE DRIVE WITH CARE AND WEAR SAFTETY BELTS AT ALL TIMES FOR PRECAUTIONS READ THE VEHICLE OWNER S GUIDE AND H RAIL OPERATORS SERVICE AND PARTS MANUAL 800118 DESCRIPTION INSTRUCTION amp SAFETY DECALS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER 40 10 12 98 lt y gt ST1652 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 14 VELCRO STEERING WHEEL LOCK Installation Instructions for The DMF Velcro Steering W
78. LE FRONT AXLE TUBES 1630 ONLY FRONT TUBE W OUT BRAKE SADDLES 818113 FRONT TUBE W BRAKE SADDLES 818114 STUB AXLE TUBE 820600 NOTE PART f S ARE FOR ONE SIDE IF YOU NEED THE WHOLE FRONT e THEN 00 en ORDER QTY 2 OF 818114 1630 amp UNDER CAB WHEELS NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 INNER INSULATOR 820009 e OUTER INSULATOR 820008 INSULATED 2 PIECE 1630 WHEEL w RACES 820494 e INSULATOR KIT W BOLTS amp NUTS 820479 BOLTS amp NUTS KIT 820539 Torque to 120 ft lbs 8 11 Type C prevailing Torque Nut 5 e only use once 9 1630 amp UNDER CAB BEARING RACE TIMKEN 567 RACE BEARING 800100 NOTE SPECIAL PROFILE WHEELS PLEASE CALL UNDER CAB AXLE ASSEMBLY ONLY NON INSULATED WITH BRAKES 110510 INSULATED WITH BRAKES 110513 UNDER CAB AXLE TUBES ONLY FRONT TUBES W BRAKE SADDLES 818114 2 pc wheel uses Decal 800300 1650 hubcap 820441 apply to hubcap cover when using 2 pc wheel e PIN 800300 DECAL 2 PC WHL INSPECTION PIN 800301 KIT 2 WHL TORQUE INDICATORS 1630 amp UNDER FRONT PARTNUMBER 820600 820603 820604 820601 820602 108268 820486 605120 820613 818107 818110 818108 818106 820608 818235 605139 DESCRIPTION AXLE TUBE DETAIL 1630 STUB AXLE INSULATOR TUBE 1630 STUBAXLE BOLTINSULATOR
79. LE ASSEMBLY DETAIL 7 10 7 9 RW 1630 STUB AXLE ASSEMBLY REAR DOUBLE INSULATED 7 11 7 10 RW 1650 WHEEL amp REAR AXLE ASSEMBLY DETAIL 7 12 7 11 RW 1650 STUB AXLE ASSEMBLY REAR DOUBLE INSULATED 7 13 7 12 REAR MOUNTING BRACKET 12 U 7 14 7 13 REAR MOUNTING BRACKET 10 3 4 Q 7 15 2015 DMF Inc All Rights Reserved 7 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 7 1 Before Ordering Parts Rear Railgear Required Information for Ordering Parts e You must have the Railgear serial number when ordering parts This uniquely identifies your Railgear as it was built to your specifications and also allows DMF to help you maintain a history of your Railgear If you are placing a parts order through a maintenance facility please inform them of the serial number so that they can relay the information when placing your order e Returns DMF has a Return Authorization Procedure You must contact DMF for an RA before returning any parts for any reason Parts will not be credited without an RA e Labor In extremely rare situations on a discretionary basis and with prior approval DMF will reimburse certain specific labor costs If you feel this may apply in your situation you must contact DMF s Service Department for a Service Authori
80. MENSION Figure 4 3 9 Mounting Plate Installation 4 3 10 Tack Welding of Spacer TACK WELD REAR FRAME BRAC KET ENSURE ALL SPAC ERS ARE FIRMLY AGAINST SIDE BRAC KET OR 5 5 amp ALIG NED WITH THE REAR MOUNTING BRAC KET TACK WELD SPACER TO MOUNTING BRACKETAS SHO WN IF MULTIPLE SPACERS ARE USED SPAC ERS NEED TO BE TAC K WELDED TO ONE ANOTHER ATTHE REAR amp TACKED ON THE SIDES IF POSSIBLE Figure 4 3 10 Tack Welding of Spacer 4 3 11 Final Rear Railgear Alignment and Weight Settings Rear Railgear alignment and weight settings can only be performed after front Railgear is installed The procedures for these final steps can be found in Section 4 10 412 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 VARYING FRONT RAILGEAR CONFIGURATIONS Due to the numerous variations between chassis DMF has designed several different mounting configurations to supply our customers with the perfect fit for their application These configurations fall into three main categories as listed below Each of these categories though similar requires varying installation procedures Please identify which category pertains to your application and familiarize yourself with the installation procedure prior to beginning 4 4 1 Traditional Long Arm Assembly This style of assembly is the most common and attaches to the front axle by way of a bracket attached to the leaf springs and to the
81. N N P P NINIT IN N ejo APPLY SILICONE BEAD TO EDGE OF SPINDLE BEFORE INSTALLING IN AXLE TUBE BOTH ENDS 2 g gt Do SENI DOSE AXLE TUBE OUTBOARD 2 J c z NOTE 2 ETT APDR NOTE Tl 1 INSTALL ALL INSULATORS ON STUB AXLE BEFORE PRESSING INTO AXLE s s AXLE ASSEMBLY 1630 REAR STUB AXLE 2 CHECK FOR ZERO CONTINUITY AFTER FRAC OTER RW 1630 DBL INSULATED AS 5 E M B LY Xe DIVERSIFIED METAL FABRICATORS INC 404 875 1512 s DATE DRAWING NUMBER 9 20 12 820703 PARTNUMBER 820458 820461 820462 820463 820541 820547 820543 605302 lt DESCRIPTION BOLT INSULATOR 1650 STUB AXLE INSULATOR DISC 1650 STUB AXLE LOCK WASHER 3 4 GRADE8 HEX HEAD CAP SCREW 3 4 10 UNC x5 LONG GRADE 8 AXLE TUBE WELDM ENT 1650 STUB AXLE GEN 2 INSULATOR TUBE 1650 STUB AXLE GEN 2 STUB AXLE DETAIL INSULATED 1650 GEN 2 HHC S 1 4 20 X 1 1 4 NYLON COINS HD OI RWI N P NN IN PP T IN APPLY SILICONE BEAD TO EDGE OF SPINDLE BEFORE INSTALLING IN AXLE TUBE TYP BOTH ENDS NO WELDING ON AXLE TUBE OUTBOARD OF SHUNT BOLT TORQUE BOLTS TO 200 FT LBS A A 6 4 2014 ADDED NOTE JDI REV DATE DESCRIPTION BY APP NOTES T
82. NG 1 1 4 TIE PIN ASSEMBLY PIVOTARM SPACER TUBE TIE PIN 3 4 SCH 40 X 7 WHEEL amp AXLE ASSEMBLY RW 1630 PIVOTARM ASSY PASSENG ER SIDE O UTER ARM RW 1630 PIVOTARM ASSY PASSENGER SIDE INNER ARM SPRING HANGER BRAC KET RUBBER MOUNTING PAD SPRING HANG ER BRAC KETASSEMBLY 818160 SPRING HANG ER BRACKET MOUNTING SPACER BAR 1 RUBBER SPAC ER MUST BE INSTALLED 818158 SPRING HANGER BRAC KET MOUNTING SPACER BAR 1 2 OPTIO NAL BETWEEN SPRING amp TOP FLATBAR SPACER PIN OFFS HYDRAULIC CYLINDER ASSEM BLY FRONTDRIVER S SIDE HYDRAULIC CYLINDER ASSEMBLY FRO NTPASSENG ER S SIDE CROSS TUBE DETAIL FRONT SEE SECTION 5 5 NUT SLOTTED HEX 1 8 COTIER PIN 3 16 X 2 NUT SLOTTED HEX 1 1 2 6 FLATWASHER 1 1 2 COTIER PIN 1 4 X 2 1 2 J CLIP 1 2 DIA FOR AIR BRAKE HOSES QTY 2 EACH SIDE INNER LONG ARM ASSEMBLY OUTER LONG ARM ASSEMBLY 818161 8 HEX NUT 3 4 10 818110 1 RW 1630 PIVOTARM ASSY DRIVER SIDE INNER ARM MOUNTING CROSS TUBES VARY ACCORDING 818107 1 RW 1630 PIVOTARM ASSY DRIVER SIDE O UTER ARM TO TRUCK SPECS 55 6 24 amp 25 ARE COMPONENTS OF ITEM 4 RESPECTIVELY MUSTHAVE SERIAL WHEN ORDERING PARTS PIVOTARMS FOR USE WITH CARGO ARMS 818106 818108 818153 ole e eI S 818127 818128 818134 818136 818137 818487 ESESFSESESESIO SS SPRING HANGER BRACKETS VARY DEPEN
83. OF TUBE 1 ADDED VIEW OE LEGEND PLATE 818754 11 20 01 ITEM 1 WAS P N 818746 amp DELETED ITEM 4 P N 818749 DATE DESCRIPTION gt UNLESS SPECIFIED TITLE COMMON SENSE PREVAILS FRAC MACH 1 32 FRAC OTHER x xx OR XXXX RW 1630UC REMOTE AIR PIN OFF ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 w DRAWN BY APPD BY DATE DRAWING NUMBER 125 MICRO I 2A AND 28 WET 10 22 01 818745 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 9 BEHIND CAB FRONT UNIT INSTALLATION Part Drawings are available in Section 8 0 NOTE Read through the Section 4 9 1 before dismantling any equipment and starting installation Factors that control installation of the behind cab unit are the location of fuel tanks relative to the rear of cab and available open frame space for proper assembly For any questions please contact DMF for assistance 4 9 1 Behind Cab General Information Ideally 36 of open frame behind the cab is required for installation including unobstructed upward movement of the brake chambers to the highway position The leading edge of the frame mounting brackets should be as close to the rear of the cab as practical Establish forward point and mark the truck frame both sides Measure from these marks 29 5 8 bracket length and mark the frame again both sides This is the clear space required to mount the frame brackets if the brakes are located behind the axle In some c
84. OLERANCES 3 1 INSTALL ALL INSULATORS ON STUB aoe TUBE ASSEMBLY INSULATED BO TH ENDS AXLE BEFORE PRESSING INTO AXLE TUBE mico RW 1650 1650 STUB AXLE GEN 2 0 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 pau DRAWING NUMBER EaDs 08 820549 PARTNUMBER DESCRIPTION 1650 REAR AXLE WELDMENT TUBE WIDE W BRAKES 800108 HUBC AP BOLTS HHC S 5 16 18 X 3 4 800109 5 16 LO C K WASHER G RADE 8 WHEEL 1650 WHL ASSY NON INS W RACES 800125 RW 1650 RACE BEARING TIMKEN 6420 800126 RW 1650 BEARING CONE TIMKEN 6466 800127 RW 1650 SEAL STANDARD C R 49928 OR NAT 415725 800130 RW 1650 NUT AXLE EUCLID E 2465 x 4 NS NON INSULATED WITH BRAKES 1650 800213 NON INSULATED NO BRAKES 1650 800214 INSULATED NO BRAKES 1650 800216 INSULATED WITH BRAKES 1650 800227 2 PC WHEEL NO BRAKES 1650 800218 1650 amp BEHIND CAB WHEELS NON INSULATED 1650 WHEEL W RACES 800015 INSULATED 1650 WHEEL W RACES 800016 INNER INSULA TO R 820020 OUTER INSULA TOR 820018 INSULA TED 2 PIEC E 1650 WHEEL W RACES 820496 1650 REAR AXLE TUBES AXLE TUBE WITH BRAKES 818209 A AXLE TUBE NO BRAKES 818210 1650 amp BEHIND BEARING RACE TIMKEN 6420 BEARING RACE 800125 RW 1650 WASHER AXLE TAB EUC LID E 2464 2 PC WHEEL WITH BRAKES 1
85. ONCE BRACKET MOUNTED AND SHIMMED 818221 818240 818250 818257 818255 818256 818248 818289 818194 818258 B W NU S REAR PIN KITS SIANDARD LINKS 818800 SLOTTED LINKS 818801 DRAWING IS FOR ILLUSTRATIVE PURPO SES YO UR PARTS MAY NOTBE EXACTLY AS PICTURED REV DATE DESCRIPTION BY TOLERANCES TLE UNLESS SPEC IFIED RW 1630 REAR RAILG EAR ASSY NON FRAC OER RW 1630 INSULATED MANUAL PIN O FFS 063 050 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SZES DATE DRAWING NUMBER ANGULAR 9 SURF FINISH THREADS 8 6 14 M1630141 TRUCK FRONT DRIVER SIDE OF TRUCK PIN OFFS TO REAR OF TRUCK STANDARD MOUNTING CONFIG PASSENGER SIDE OF TRUCK PASSENGER SIDE OF RAILGEAR DRIVER SIDE OF RAILGEAR TRUCK FRONT DRIVER SIDE OF TRUCK BEFORE ORDERING REAR CYLINDERS LINKS AND OR BRAKES ONLY WHEN ORDERING REAR PARIS IT IS IMPORTANT TO NOTE WHICH WAY THE PIN OFFS ARE FACING IF THEY ARE FACING TOWARD THE REAR OF THE TRUCK THEN THIS IS CONSIDERED OUR STANDARD MOUNTING CONFIGURATION THEN DRIVER S SIDE amp PASSENGER S SIDE TERMINOLOGY IS CONSISTENT WITH THE LAYOUT OF THE VEHICLE HOWEVER IF THE PIN OFFS ARE FACING TOWARD THE FRONT OF THE TRUCK IE UNDERNEATH THE TRUCK WHI
86. ONTROL CIRCUIT SEE DRAWING 818400 FOR REAR BRAKES AND PART NUMBERS FOR OTHER COMPONENTS T I I I I I I I I I I I I lt 7 DESCRIPTION TITLE AIR BRAKE CONTROL KIT FOR BEHIND CAB GEAR DIVERSIFIED METAL FABRICATORS INC 404 875 1512 1 DRAWN BY APPD BY DATE DRAWING NUMBER REV a 28 BJF 7 17 13 Ty 78701 DIVERSIFIED METAL FABRICATORS INC RW 1630 5 3 6 Inspection and Adjustment Inspect and adjust brake shoes per Figure 5 3 6 ADJUST GAP WITH CLEVIS amp JAM NON 2 g 7 1 8 MIN SHOE b THICKNESS DJUST TO 1 16 REPLACE SHOE IF UNABLE TO DJUST TO MAX ALLOWED 1 4 Figure 5 3 6 Brake Inspection and Alignment 5 3 7 Testing Operate the vehicle on a test track With the on off toggle valve on and the ball valve s open check that 1 when the vehicle brake pedal is depressed the guide wheel brakes clamp the Rail wheel enough to begin slowing its rotation but not enough to totally lock the Rail Wheel The Rail Wheels should not be allowed to lock up since that will cause a flat spot on the wheel due to the sliding action on the rail 2 the brakes properly release when the brake pedal
87. OTE If the required ground clearance cannot be achieved the front truck axle may have to be blocked down to provide additional clearance Have this work performed by a professional axle shop that can ensure these changes will not produce unsafe steering geometry or other problems for the vehicle 3 After achieving proper ground clearance swing the front spring bracket into position normal to the front leaf springs and insert the upper pin 4 Weld spacers onto the front spring bracket above or below the leaf springs as shown in figure 4 6 2 This will restrict the amount of vertical travel while still allowing fore and aft travel as the suspension flexes 5 Ensure that the safety pin off pins are removed and actuate the Railgear through its full range of motion to check that there is proper clearance 6 Since the front mounting bracket is no longer pinned to a fixed point on the truck frame a permanent attachment is to be made at the truck axle see figure 4 6 2 The width of the flat bar depends on the distance between the rear spring hanger and the web of the truck axle I beam The flat bar is to be welded securely to the spring hanger and attached to the axle U bolt as shown 42 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 7 COMPLETING FRONT INSTALLATION 4 7 1 Align Front Railgear The front Railgear now is ready to be squared up and aligned Three measurements need to be taken to ensu
88. PASSENGER S 18 818491 1 VALVE MOUNT BRKT FRONT AR BRAKE J 19 818493 1 VALVE MOUNT BRKT REAR AR BRAKE 20 818421 4 HEX HEAD 5 16 18 X I 1 s 22 818424 2 ROUND HEAD MACHINE SCREW fi0 24 X 3 2 24 s05101 2 fi0 FLAT WAHR C C 25 2 fi0 24 REX NUT 26 818887 2 RD HEAD MACHINE SCREW 10 24 X TOO Note Items 5 6 7 8 amp 13 shipped assembled Rear Kit p n 818415 INSTALLER S X SUPPLY LINE INCLUDED WITH AXLE KIT ONLY 7 17 13 CORRECTED HARDWARE PART 5 B 8 19 09 REVISED ITEM 1 TO QTY 1 AND ADDED NOTES ves A 11 28 94 ADDED TANKS Iwsw REV DATE DESCRIPTION amp v APP COBRA AIR BRAKE CONTROL SYSTEM ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV LJ 05 17 92 lt Tl 818400 c 1 78703 1 AIR TOGGLE VALVE TWO CIRCUIT BENDIX TW 2 2 818490 1 AR RELAY MIDLAND KN28500 4 818498 1 3 8 MALE NIPPLE 5 818488 1 VALVE BRASS BALL 3 8 PBVSOOP 6 6 818492 1 HOSE AIR LINE FRONT LH W SPRING GUARD HO6906 X 62 8 78798 2 BRAKE CHAMBER TYPE 24 COMBO NOT PROVIDED SHOWN FOR REF FROM VEHICLE PARKING BRAKE CONTROL CIRCUIT FROM VEHICLE SERVICE BRAKE C
89. RACKET FULLY WELD SPACER TO MOUNTING BRACKETAS lt VL 222 A SHOWN IF MULTIPLE SPAC ERS ARE USED SPAC ERS NEED TO BE WELDED TO ONE ANOTHER ATTHE REAR amp TACKED ON THE SIDES IF POSSIBLE TRUC K FRAME Lam FRAME BRACKET 5 8 11 GRADE 5 BOLTS NYLOCK NUTS amp FLATWASHERS NOT PROVIDED LENG TH TO BE DETERMINED ONCE BRACKET MOUNTED amp SHIMM ED 4 HOLE MOUNTING PLATE FOR PARTS AND ASSEMBLY DRAWING S 9 PLEASE REFER TO THEMANUAL TOTAL SPACER HEIG HT T REV DATE DESCRIPTION BY APP TOLERANC 5 TL ONCE THE REAR BRAC KET IS CO RREC TLY CENTERED VERTIC ALLY POSITIONED AND ALIGNED CWC eo RW I630 REAR RAILG EARIIN STALL GUIDE MEASURE 1 UP FROM THE BOTTOM oi THE SLOT IN REAR BRACKET SIDE PLATE AND DRILL POM B FIRST 5 8 HOLE THRO UG H THE SHIM S IF APPLIC ABLE AND TRUCK FRAME IF ANY SPAC ERS Eas Drawing isforillustrative purposes Your kes bmwwer gt DRAWING NUMBER ARE INSTALLED ADD THE TOTAL SPACER HEIGHT TO 1 DIMENSIO N parts not be exactly as pictured mu um 15i aut H gt M1630140 PARTNO DESCRIPTION 1 mer PUMP EXISTING 6 to 7 gpm 2000 ps MINIMUM FITTING ELBOW 3 4 MPT x 08 JIC HYD CYL HOSES 96 qty 4 04 wi
90. REAR VALVE PRESSURE RELIEF VALVE ua TO TANK w NO OBSTRUCTION OR FRTERS y FROM FRONT VALVE INLET CYLINDER BLIND END CYLINDER ROD END 1 2 pl NO O O REAR VALVE TO HYDRAULIC i u NE HYD CYL HOSES 2 a ASSY TaN LA J FRONT PTO PUMP FILTER Y fener sermo UI VALVE ASSY i 2000 psi MAX FRONT VALVE NOTE DEPENDING ES DIRECTION OF HANDLE UP DOWN YOU MUST RE PLUMB YOUR F 1 FROM ABOVE SEE DIAGRAM BELOW TROU VALVE MEME TOUTT PORT a al 0 pe TN NS B REAR VALVE NOTE DOES NOT HAVE TO BE RE PLUMBED DEPENDING ON PULL TO RAISE eman i DIRECTION OF HANDLES UP DOWN PUSH TO LOWER J PLUMBING FOR REVERSED HANDLE ONLY PLUMBING FOR EXTERNAL LOCKING VALVE PLUMBING FOR EXTERNAL LOCKING VALVE ISOMETRIC VIEW OF FRONT VALVE ASSY WITH T FITTINGS ON FRONT VALVE STD HANDLE W 90deg FITTINGS ON FRONT VALVE STD HANDLE FROM DIVERTER INLET CYLINDER BLIND ENDS CYLINDER ROD ENDS RELIEF SETTING 2500 psi MAX TO REAR VALVE TO FRONT VALVE ASSY IN PORT 1 TO FRONT VALVE ASSY IN PORT TO FRONT VALVE ASSY IN PORT RELIEF SETTING 2500 psi MAX FRONT L VALVE ASSY VALVE ASSY VALVE ASSY FROM FRONT VALVE ASSY OUT PORT p 1 OR REPLACE T HTTINGS W FROM FRONT VALVE ASSY OUT
91. RM 1 G INS 4 WI M INS Q INS 5 CH 6 REI D INSTALI ER H INSTALI 1 ADJUS 1 TIGH 3 BACK OFF NUT ITEM 5 APPI ITH c WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING L SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE RD SIDE OF WHEEL L INNER WHEEL NUT ITEM 5 T BEARING IN OUTBOAI BEARING L OUTER WHEEL NUT BEAD OF SILICONE ON ALI P N 800020 ALL HARDWARE KIT FOR RW 1630 WHEEL Does not include silicon for hubcap or wheel grease or bearing race WHEEL HEAVILY BY HAND 25 to 50 ft Ib 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS ROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010 OF ENDPLAY ONE HAND FIRMLY GRAB WHEEL amp ROTATE ECK WHEEL ADJUSTMEN A PROPERLY ADJUSTED WH a WILL SPIN FREE FOR A SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT PEAT IF ADJUSTMENT J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE K ADJUST INNER WHEEL NUT L INSTALL TAB WASHER ITEM 7 ALI N SELECT THREE TABS THA O FILL OI P RUNA OUTER DRIVER
92. RSIFIED METAL FABRICATORS INC 404 875 1512 AND 1 BLOCKS DRLL sizes 0 DRAWN BY APPD BY DATE DRAWING NUMBER REV SALE Yue WAK 6 24 94 dy B TITLE SAE JIC 37 Degree Fitting Installation ITEM PART NO DESCRIPTION Po PURPOSE To Establish Production Methods For The Installation Of SAE JIC Medium Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 4000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With SAE JIC 37 Degree Flared Ends PROCEDURE A Inspect fitting components to ensure that mating parts are free of burrs nicks scratches or any foreign material B Align tube flare against nose of fitting body and screw on the nut finger tight clamping the tube flare between the fitting nose and the nut C Tighten the nut the indicated Flats From Finger Tight F F F T listed in the chart below Use a second wrench to hold the hose in proper alignment while tightening to avoid twisting the lay line One flat on a hex is equal to 1 6th of a full turn Tolerance on tightening is plus or minus 1 4 flat 1 24th of full turn SAE JIC 37 Flare Fittings 7 16 20 9 16 18 3 4 16 1 1 16 12 1 5 16 12 1 5 8 12 1 7 8 12 Swivel Nut Tube or Hose Connection Connection F F F T F F F T Af DATE DESCRIPTION TOLERANCES TITLE PRODUCTION PROCEEDURE 005 JI
93. SHORT SLOTTED P N 819205 P N 819207 818265 818243 Truck Front Truck Front E 818655 Truck Rear 818655 CABLE REMOTE SHORT CABLE REMOTE SHORT SLOTTED P N 819204 P N 819206 SHORT STANDARD amp SLOTTED LINKS DIVERSIFIED METAL FABRIC 404 875 1512 DRAWING NUMBER M1630108 Truck Rear 818284 Note Links are sold individually unless you want a lull set of all 8 Please refer to full set p n s shown below The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same for long links no matter what pin off option you have MANUAL LONG _ P N 819208 MARIS os NTER LONG SLOTTED LINKS 818242 Truck Front Truck Front mede Truck Rear AIR REMOTE LONG SLOTTED AIR REMOTE LONG P N 819215 P N 819213 Truck Front T di Truck Rear in Truck Rear CABLE REMOTE LONG SLOTTED CABLE REMOTE LONG P N 819214 P N 819212 LONG STANDARD amp SLOTTED LINKS DIVERSIFIED METAL FABRIC ATO RSJNC 404 875 1512 DRAWING NUMBER M1630109 818279 818242 Truck Front Wheel Bearing Grease PARTS Must have serial when ordering 7 Factory Standard Citgo Syndurance Premium Synthetic 460 2 a 7 2 COMPLETE REAR AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS 2 800102 R ANDA 6 Hi E 5 Warm Climates Mystik JT 6 Hi T
94. SIDE PIVOT ARM INNER PIVOT ARM 1 INNER PASSENGER SIDE PIVOT aP ASE CR SDE PVO ARN 5 8 11 x 4 Grade 8 Bolts Must only use once WITHA DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND IS NECESSARY EM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 ITEM 8 AND TIGHTEN HEAVILY BY HAND MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS UTBOARD CAVITY COMPLETELY HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB L HUBCAP WITH PROVI DED SCREWS Factory Standard Citgo Syndurance Premium Synthetic 460 2 Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent NOTE ALL PARTS ARE NOT THE SAME BETWEEN 1630 FRONT amp UNDER CAB FRONT SEE FRONT RAILGEAR PARTS SECTION MANUAL FOR SPECIFIC UNDER PARTS Must be hardened washer Must only use once P N 820494 2 INSULATED 1630 WHEEL W RACES REPLACES ITEMS 1 KEEP ALL OTHER PARTS EXCEPT HUBCAP PARTS Must have serial when ordering COMPLETE FRONT AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS PIVOT ARMS 1630 ONLY NON INSULATED WITH BRAKES 1630 800060 NON INSULATED NO BRAKES 1630 800022 INSULATED NO BRAKES 1630 800026 INSULATED WITH BRAKES 1630 800061 2 PC WHEEL INSULATED WITH BRAKES 1630 800075 STUB AX
95. Spacer 4 13 INSTALL DECALS e Label the vehicle according to the diagram on the back of the decal sheet See next page 4 36 2015 DMF Inc All Rights Reserved ITEM PART NO DESCRIPTION 1 800190 P N s 800113 800114 800116 800118 800119 amp 800122 2 5 800117 amp 800135 INSPECTION AND MAINTENANCE OF D M F GUIDE WHEEL SYSTEM AN C A U T O N AN DAILY Visually inspect rail gear for hydraulic leaks loose fasteners and excessive wear Spin all four wheels noting any bearing noise or resistance Check level of hydraulic oil Compare left and right wheels for wear particularly diagonal flanges SECURE RAILDOGS BEFORE OPERATING DUMP RELEASE BEFORE TRAVEL 800122 WEEKLY Grease all fittings on rail Six 6 on front assembly Fourteen 14 on rear assembly Inspect the bearing grease every 2 000 miles or 6 months whichever comes first Inspect bearings and grease cavity by removing hubcaps Unless bearing problem is suspected the bearings do not need to be removed or repacked If repacking is required the grease cavity should be only 80 filled with suitable grease Replace hubcaps using a bead of Form A Gasket or equal ANNUALLY Change hydraulic oil filter element DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ATLANTA GA OPERATION OF D M F GUIDE WHEEL SYSTEM TO PLACE VEHICLE ON RAIL 1 Drive vehicle on crossing centering it over tracks 2
96. TH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO 240208 O RING GLAND 2 338 PASE Or SYEINDE E 240209 BACKUP RING GLAND 8 338 IF THE TUBES ARE FACING YOU OR CLOSEST TO YOU THEN 4 240254 WELD 55 3 1 2 TUBE SAE PORT LOCKING VALVE RR LH IT IS A DRIVER SIDE CYLINDER DS PART 240232 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 STRAIGHT IF THE TUBES ARE FACING AWAY FROM Y THEN IS A PASSENGEH DE PS ANA Hor 240258 90 DEGREE ELBOW 4 MJIC x 3 SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123 A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP UNLESS SPECT mz CYLINDER REAR SAE PORT L VLV 3 1 2 BORE x AC oW ue 9 1 2 STROKE LH DRIVER SIDE x on H DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES DRAWN BY APPD BY DATE DRAWING NUMBER ANGULAR SURF FINISH 125 MICRO THREADS 2A AND 2B BJF 10 7 09 240256 PART NO DESCRIPTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLO
97. TIL FLUSH WITH OUTBOARD RACE INSERT BEARING IN OUTBOARD SIDE OF WHEEL INSTALL INNER WHEEL NUT ITEM 8 ADJ UST BEARING TIGHTEN WHEEL HEAVILY BY HAND 25 TO 50 FT LB ROTATE WHEEL ONE FULL TURN IN BO TH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS BACK NUT OFF ITEM 8 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010IN OF ENDPLAY WITH ONE HAND FIRMLY GRAB WHEEL AND ROTATE CHECK WHEEL ADJ USTM ENT WITH DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJ USTED WHEEL a SPIN FREE FOR AT LEAST 1 2 TURN IF ROTATED HEAVILY BY HAND b NO SIGNIFIC ANTENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 1650 amp BEHIND CAB AXLE REPEATIF ADJ USIMENT IS NEC ESSARY ux INSTALL TAB WASHER ITEM 9 LINE THE TAB UP WITH KEYWAY IN AXLE aes ODED 820018 820020 820479 820555 INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND sna REDRAWN 88209 WAS 818205 SELEC T THREE TABS THAT MOST C LEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS FILL OUTBOARD CAVITY COMPLETELY RUN A BEAD OF SILICON ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB INSTALL HUBCAP WITH PROVIDED SC REWS RW le50 I or 5 DIVERSIFIED METAL FABRICA TORS NC 875 1512 P N 800021 ALL HARDWARE KIT FOR RW 1650 amp BEHIND CAB WHEEL amp 1650 2 PC WHEEL mum DRAWING NUMBER Sce DOES NOTINCLUDE SILICON FOR HUBCAP OR WHEEL G REASE OR BEAR
98. TMENT PROCEDURES x DIVERSIFIED METAL FABRICATORS INC RW 1630 4 11 RAIL TEST Run vehicle forwards and backwards on rail e f available run the vehicle through curves and switches Verify alignment by observing the wear pattern on the wheel and the behavior of the vehicle If adjustment is required refer to 4 10 Alignment 4 12 FINAL WELD OUT Front Railgear e Weld inboard side of outside pivot arm to axle tube all the way around as shown in figure 4 12 When welding stub axles weld the driver side sleeve in the openings to the axle and the inboard side of the passenger side outer arm see figure 4 12 B do not weld on the axle tube outboard of the shunt bolt The inside Pivot Arms should not be welded to the Axle Tube to facilitate ease of disassembly for repair or future maintenance MUSTBE WELDED IN RAIL POSITION ONCE FINAL ALIGNMENT amp WEIG HTS ARE SET THE INBOARD SIDE OF THE OUTER PIVOTARM S MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND Figure 4 12 A Standard Railgear Final Weld out J O 2015 DNF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOTARM MUSTBE FULLY WELDED COMPLETE STRUC TURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENTAND WEIG HTS ARE SET DO NOTWELD DRIVER SIDE PIVOTARMS WITH STUB AXLE NO WELDING ON AXLE TUBE OUTBOARD OF SHUNTBOLT MUST B
99. TS LIST REFERENCE TABLES uc DESCRIPTION OLERANCES UNLESS SPECIFIED COMMON SENSE PREVAILS RW 1650 BEHIND CAB FRONT RAILGEAR ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 5 S H 2 DRAWN BY BY DATE DRAWING NUMBER REV 2 28798 MI 1 5 1 2 CROSS TUBE P 810349 3 00 CROSS TUBE P N 810154 5 00 HIGH 3 PC CROSS TUBE P N 810107 e 6 00 HIGH 3 PC CROSS TUBE P N 810328 D 5 00 4 00 CROSS TUBE P N 810267 EE VOLVO CROSS TUBE P N 809999 LE ILO 5 00 CROSS TUBE P N 810270 2 00 CROSS TUBE P N 810264 DRIVER SIDE SHOWN P N 810388 PASSENGER SIDE OPPOSITE HAND P N 810389 REV DATE DESCRIPTION BY HESS IFIED E RC HRC ETE VARIOUS CROSS TUBE DETAILS FRAC x XX DIVERSIFIED METAL FABRICATORS INC 404 875 1512 h DRAWING NUMBER ANGULAR 1 SURF FINISH METER MGENN101 Exerci 4 SPRING HANGER P N 818155 6 5 8 OFFSETSPRING HANGER P N 818172 6 5 8 SPRING HANGER P N 818170 10 000 9 1 2 OFFSETSPRING HANGER P N 810136 REV DATE DESCRIPTION BY 5
100. UR 1650 2PC WHEEL HOB DETAIL 820452 FIBER RING WHEEL INSULATOR DETAIL 800125 RW 1650 BEARING RACE TIMKEN 6420 820483 RW 1630 2 PC HUB DETAIL W QTY 2 RACE BEARINGS 820478 2 PC WHEEL FIBER SPAC ER RING 820482 FIBER RING WHEEL INSULATOR DETAIL EM ESD DEA DING RACE HM ses 820521 RW 1650 2 PC WHEEL TREAD POST HEAT TREAT 820480 FIBER BOLTC OLLAR 2 PC WHEEL 2 Sasa 820485 2 WHEEL HARDENED 5 8 FLAT WASHER 7 820485 2 PC WHEEL HARDENED 5 8 FLAT WASHER 820487 NUT LOCK LN5 8 11 TYPE C 8 820484 STEEL WASHER RING 2 PIECE WHEEL 820441 HUBCAP 1650 7 B C FLAT 9 1820487 NUT LOCK LN5 8 11 TYPE C 800109 5 16 LOCK WASHER GRADES 10 800108 HUBCAP BOLTS HHCS 5 16 18 X 3 4 800108 HUBCAP BOLTS HHC S 5 16 18 X 3 4 800109 LOCK WASHERS LW 5 16 13 14 820486 HHCS 5 8 11 UNC x 4 GRADE 8 820441 HUBC AP 1650 7 B C FLAT 820484 STEEL WASHER RING 2 PIECE WHEEL 800300 DECAL 2 PC WHEEL RW 1630 50 INSPEC TIO NS 800300 DECAL 2 PC WHEEL RW 1630 50 INSPEC TIO NS 800301 KIT RW 1630 50 2 WHEEL 23 8MM INDIC ATO RS 800301 KIT 2 PC WHEEL INDICATORS 8 G REEN 1 RED P N 4800021 ALL HARDWARE KIT FOR RW 1650 WHEEL see drawing M1650103 in Section 5 3 P N 800020 ALL HARDWARE KIT FOR RW 1630 WHEEL see drawing M1630103 in Section 5 3 oo oo col
101. Valve Plate Assembly and Rear Frame Bracket an airbrake relay valve will be located The CONTROL line to this relay valve comes from the toggle valve described above The SUPPLY line to this relay comes from the Pressure Protection Valve which is plumbed onto the air reservoir There is a ball valve and an adjustable pressure regulator in the SUPPLY line before the relay valve The ball valve will disconnect the guide wheel braking system from the vehicle airbrake system regardless of the position of the toggle valve by interrupting the SUPPLY line air pressure to the guide wheel system only The adjustable pressure regulator allows the braking effort on each axle to be set so that the Rail wheels do not lock up and slide The guide wheel brake chambers are connected to the DELIVERY ports on the guide wheel air brakes relay valve Install air lines and valves per the drawing on next page Make certain that the Front Air Brake Valve indicates that it has been preset to 75 psi and the Rear Air Brake Valve is labeled 30 psi The brake valves are already preset at the factory front at 75 psi rear at 30 psi 5 3 5 Cobra Air Brake System Plumbing Overview See additional detailed drawing on next page 2015 DMF Inc All Rights Reserved 5 9 TEM PART NO OY amp DESCRIPTON 1 818483 1 VALVE PRESSURE PROTECTION BW103976 SPL PR 4 2 818484 1 MTG ANGLE BRKT AIR BRAKE VALVE OPTIONAL 3 81848
102. WELDING MACHINE GROUND CLAMP ON RAILWHEELS THIS WILL CAUSE ARCING ACROSS THE BEARING S INSIDE THE WHEEL amp LEADTO PREMATURE BEARING FAILURE FRONTMOUNTING PIN LEAF SPRING S FRAME EXTENSION TRUCK FRAME Q ONCE FINAL ALIGNMENT amp WEIG HTS ARE SET FRONTCROSS TUBE MUST BE FULLY WELDED COMPLETE SPRING DISTANCE STRUCTURAL WELDS TO TRUCK FRAME OR FRAME EXTENSIONS 4 MAX PX ALL THE WAY AROUND SPRING BRACKET ONCE FINAL ALIGNMENT amp WEIG HTS ARE SET IF SHIM S REQUIRED FULLY WELD ALL SHIM S IN ALL LO CATIONS IN ONEPLACE IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED AT LOCATIONS SHOULD BE WELDED TO ONE J SPRING BRACKET ANOTHER HEIG HT 25 1 2 1 2 INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE 12 3 4 1 2 NOTE SHIM S SHO ULD BE PLACED ON BOTH PIVOTARMS FOR A GIVEN SIDE OF THE TRUCK MUST BE WELDED IN RAIL POSITION gc FOR PARTS AND ASSEMBLY DRAWING S THE INBOARD SIDE O F THE OUTER PIVOTARM gt PLEASE REFER THE MANUAL MUST BE FULLY WELDED COMPLETE STRUC TURAL WELDS ALL THE WAY AROUND ONCE FINALAUG NMENT lt T Dra wing isfor illustrative purposes Your amp WEIG HTS ARE SET m 3 gt f a parts may not be exactly aspictured DO NOTWELD DRIVER SIDE PIVOT ARMS WITH STUB AXLE
103. ail brakes are applied simultaneously with the truck brakes when the operator presses the brake pedal There is also a dashboard mounted switch that permits the operator to enable or disable the rail braking system Options There are several options available for RW 1630 Railgear The most commonly ordered options include rail wheel brakes for improved stopping on rail insulated wheels to prevent crossing signal actuation rail sweeps to clear the rail of potentially damaging materials and remote pin 1 2 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 offs for ease of operation Other less common options are non standard track gauges slotted links for improved hi rail performance at crossings and two piece wheels for extreme conditions 1 2 RAILGEAR DMF s Heavy Duty Front Railgear is available 3 different variations standard front Railgear uses a 1630 axle see section 1 2 1 the Behind Cab variation uses an extra heavy duty 1650 axle and wheels see section 1 2 2 and the Under Cab variation uses the 1630 axle see section 1 2 3 1 2 1 Standard Front Railgear Components Figure 1 2 1 shows the individual parts of the installed front Railgear These item descriptions will be used throughout this installation manual DMF Railgear assemblies are also referred to as guide wheels Rail wheels or hi rail gear Front Railgear attached to front vehicle springs and front bumper
104. ample shim on left side it will push left axle forward Once proper shimming has been obtained weld the shim into place on the pivot arm Max allowable 1 4 Contact DMF if outside the maximum range RAIL WHEEL LOAD ADJUSTMENT PROCEDURE Tire traction varies w every truck based on several factors such as weight amp tire design It can also Vary on the same truck as equipment is added or deleted Thus we recommend performing the traction adjustments after all equipment is installed or removed Since every truck differs there is no exact procedure However we have found the following two methods to be a good guide The true test is how the vehicle performs on rail METHOD 1 Note Method 1 is a visual procedure of the tire capping on rail 1 Grind off the welds on the 2 four hole mounting plates at the rear mounting bracket 2 Loosen the 8 rear bracket mounting bolts 3 Lower the railgear supporting the railgear with a floor jack or with the unit itself 4 Remove or add spacer shim material located between the bottom of the truck frame and the shelf on the rear mounting bracket Add shim to decrease traction and remove shim to increase traction ref side dwg for illustration of proper tire capping 5 Raise Railgear once again to contact the bottom of the truck frame 6 Re tighten the rear mounting bracket bolts to 154 ft Ib torque and re weld the mounting plates and shims to the bracket per rear install detail in
105. an a 1 16 gap exists between the rear Railgear bracket side plate and the side of the truck frame install equal amount of shims on each side to fill the gap thus keeping the Railgear bracket centered Note that DMF provides shims of different thicknesses and it is important that the same amount of shim measurement is achieved on both sides With the rear bracket correctly located against bottom of frame rail and centered there are two differing methods of setting a preliminary weight setting 1 The first method is to measure from top of rear bracket plate to floor and adjust bracket with temporary spacers as shown in Table 4 3 5 This should provide a good starting point for final weight setting 26 27 28 29 30 31 32 33 Xtra Short Links 0 1 2 3 Short Links 0 1 2 3 Long Links 0 1 2 3 Table 4 3 5 Shimming Chart 2 The second method is to insert the minimum 1 2 or maximum 3 of spacers and then during the final weight setting add or remove spacers as appropriate until optimal weight setting is achieved Once spacers are positioned temporarily clamp chain or otherwise secure rear Railgear to truck frame Keep in mind that spacers and rear bracket may have to be adjusted for final weight setting and squaring aligning with the truck axle 4 3 6 Square Rear Railgear with Truck Axle The Rear Railgear needs to be made absolutely square with the rear
106. areas are not corrected it will cause difficulties aligning and operating the Railgear 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 on long wheelbase vehicles to prevent front tandem walking off in curves 2015 DMF Inc All Rights Reserved 4 5 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 2 3 Hydraulic System The truck should have a hydraulic system installed before installing the railgear Hydraulic pressure will be needed to assist during the installation process Please see section 6 0 for information on installing or modifying an existing hydraulic system for railgear 4 2 4 Front and Rear Installation Rails In order to install the Railgear 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 4 2 4 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 amp the parking brake is set 4 2 5 Installation Rails
107. ared individually to the truck frame you must perform a final overall alignment of front to rear Railgear and also adjust the weight setting 43 O 2015 DMF Inc All Rights Reserved ALIGNMENT PROCEDURE A STEPS 1 and 2 must be completed in listed order and are assumed to be within specifications and should only be addressed if after alignment of the railgear excessive flanging occurs 1 Frame should be square to within 1 8 maximum on the diagonal 2 Rear drive axle should be square to frame within 1 1 6 maximum on the diagonal to achieve 0 thrust angle this should be checked by a qualified alignment shop B The following procedure applies to shop or field inspection 1 Check air pressure in all tires tires should be inflated to the minimum rating of the wheel or tire 2 Place vehicle on straight and level track or 3 channel to simulate rail Lower the railgear to the rail so that front to rear and diagonal measurements can be made Note these measurements can be made from any convenient locations as long as it stays consistent from side to side 3 If diagonal measurement is out of tolerance adjustment of the front railgear must be made The procedure for this is as follows for D 1 amp D 2 only Place shim material between the stop block on the pivot arm see dwg below amp where it comes into contact with the long arm The location for the shim is most accessible from behind the front Railgear axle ex
108. ases step side fuel tanks on either side of the cab may need to be moved forward to achieve the desired space near the rear of the cab It may also be necessary to re locate tool boxes hydraulic tanks air tanks etc rearward 31 3 4 is the minimum vertical ground clearance at the rail width needed for the brake chambers in the highway position The guide wheels are reversible at installation If the wheels are insulated it is noted that DMF installs the insulation on the driver s side wheel which in this case locates the brakes to the rear of the axle Keep in mind that even though this feature allows positioning of the brakes to the front or rear of the unit as space permits an insulated wheel reverses to the passenger side of the truck if the brakes are in front of the axle NOTE The rear position is desirable from the standpoint of protecting the brake assembly from obstructions in the forward travel mode The Railgear is designed to provide 9 of ground clearance beneath the rail wheels when the Railgear is in the highway position Solid spacers must be welded to the frame mounting bracket shelves to achieve 9 of ground clearance when the railgear is pushed up flush to the bottom of the truck frame and the railgear is in the highway position Be mindful of clearance required for the driveshaft or other frame mounted components when raising up the railgear The design width of the behind cab unit between the inboard side of the
109. bly in vertical position align piston with tube bore engage piston in tube bore strike rod end wit hammer until piston is below first cylinder port Slide gland down on rod engage gland threads into barrel by hand LQmTnImuocou A B C D E F G H Screw gland into barrel with spanner wrench until gland face contacts barrel tube end H Install two 2 hydraulic fittings into cylinder ports per PPO03 PRESSURE TESTING A Connect hydraulic power unit to cylinder P TEE B Operate cylinder through complete cycle to purge air and fill with clean hydraulic oil RE C Operate cylinder to full extension and retraction and maintain at 3300 PSI for 15 seconds at each extent While maintaining pressure at each extent visually inspect ports rod seal gland OD seal and cylinder bottom areas for leakage D Disconnect hydraulic power unit and install caps on port fittings E Impression sfamp cylinder bottom when all preceding steps have been successfully accomplished COMMENTS Specific assembly instructions on prints are performed with preference over this procedure A 5 25 12 USE 19260 INSTEAD OF HYDRAULIC OIL 7 16 11 REMOVED CYLINDER PART S FOR CYLINDERS GREATER THAN 04 5 DO NOT REED SENDER ESTING HONING DESCRIPTION ALLOW CYLINDER TO BOTTOM DURING mas ERATES PRODUCTION PROCEDURE 008 TESTING BLOCK ROD AGAINST GLAND WITH PIN 2255275 CYLINDER ASSEMBLY DIVE
110. bsite listed below We reserve the right to update our manuals without notice You can download a current manual at our website http www dmfatlanta com Thank you for choosing DMF Railgear We make every effort to provide quality safe and rugged products for the railroad We hope you ll find our gear to be satisfactory in every way We take product support very seriously so if you have any questions please contact us Contact Diversified Metal Fabricators 665 Pylant St NE Atlanta GA 30306 404 875 1512 404 875 4835 Fax 404 607 1684 Parts http www dmfatlanta com info dmfatlanta com Ship to 668 Drewry St NE Atlanta GA 30306 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC SECTION 1 0 SECTION 2 0 SECTION 3 0 SECTION 4 0 SECTION 5 0 SECTION 6 0 TABLE OF CONTENTS GENERAL INFORMATION 1 1 General Description 1 2 1 2 Front m 1 3 1 3 Rear Railgear aaa s RAE EE asua yay vn 1 5 OPERATIONS 2 1 Before You Operate the Railgear 2 2 2 2 Anti Lock Brake System 2 3 2 3 Highway 2 4 2 4 Getting on the Rail 2 4 2 5 Getting off the 2 1 2 5 ROUTI NE MAI NTENANCE 3 1
111. c rri 4 6 4 3 INSTALLATION OF REAR RAILGEAR 4 7 4 3 1 General Information ene uay aya eee eee eee nnn 4 7 4 3 2 Diagram of Key 5 0 4 8 4 3 3 Location of Rear Railgear 2 hen 4 9 4 3 4 Location and Clearance of 4 9 4 3 5 Shimming and Temporarily Spacing Rear 4 10 4 3 6 Square Rear Railgear with Truck Axle r 4 10 4 3 7 Squaring up Rear Railgear to Truck 4 11 4 3 8 Temporarily Securing Rear Bracket 4 11 4 3 9 Mounting Plate 0 nens 4 12 4 3 10 Tack Welding of Spacer 2 cece eee eee eee ene ese eme e hens 4 12 4 3 11 Final Rear Railgear Alignment and Weight SettingsS 4 12 4 4 VARYING FRONT RAI LGEAR CONFIGURATIONS 4 13 4 4 1 Traditional Long Arm lt lt ee mese nn 4 13 444 2 Cargo Armi Assembly eeecressdecetvE eerte iunt i ERR vere atr dor A EPI H E
112. chassis frame with a stationary pin This design allows the front rail wheels to ride on the chassis suspension alleviating vibration from track irregularities 4 4 2 Cargo Arm Assembly This style of assembly is normally used when chassis components such as a low hanging radiator or steering components prohibit the use of the traditional long arm configuration It is attached to the chassis by way of brackets on the front leaf springs 4 4 3 Mid Mount Assembly This style of assembly is mounted either under or behind the chassis cab and is often used to meet strict curvature requirements For more information on Mid Mount Assemblies please see Section 4 8 and 4 9 2015 DMF Inc All Rights Reserved 4 13 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 5 TRADITIONAL LONG ARM ASSEMBLY INSTALLATION 4 5 1 General Information There are several items to note before you begin the installation of the front Railgear e The Railgear unit that we have shipped to you has been designed for your specific truck However before starting the front Railgear installation check the vehicle s front tire spacing The front Railgear 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 e Check to see if Frame Extensions are needed As seen in section 8 3 measure your long arm from front to rear mounting pin hole to determine dimension between holes Starting f
113. dividually unless you require an entire set of 8 4 front 4 rear See drawings for additional clarification on link type i e long short or extra short and the appropriate part numbers for ordering e Note Short links are DMF s default configuration for our Railgear 7 2 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 Cylinders Brakes also see drawing on next page When ordering rear cylinders it is important to note which way the pin offs are facing if they are facing toward the rear of the truck then this is considered our standard mounting configuration then driver s side and passenger s side terminology is consistent with the layout of the vehicle HOWEVER if the pin offs are facing toward the front of the truck i e underneath the truck which is usually done to accommodate clearance issues when installing air remote pin offs terminology is reversed In that case the driver s side cylinder is actually on the passenger s side of the vehicle and should be ordered as the driver s side The reverse applies for the other side of the vehicle If you are unsure or have questions please speak to an DMF parts representative for clarification Note that there are two sizes of rear cylinders Standard and Extra Short The only difference between these two cylinders is their barrel length so please confirm the length of your cylinder and select the appropriate drawing for part nu
114. e cab with 16 guide wheels GVWR Range 33 000 Ibs and above Approx Installed Weight Front 1700 Ibs Capacity 40 000 pounds per Railgear axle 20 MPH For parts drawings see Section 8 0 and for installation instructions see Section 4 0 1 4 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 1 3 REAR RAILGEAR 1 3 1 Rear Railgear Components Including RW 1630 and RW 1650 DMF offers two different variations of Rear Railgear RW 1630 and RW 1650 The components are the same other than the axles and wheels which have different weight capacities RW 1630 GVWR Range 33 000 165 and above Approx Installed Weight Rear 1185 Ibs Capacity 40 000 pounds per Railgear axle 20 MPH RW 1650 GVWR Range 33 000 Ibs and above for heavy load applications Approx Installed Weight Rear 1385 lbs Capacity 70 000 pounds per Railgear axle 20 MPH Figure 1 3 1 shows the individual parts of the installed rear Railgear with the rail wheels in the rail position These item descriptions will be used throughout this installation manual TRUCK FRAME TRUCK TIRES B ITEM DESCRIPTION ITEM DESCRIPTION A REAR FRAME MOUNTING BRACKET FLAT PLATE H REAR AXLE B 4 HOLE MOUNTING PLATE INSIDE BRACKET REAR RAIL WHEEL SP
115. e fault and should be checked out Please refer to the truck s operation manual 2015 DMF Inc All Rights Reserved 2 3 DIVERSIFIED METAL FABRICATORS INC RW 1630 2 3 HIGHWAY OPERATION Before operating a Railgear equipped vehicle on the highway 1 Verify Railgear is in highway position 2 Verify pins are properly and fully inserted in both front and rear Railgear even if the Railgear on your truck is equipped with a locking valve system you MUST verify that the pins are correctly inserted 3 Steering wheel lock has been removed if applicable 4 Verify that Railgear brakes have been disengaged if applicable 5 Verify PTO has been disengaged and that the indicator light is OFF 2 4 GETTING ON THE RAIL 2 4 1 Getting onto the Rail 1 At the track crossing drive past the track then back the vehicle onto the rails Engaging the rear Railgear first will allow your vehicle to side shift and align itself to the rail making it easier to engage the front Railgear 2 Engage the truck s parking brake to prevent the truck from rolling 2 4 2 Lower Rear Guide Wheels 3 If the Railgear has brakes turn brake switch on 4 Engage the PTO leave the truck running and the transmission in neutral gear 5 Remove the Safety pin off pins 4 pins 2 front and 2 rear on both driver and passenger sides If pins are too tight to be easily removed verify that Railgear is fully raised by briefly pulling bumping the valve handle t
116. e figures 4 7 1 A and 4 7 1 B for diagram of recommended tack locations for standard and stub axle The front Railgear is ready to be lowered on the Installation Rails As the Railgear is lowered check the clearance from the truck tire to the Rail Wheels If there is any interference stop lowering the wheels and retrace the installation steps to fix the problem When the Railgear is completely lowered the front truck tires should be approximately 2 inches above the Installation Rails If Railgear 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 Railgear Valve is set high enough As a final review recheck the center alignment of the Rail Wheels to the truck frame If it is off break the tacks holding the Axle Tube and slide the Axle Tube to the correct position and re tack in place MUST BE WELDED IN RAIL POSITION RECOMMENDED TEMPORARY TACK LOCATION FOR STANDARD FRONTAXLE Figure 4 7 1 A Recommended Tack Location for Standard Front Axle 424 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 MUST BE WELDED IN RAIL POSITION RECOMMENDED TACK LOCATION ON PASSENGER SIDE OF FRONT STUB AXLE DO NOTWELD DRIVER SIDE PIVOTARMS WITH STUB AXLE NO WELDING ON AXLE TUBE OUTBOARD OF SHUNTBOLT MUST BE WELDED IN RAIL POSITION RECOMMENDED TACK LOCATION
117. ear as possible to the front Railgear control valve In this location 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 P N 818700 FRONT CABLE REMOTE PIN OFF ASSY Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex 818757 PIN OFF HOUSING WELDMENT end cap Replace the T handle on the cable 1 4 FENDER FLAT WASHER 5 16 HEX NUT 5 8 HEX NUT 7 16 LOCK WASHER 1 4 C HEX NUT 7 16 FLAT WASHER P N 818758 7 16 C HEX JAM NUT N PIN OFF PIN SAL 4 x 3 470 w 1 4 20 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK WASHER KIT P N 818763 CABLE P O 3 4 PIN FOR BRAZIL e INCLUDES 818576 CABLE ASSY QTY 2 818759 3 4 PIN QTY 2 amp 818767 WASHER QTY 2 MOUNT INSIDE FOR BRAZIL 7 16 INTERNAL LOCK WASHER 7 16 C HEX END CAP 818587 REM AIR P O FITTING 818593 REM P O AIR CTRL WISE gue TRUCK SUPPLY 55 818785 HOUSING WELDMENT H S Truck P N 818785 PIN OFF HOUSING WELDMENT pU STAR 1 4 FENDER FLAT WASHER 1 4 FENDER FLAT WASHER P N 818599 5 16 24 JAM HEX NUT P N 818599 5 16 24 HEX NUT P N 818596 5 8 18 HEX NUT 5 8 HEX NUT P N 818755 AIR CYLINDER P N 818755 AIR CYLINDER NS P N 818758 DRIVER SIDE PASSENGER SIDE PIN OFF PIN 2 7 8 x 3 4 DIA w 5 16 24 MOUNT INSIDE FOR BRAZIL P N 818528 TEE 818591 1 4 TUBE 8 16 13
118. emp Multi Purpose Grease 2 or equivalent INSULATED NO BRAKES 1630 amp UNDER CAB 800204 4 WEF 2 1630 WHL ASSY NON INS W RACES NOTE DRAWING amp PART NUMBERS ARE APPLICABLE FOR INSULATED WITH BRAKES 1630 amp UNDER CAB 800208 5 80005 2 3 RW 1630 NUT INNER WHEEL EUCLID E 540 BOTH 1630 AND UNDER CAB REAR NON INSULATED NO BRAKES 1630 amp UNDER CAB 800202 i MASHER I NON INSULATED WITH BRAKES 1630 amp UNDER 800206 75 800106 71 2 RH 2 PC INSULATED NO BRAKES 1630 amp UNDER CAB 8002384 9 818104 2 RW 1630 HUBCAP 2 PC INSULATED WITH BRAKES 1630 amp UNDER CAB 800260 10 800109 8 ASHER 11 800108 8 8 x 3 4 1630 amp UNDER CAB AXLE TUBES 1630 amp UNDER CAB BEARING RACE 12 800101 2 BEARING RAC M MP P N 8 AXLE TUBE NO BRAKES 818308 TIMKEN 563 BEARING RACE 15 8181001 1 R AX ANDAR 4 X AXLE TUBE WITH BRAKES 818200 800101 BRAKE SADDLES 1630 amp UNDER CAB WHEELS INSULATED 2 PIECE 1630 WHEEL w RACES 820494 INSULATOR KIT W BOLTS amp NUTS 820479 BOLTS amp NUTS KIT 820539 NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 INNER INSULATOR 820009 OUTER INSULATOR 820008 NOTE SPECIAL PROFILE WHEELS PLEASE CALL 5 8 11 x 4 Grade 8 Bolts Must only use once WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS
119. equired in both the rail and highway positions Operation Controls e Locate and familiarize yourself with the front and rear Railgear operating controls e Locate Power Take Off PTO toggle switch control and indicator light typically found on the dashboard e f your truck is equipped with Railgear brakes locate the brake switch on the dashboard of the truck e Identify the type of steering lock used on your truck 2 1 2 Daily I nspection Before operating your Railgear equipped vehicle whether for highway or rail use it is imperative that you perform a daily inspection see Section 3 1 1 for Daily Inspection List If any items found during your inspection do not conform to requirements it is your responsibility to take corrective action before any use of the vehicle 2 2 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 2 2 ANTI LOCK BRAKE SYSTEM ABS 2 2 1 Trucks Equipped with ABS All medium and heavy duty trucks manufactured after March 1 1998 and equipped with air brakes are required by federal law to also include ABS The system is designed to prevent wheel lock up during braking 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 t
120. er s intended pressure for a given load Reference your tire manufacturer s load rating and inflation chart Inflating tires to their max side wall pressure may result in drastically reduced contact with the rail if under loaded e Ifthe rear truck frame does not extend the minimum of 21 1 4 for single axle or 17 1 4 for tandem axle trucks it should be properly lengthened to provide the necessary mounting clearance for the Railgear 2015 DMF Inc All Rights Reserved 4 7 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 2 Diagram of Key Components Figure 4 3 2 shows the individual parts of the installed rear Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual TRUCK FRAME TRUCK TIRES B ITEM DESCRIPTION ITEM DESCRIPTION A REAR FRAME MOUNTING BRACKET FLAT PLATE H REAR AXLE B 4 HOLE MOUNTING PLATE INSIDE BRACKET 1 REAR RAIL WHEEL C SPACER S IF REQUIRED J REAR UPPER MOUNTING PINS D REAR HYDRAULIC VALVE ASSEMBLY K REAR LOWER MOUNTING PINS E REAR UPPER LINKS 4 L REAR CYLINDER PINS F REAR LOWER LINKS 4 M REAR BRACKET SHIM S PLATE G REAR LIFT CYLINDERS 2 N SIDE PLATE Figure 4 3 2 Diagram of Key Components 4 B O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630
121. erved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 15 INSTALLATION REVIEW CHECKLIST The following checklist is intended to assist the installer in re checking and verifying aspects of the installation that are often overlooked or forgotten Check tire pressures L Rail test the truck to check for good traction and braking A good industrial siding or some authorized track time will be required Check that Rail wheels with brakes do not lock up or slide L Adjust the Railgear height as required Re check alignment of the Rear Railgear to the rear axle Weld the Mounting Plate to the Rear Frame Bracket with two 2 welds at the top center and bottom center Welding the plates must be done DO NOT forget to do it Double check all welds and fasteners and mounting cotter pins Tie strap all hydraulic hoses air hoses and electrical wires away from exhausts and moving parts Ensure that all hydraulic and air hoses have sufficient radius at bends Top off the hydraulic oil in the tank L Verify grease installed at all grease fittings see section 3 2 Touch up the black acrylic enamel paint on the Front and Rear Railgear UL Raise the Railgear highway position and install all of the pin offs L Apply the Decal Kit L Check Front Alignment o Front Mounting Pin height 25 1 2 o Rear Mounting Pin height 12 3 4 L Check Rear Alignment o Tire to Rail Wheel center Single Axle 15 1 4 Tandem Axle 11
122. est Road Test and Final Inspection are performed at the end 4 1 3 Required Tools amp Materials Aside from general shop tools and safety equipment the following tools will be required e Arc or MIG Welder Surge Protector Protects ECM from damage during welding Cutting Torch Hand Grinder Frame Drill Air Saw Angle Finder Test Rail See Section 4 2 4 Hydraulic Oil ASTM D6158 HM Unax RX 46 Hydraulic Oil Shell Tellus EE 46 or equal or some customers operate on DEXRON III ATF Fluid e Wheel Bearing Grease Grease Fittings o Factory Standard Citgo Syndurance Premium Synthetic 460 2 o Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent Additionally the following tools are recommended e Transmission Jack Motorcycle Lift Pallet Jack or Forklift e Overhead Crane e Work Lights e Wheel Dolly 4 1 4 Bolt Torque Specifications See following page for recommended torque specifications 2015 DMF Inc All Rights Reserved 4 3 a oe TITLE Purchased Fastener Torque Specification PURPOSE To Establish Production Methods For The Installation Of Commonly Purchased Threaded Fasteners COMMON USAGE Most Areas Of Multiple Part Assembly And Retention PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Most Common Sizes Of SAE J429 Grade 5 And 8 And Of ASTM A574 Alloy Bolts PROCEDURE A Identify The Fastener As Either Fine Or Coarse Thread Select The Appropriate Chart Below B Identify The
123. f to be adjusted much higher than its valve can withstand To ensure correct system pressure check with a gauge 6 2 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 6 1 3 Hydraulic System Installation Continued From the output side of the Pressure Relief valve or the Diverter valve if appropriate route a pressure line SAE 100R2 8 and 8 JIC swivels at each end to the center of the front bumper Connect the pressure line to the IN port of the front Railgear valve From the OUT port of the front Railgear valve route a pressure line SAE 100R2 8 and 8 JIC swivels at each end to the IN port of the rear Railgear valve Lastly run a hydraulic line from the OUT port of the rear Railgear to the tank ensuring that there no obstructions such as filters or other equipment The remaining ports on the front and rear valve assemblies connect to the Railgear cylinders with SAE 100R1 4 hose and 4 JIC swivels The rear cylinder hydraulic hoses are installed at the factory Check that proper hose clearance is obtained to avoid chafing and shield hoses if necessary 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 resulting in possible injury and or damage 2015 DMF Inc All Rights Reserved 6 3 ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION
124. h each lip o ring insert side facing the closer piston face GLAND A Inspect OD and bore for sharp edges Deburr as neccessary Clean and blow off with shop air n Use Blue Assemblee 9260 to aid in assembly Install wiper ring in bore with lip facing outboard Install seal in bore with lip o ring insert side facing inboard Inspect for seal damage Any shaved seal material requires replacement Install backing ring in O ring groove on OD with concave surface facing inboard Install O ring on inboard side of groove in Step G Inspect O ring for damage ROD ASSEMBLY Clean and inspect shaft surface for scratches and dings Install grease fitting in rod end per 1 Use Blue Assemblee Goo 19260 to aid in assembly Install gland assembly onto rod with the outboard side facing the rod end Install rod O ring onto threaded end of rod Inspect O ring for damage 1 Install piston assembly onto with the O ring counterbore facing O ring in Step E Be certain that O ring seats in counterbore Install self locking rod nut on rod Tighten to 200 to 300 foot pounds torque Torque will vary based on rod amp nut size CYLINDER ASSEMBLY A Inspect cylinder ports for minimum three 3 threads and no burrs Deburr as neccessary Clean tube ID threads and bore and blow out with shop air Inspect threads for debris Support cylinder barrel assembly with gland end facing Maintain assem
125. heel Lock Overview The DMF Velcro steering wheel lock consists of two 2 wide adhesive backed hook strips and a 4 wide piece of loop fabric piece of adhesive backed hook is placed on the steering wheel column and a second piece placed on the top flat of the steering wheel hub The 4 wide piece of loop fabric can then be applied to bridge the gap between column and wheel preventing the front tires from accidentally being turned while on the rail However in the event of an emergency the steering wheel can be forcibly turned and the Velcro fasteners will separate allowing the driver to steer the vehicle 1 Clean the areas where the self adhesive 2 wide hook strips will be applied on the steering column and wheel with rubbing alcohol and a clean cloth 2 Allow the column and wheel to dry 3 Remove the adhesive backing from the hook strips and apply them to the top of the steering wheel hub and the column as close to the wheel column gap as possible NOTE Trim the strips to fit around obstructions such as hazard light switches 4 Allow the adhesive to cure for 24 hours prior to attaching the 4 loop fabric 5 When putting the truck on the rail position the 4 loop fabric to bridge the gap between the hooks on both the column and wheel as shown below and press firmly 6 To remove the lock simply pull on the D ring and store the piece of Velcro fabric 4380 2015 DMF Inc All Rights Res
126. hen 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 Allied Bendix 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 operation manual 2 2 2 Rail Operation of Trucks with ABS When the Railgear is in the rail position the front truck tires are lifted off the ground This may produce an ABS fault and cause the ABS light to illuminate In this condition the brakes will still function but the ABS system will not If 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 light after a few seconds If the amber light remains on during road operation the truck s brake system may have an activ
127. ights Reserved 8 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 8 1 Before Ordering Parts Front Railgear Required Information for Ordering Parts e You must have the Railgear serial number when ordering parts This uniquely identifies your Railgear as it was built to your specifications and also allows DMF to help you maintain a history of your Railgear If you are placing a parts order through a maintenance facility please inform them of the serial number so that they can relay the information when placing your order e Returns DMF has a Return Authorization Procedure You must contact DMF for an RA before returning any parts for any reason Parts will not be credited without an RA e Labor In extremely rare situations on a discretionary basis and with prior approval DMF will reimburse certain specific labor costs If you feel this may apply in your situation you must contact DMF s Service Department for a Service Authorization Number SA No labor will be reimbursed without an SA The SA must be included on your request for reimbursement e Please use driver s side passenger s side terminology instead of left right side when describing issues with your Railgear This ensures that everyone involved is clear about where the issue is occurring Other Considerations for Ordering Parts This is a list of considerations to make before placing a parts order with DMF There are many variations and customer requirements tha
128. ipped Figure 4 5 2 Diagram of Key Components 2 BE aye AXLE 4 4 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 5 3 Frame Extension Installation Remove the truck s front bumper If frame extensions are not required please skip forward to section 4 5 4 Bolt the Frame Extension to the truck frame refer to Figure 4 5 5 Make sure that the tilt of the cab s hood will clear the Frame Extensions Trim the brackets and re gusset them if necessary Alltruck Frame Extensions that are bolt on brackets must use 5 8 18 Gr 8 or stronger bolts hardened steel washers and Gr 8 prevailing torque locknuts All of the fasteners should be tightened to torque specs in section 4 1 4 When choosing bolts make sure to use a bolt which has threads that begin past the joint seam See Figure 4 5 3 for an illustration Check that the Frame Extension tubes are level front to rear and side to side with the frame FRAME EXTENSION TRUCK FRAME THREADS BEGIN Figure 4 5 3 Bolted Joint Cross Section NOTE DMF front frame extensions are designed to support the Railgear only It is the installer s responsibility to properly engineer brackets for rail racks boom rests and etc In normal applications mount the Front Valve Plate Assembly between the Frame Extensions with the Front Valve on the underside and
129. is released If brakes do not function properly contact a Service Representative at DMF 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 5 3 8 Brake Parts See drawing on next page for brake parts schematic 5 12 2015 DMF Inc All Rights Reserved 1 NOTE 2 1 AIR BRAKE CHAMBER FRONT SEE NOTE 2 2 818462 2 BRAKE SADDLE 16 MOUNTS ON AXLE TUBE _ COBRA AIR BRAKE ASSEMBLY REAR DRIVER S SIDE BOLT MOUNTING 1 2 13 x 1 1 2 Gr8 COBRA AIR BRAKE ASSEMBLY REAR PASSENGER S SIDE COBRA AIR BRAKE ASSEMBLY FRONT RETRO FIT KIT 5 818454 2 BRAKE SHOE COBRA AIR BRAKE ASSEMBLY REAR RETRO FIT KIT 6 818456 1 COTTER PIN 1 8 x 1 1 2 COBRA AIR BRAKE ASSEMBLY COMPLETE RETRO FIT KIT F amp R 7 818407 1 BRAKE BRACKET WELDMENT 3 81455 1 CLEVIS NOTE 1 9 818457 1 5 PIN 1 2 1 1 2 w COTTER PIN 10 818470 1 COBRA BRAKE SHOE V 26 ii 818431 1 BRAKE ARM CASTING A 12 818513 1 BRAKE SHOE CLIP ASSEMBLY BOLT MOUNTING 3 8 16 x 1 Gr8 16 818450 2 WASHER LOCK 3 8 ROLL PIN 5 32 x 1 1 2 Must have serial when ordering parts KIT P N
130. izontal In the highway position the brake assemblies should be located above the stowed guidewheel and rotated forward by about fifteen degrees 4 8 5 Welding Once the brake and axle positions have been determined you must weld the axle tubes to the lower arm weldments This may be done on the inboard sides of the lower arms Follow the established procedure for welding the axle tubes to the pivot arms found in Sections 4 7 and 4 12 2015 DMF Inc All Rights Reserved 4 27 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 8 6 Remote Air Pin Off Installation The positions for the upper and lower pin offs are located on the inside of each upper arm assembly Due to inaccessibility operation of the pin offs is achieved from a remote location preferably on or near the driver s side of the truck frame The DMF furnished remote pin off assemblies are air operated and include lock pin housings air control valve cylinders and pre set proximity sensors with LED position indicators A legend plate DMF 818754 is also furnished to locate and install the air control valve and LEDs This plate when installed with the LEDs indicates engagement or dis engagement of the lock pins Please refer to the enclosed drawing 818745 for installation instructions of the pin off assembly See Drawing on Next Page 4 8 7 Completion Finish installing rear Railgear options hydraulic system etc as per the standard Railgear installation instructions
131. mbers Rear Mounting Bracket It is important to know your rear frame width first and then refer to the Rear Frame Drawing and use the provided chart to find your part number It is also important to note the thickness of the rear mounting bracket flat plate because we offer different thickness Please note the height of your rear mounting bracket side plates because we offer different heights Shims are available to adapt wider brackets to different frame widths If your exact measurements are not available on the parts list please discuss this with the DMF Parts department and we will work with you to get the appropriate rear bracket and necessary shims 2015 DMF Inc All Rights Reserved 7 3 NUMBER DESCRIPTION WHEEL amp AXLE ASSY REAR RW 1630 REAR LINK ASSY SHORT SLO TIED REAR MOUNTING BRACKET REAR MOUNTING BRACKET PLATE CYLINDER ROD PIN UPPER PIN ASSY LOWER PIN ASSY W HEAD FOR SLOTTED LINKS SLOTTED LINK PIN HEAD NUT SLOTTED HEX 1 1 4 7 COTIER PIN 3 16 X 2 FLATWASHER 1 1 4 REAR BRAC KET SHIMS PACKAGE COTTER PIN 1 4 X 2 1 2 HYDRAULIC CYLINDER ASSY DRIVER SIDE HYDRAULIC CYLINDER ASSY PASSENG ER SIDE PIN O FF ASSY REAR DRIVER SIDE PIN O FF ASSY REAR PASSENG ER SIDE TEM S 16 amp 17 ARE COMPONENTS OF ITEM 2 5 8 11 HEX BOLTS 5 8 11 NYLO CK NUTS amp 5 8 FLAT WASHERS NOTPROVIDED FASTEN TO 154 LB FT MUST BE GRADE 5 FOR REAR ONLY LENGTH TO BE DETERMINED
132. n ordering parts A 5 26 11 FIXED TYPO AUXILIARY wa A 8 11 10 CHANGED P N 108042 TO 108041 vec P N 818234 P N 818245 DESCRIPTION PASSENGER SIDE DRIVER SIDE UN ESS TITLE REAR REAR RW 1630 ASSORTED PIN OFF ASSEMBLIES DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE uei J DRAWING NUMBER 1 50 SU M1630100 NOTE 1 SPECIFY THE CABLE THAT BEST FITS YOUR APPLICATION REPLACEMENT CABLES pm uem 818577 818576 s so 1 P N 818589 CONVERTS REMOTE CABLE PIN OFFS TO REMOTE AIR OPERATED PIN OFF ASSEMBLY Note Remote Rear Pin Offs There are two different types of remote pin offs available for both front and rear Railgear and they can be used in any combination The two different types are Cable operated Cable operated with air Remote pin offs are not installed at the factory to prevent damage during shipment Note Remote Rear Pin Offs Once cables are installed to pins route cables to easily accessible location for operator use preferably as near as possible to the rear Railgear control valves In this location 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 Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex end cap Replace the T handle on the cable 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK
133. ooting On track Problems Symptom Possible Cause Diagnostic Step Corrective Action Rail wheel vibration noise Damaged Tread Flange Patterned Wear on Tread Flange Loose Wheel Inspect treads Flange Inspect treads Flange Check wheel end play detailed instructions at Section 7 0 amp 8 0 for appropriate wheel amp axle assy drawings Replace wheel Replace wheel Follow detailed instructions at Section 7 0 amp 8 0 Vehicle tracking to one side wandering Misalignment Overload or load imbalance Un Even Rail Wheel Load Vehicle Load Excessive Wheel Wear Check Alignment see Section 4 10 Visually inspect scale vehicle Weigh Vehicle and Check Rail Wheel Load Check Alignment and Wheel Wear Adjust Alignment Unload and or redistribute load Adjust Load Distribution and Re set Rail Wheel Load Adjust Alignment Replace Worn Wheels Insufficient traction or braking Rail Wheel Load set too low Tires worn See Section 4 10 Inspect Tires Set Rail Wheel Load Replace tires Table 3 1 1 Troubleshooting On Track Problems 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 3 4 Derailment In the case of a minor derailment the cause of the derailment should be determined and corrective steps taken The vehicle should be inspected to determine if repairs or adjustments are required This inspec
134. or assistance Once properly shimmed the hydraulic system should already be properly positioned to hold the shims in place until alignment can be completed Check for truck frame spring steering gear or other truck component interference with the Railgear particularly the Long Arms see CLEARANCE NOTE in section 4 5 7 Front Mounting Pin ground clearance may be reduced to as low as 24 to provide for proper fit Repeat process on passenger side 2015 DMF Inc All Rights Reserved 4 19 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 5 7 Front Railgear Clearance CHECK FOR INTERFERENCE P IN THIS AREA Figure 4 5 7 Front Railgear Clearance CLEARANCE NOTE Proper clearances will allow the Railgear 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 4 5 7 Since the Railgear 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 Railgear effectively rotates about the Front Mounting Pin Therefore the pa
135. ously specified in Section 3 1 1 check the bolt torque indicators the tabs around each bolt daily to ensure that they have not moved If torque indicators are missing or damaged please contact DMF for replacements If torque indicators have moved follow the procedure below to remedy the situation 1 Remove the green torque indicator Re torque the loose nut see torque specifications in drawing M1630106 on the next page and then replace with a red torque indicator DMF provides one red torque indicator per wheel To install a torque indicator place it over the nut with the raised collar resting against the wheel Push with both thumbs or a socket flush to the wheel 2 The next time that the vehicle is in a shop for service or repair disassemble the wheel and inspect all the components for damage Replace damaged or worn components and re assemble the wheel with new bolts nuts and washers See drawing M1630106 on the next page for the type of hardware required and the torque spec Nuts bolts and washers may only be used once If the wheel is disassembled all of the nuts bolts and washers must be replaced Please contact DMF if you have any questions regarding our two piece wheels 5 14 2015 DMF Inc All Rights Reserved RW 1650 2 PC WHEEL PARTS RW 1630 2 PC WHEEL PARTS ITEM NO PARTNUMBER DESCRIPTION NO PARTNUMBER DESCRIPTION 820492 RW 1630 2 WHEEL TREAD DETAIL 320490 1
136. oward you 6 Push valve handles to lower wheels and engage rail N To assist with alignment of the wheels to the rail you can also use the valve handles independently to lower one side at a time to engage the rail at which point you can then lower the opposite side This will cause your vehicle to side shift and align itself with the rail 8 When both wheels are in rail position and properly engaging rail replace safety pin off pins 2 4 3 Lower Front Guide Wheels 9 If necessary drive the truck into position to line up the front guide wheels with the rail 10 Ensure that the PTO is engaged this was engaged during the lowering of the rear Railgear 11 Ensure front safety pin off pins are removed 12 Check and make sure that the front guide wheels line up with the rail 13 Push valve handle to lower wheels and engage rail 14 If you do not require the use of the PTO for additional equipment it can now be disengaged 15 Disengage the truck s parking brake when you are ready to proceed NOTE The front guide wheel assembly is an over center design and does not require safety pin off pins engaged in rail mode 2 4 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 2 4 4 On the Tracks Do not exceed posted track speed limit and at no time exceed 30 MPH while on the track Be aware that some Railgear is insulated and will not operate the crossing gate circuits You are responsible
137. ps with Cobra Air Brakes bolt the shorter Mounting Bracket directly to the Air 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 REAR RAILSWEEP ASSEMBLY ds WELD ON USED w o BRAKES REAR RAILSWEEP ASSEMBLY BOLT ON USED w BRAKES N FRONT RAILSWEEP ASSEMBLY BOLT ON USED w BRAKES B18508 oo 9 102408 Pe se 818505 RUBBER SwEEP FRONT RAILSWEEP ASSEMBLY USED w UNDER CAB RAILGEAR Figure 5 1 A Rail Sweeps REAR RAILGEAR FRONT RAILGEAR ED doob Figure 5 1 B Rail Sweep Position RAIL SWEEP RAIL SWEEP v 5 2 2015 DMF Inc Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 5 2 PIN OFF OPTIONS See drawings on next three pages 2015 DMF Inc All Rights Reserved 5 3 PART NO QIY DESCRIPTION NOTE IF YOU ORDER MANUAL PIN OFFS WITH YOUR RAILGEAR THEY SHOULD ALREADY BE WELDED IN THEIR PROPER LOCATION L2 P N 108045 AUXILIARY ASSEMBLY P N 108044 AUXILIARY PIN OFF CHAIN P N 108041 1 5 8 ASSEMBLY w CHAIN BEHIND CAB BEHIND CAB PIN OFF P N 818163 P N 818164 DRIVER S SIDE PASSENGERS SIDE FRONT O FRONT SIDE VIEW 1650 50 MANUAL PIN OFFS C Must have serial whe
138. racket information Contact DMF for assistance 5 Once spacers are in place with spring bracket at the appropriate height attach the Spring Bracket to the truck spring using a Rubber Spacer already supplied directly on top of the leaf springs and then a 1 x 2 flat bar Spacer already supplied on top of the Rubber Spacer and two 3 4 10 hex nuts per stud The top Spacer has no effect on the height of the Railgear and is only used for clamping purposes 6 The nuts should be tightened down until the Rubber Spacer begins to deform from the downward pressure Caution Do not over tighten 7 Repeat process on passenger side ensuring that the back of spring hanger to front of axle web dimensions are equal on both sides Route and Attach Hydraulics 4 Route all hydraulic lines as shown in Section 6 0 5 Engage the PTO and allow hydraulic circuit to self bleed 6 Inspect all connections for leaks and tighten as necessary Mounting Front Spring Bracket 1 Ensure that both spring bracket hangers are properly installed before attempting to install front spring bracket 2 Ensure that the safety pin off pins are in the highway position Then place a floor jack under the center of the Railgear axle Using the jack raise the Railgear up toward the truck s leaf springs paying close attention to clearances to prevent damaging chassis components Raise the axle until a 10 minimum 8 ground clearance is achieved at the rail wheel flange N
139. re 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 Railgear 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 If the measurements are off square the Railgear 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 misaligned and needs to be corrected After these alignment checks and after ensuring there are sufficient clearances the Frame Mounting Brackets can be tack welded to the Frame Extensions NOTE Do not attach the welding machine 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
140. rking brakes Make sure surrounding area is free and clear of any obstacles and vehicles before pulling off of the rail and onto the road If 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 light after a few seconds If the amber light remains on during road operation the truck s brake system may have an active fault and should be checked out Please refer to the truck s operation manual 2015 DMF Inc All Rights Reserved 2 5 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2 6 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 3 0 ROUTINE MAINTENANCE 3 1 Inspection and Maintenance 3 2 3 1 1 PEE 3 2 3 1 2 Weekly 3 2 3 1 3 Bi annuallyu am ET 3 3 3 1 4 Annual Maintenance or as 3 3 3 2 Lubrication Specification 3 3 3 3 3 5 3 3 1 Troubleshooting On track 3 5 3 4
141. rom approximate installed location of rear mounting pin on figure 4 5 5 extend a tape measure to the length found in dimension between holes Raise end of tape measure up toward truck frame if you contact suitable mounting location no frame extensions should be needed If the end of the tape measure is beyond the front of the truck frame then front frame extensions are likely required Please contact DMF if you have any questions or for ordering information Also see section 4 5 3 for Frame Extension installation instructions e Check for sufficient clearances to prevent interference with Railgear and other parts of the truck ie Frame steering boxes shocks oil filters etc See section 4 5 7 for complete Clearance Note If notable clearance issues are found please contact DMF prior to continuing installation 4 5 2 Diagram of Key Components Figure 4 5 2 shows the individual parts of the installed front Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual TRUCK FRAME Q FRONT TRUCK 4 SPRING Item Description SPRING BRACKET SPACERS if required SPACER Top required RUBBER SPACER REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM FRONT MOUNTING PIN CROSS TUBE FRONT EXTENSION if required COBRA BRAKES if equ
142. rt of the Railgear 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 4 20 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 6 CARGO ARM FRONT ASSEMBLY INSTALLATION 4 6 1 Front Cargo Arms In some applications the front Railgear long arms that extend beyond the front of the truck to frame extensions cannot be used due to possible interference with other truck components If this is the case DMF supplies a front Railgear unit that includes much shorter long arms Referred to as Cargo Arms With some modifications that will be detailed further the rear of the arms mount to the truck springs in the same manner as a standard set of long arms while the front of the arms mounts further forward on the leaf springs thus utilizing the suspension of the chassis 4 6 2 Diagram of Key Components Front Mounting Dimensions Figure 4 6 2 shows the individual parts of the installed front Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual TO MAINTAIN GROUND CLEARANCE ADD PIPE OVER PIN amp FLAT BAR TO SPACE GAP OVER SPRING 3 8 7 FRONT TRUCK SPRING SECURE SPRING HANGER TO AXLE BY ADDING A 3 4 THICK FLAT BAR AS SHOWN DRILL HOLES TO MATCH EXISTING U BOLT ON TRUCK TRUCK AXLE
143. s see section 7 0 amp 8 0 for appropriate wheel amp axle assembly drawings Ensure axle threads are not stripped or damaged Any items noted should be repaired using specifications in the manual to ensure they are repaired to initial install standards Please contact DMF for any assistance you may require 3 6 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 4 0 RAILGEAR I NSTALLATI ON 4 1 _ PRE INSTALL u ninian nn pannua aaraa pak aaan ah a anaana ianaeaieo an 4 3 14 Safety Statements uean REIR ITANE RIA DEA NA 4 3 4 1 2 Installation Order reden Ea E a ia a 4 3 4 1 3 Required Tools amp 005000 4 3 4 1 4 Bolt Torque 5 2 00 hens 4 3 4 1 5 Welding II III meme menn ene ne en hen nnne 4 5 4 2 INITIAL 5 5 4 5 422210 AW ORK AEC ssh erect PE e 4 5 42 2 Truck Conditoris Lala Q a ete ent 4 5 4 2 3 Hydraulic System sce aaaea aE KEINE p a aa 4 6 4 2 4 Front and Rear Installation Rails mnn 4 6 42 5 nstallation Ralls 2 e
144. sembly attaches to the frame and front axle and lifts the front truck tires off the track thus utilizing the vehicle s front suspension This design supports the vehicle as it was intended and helps the truck navigate curves smoothly and damps out the effects of track irregularities The rear assembly attaches directly to the truck frame behind the rear axle tandem spring hangers It deploys with an articulating dual scissor action that allows the rear Railgear to be moved both vertically and horizontally This mechanism provides the side shift action which has made DMF gear so well known in the industry It gives operators a greater margin for aligning the vehicle to the track which speeds and simplifies the process of getting the vehicle on rail DMF RW 1630 Railgear is designed for vehicles with GVWR s 33 000 Ibs and above For greater capacity you can upgrade to our RW 1650 rear gear It can boost your Railgear weight capacity by supplying a larger axle bigger bearings and special hardened rail wheels The front Railgear and all other components remain the same as standard RW 1630 In addition to the high capacity axle upgrade available with our RW 1650 Railgear we also offer additional options for extreme conditions or tight curvature situations See Sections 1 2 and 1 3 for specific configuration information For purposes of this manual we will refer to RW 1630 when discussing either RW 1630 or RW1630 50 and we will explicitly call ou
145. st half of the spacer is seated on the leaf spring closest to the front truck axle If the spacer is not at least half seated move spring bracket hanger forward to next leaf spring The spring hanger can be moved 6 max from front truck axle 3 Once positioned place a floor jack under the outboard and inboard long arm close to the spring hanger on the driver s side Using the jack raise the spring hanger up toward the truck s leaf springs You will raise and lower the long arms until the Rear Mounting Pin is 12 3 4 V2 from the floor See figure 4 5 5 4 Once you achieve the desired height insert 1 x2 flat bar spacers between spring hanger and leaf spring up to a maximum of 4 If you need more than 4 of spacers a change of spring brackets may be required see section 8 0 for spring bracket information Contact DMF for assistance 5 Once spacers are in place with spring bracket at the appropriate height attach the Spring Bracket to the truck spring using a Rubber Spacer already supplied directly on top of the leaf springs and then a 1 x 2 flat bar Spacer already supplied on top of the Rubber Spacer and two 3 4 10 hex nuts per stud The top Spacer has no effect on the height of the Railgear and is only used for clamping purposes 4 18 6 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 6 The nuts should be tightened down until the Rubber Spacer begins to deform from the 7
146. system contamination C Screw fitting into female pipe port to the finger tight position D Wrench tighten the fitting to the appropriate Turns From Finger Tight T F F T shown in chart below Make sure that tube end of shaped fitting is aligned to receive in coming tube or hose assembly STEEL PIPE THREAD FITTINGS Fitting Pipe Thread Size Size NPT T F F T 1 8 27 1 8 27 1 4 18 3 8 18 1 2 14 3 4 14 3 4 14 1 11 1 2 1 1 4 11 1 2 1 1 2 11 1 2 COMMENTS Teflon Tape May Be Used In Certain Situations With Engineering I wr Fitting 15 Limited One Or Two 5 DESCRIPTION TITLE PRODUCTION PROCEDURE 004 PIPE FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 1 065 005 ES DRAWN BY APPD BY DATE DRAWING NUMBER REV v l TSH 06 02 94 401 4 DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 7 0 REAR RAILGEAR PARTS 7 1 BEFORE ORDERING PARTS REAR RAILGEAR Q 7 2 7 2 REAR PARTS DETAIL DRAWINGQ U 7 4 7 3 RW 1630 PIN OFF ORIENTATION U U Q 7 5 7 4 LI NK DIMENSIONS 7 6 7 5 EXTRA SHORT LINKS U u u u 7 7 7 6 SHORTLINKS 7 8 7 7 LONG LINKS 7 9 7 8 RW 1630 WHEEL amp REAR AX
147. t any differences when appropriate Materials All structural members and brackets are constructed of carbon steel The 16 guide wheels for DMF RW 1630 Railgear are machined from hardened steel castings and are fitted to high strength alloy steel axles with heavy duty tapered roller bearings Installation Both DMF front and rear guide wheel units bolt to the truck frame using only hand tools found in any shop They are designed to minimize the amount of space required and in many cases fit within the existing boundaries of the vehicle The front units however sometimes require a bolt on frame extension to complete the installation Rear RW 1630 Railgear mounts below the top of frame and directly behind the rear axle spring hangers 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 The optional RW 1630 rail brakes are of the air actuated external Cobra shoe type The rail brakes use a truck style air chamber to supply the clamping force Supply pressure comes from the vehicle s air system A pressure protection valve separates the Railgear and the truck s air systems preventing a failure in the rail brake system from adversely affecting truck braking The r
148. t or the Non Adjustable chart below One Flat on a hex is equal to 1 6th of a full turn Tolerance on tightening is plus or minus 1 4 flat 1 24th of full turn G Inspect to ensure that O Ring is not pinched and back up washer hex seats flat on face of port ADJUSTABLE FITTINGS Ge em _ Size Thread Size F F F T s a 5 5 wes fs ere NON ADJUSTABLE FITTINGS E en Size Thread Size F F F T e wes fis s fos LATO o o OO OOO DESCRIPTION TITLE PRODUCTION PROCEDURE 003 O RING FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 005 ZEN DRAWN BY APPD BY DATE DRAWING NUMBER REV AP I TSH 06 02 94 Ty PART NO DESCRIPTION PO T O Eh TITLE National Pipe Thread NPT Fitting Installation PURPOSE To Establish Production Methods For The Installation Of NPT Medium Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 3000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With Tapered Pipe Threads PROCEDURE A Inspect port components to ensure that male and female threads are free of nicks burrs dirt etc B Apply sealant lubricant to male pipe threads Use only Permatex 14D Thread Sealant With Teflon paste or Engineering approved equal The first few threads must be left uncovered to avoid
149. t we strive to accommodate and as a result the more information you can provide to us when placing an order the more likely that we will be able to help you quickly and efficiently e Cross Tubes Spring Hangers and Long Arms are available in a variety of sizes and lengths Please be sure to check drawings for details before placing your order Wheels e f you are a customer using special wheel profiles this is especially prevalent in Metros please be sure to inform the DMF Parts Department that there may be a special wheel profile involved in your order DMF offers both insulated and non insulated wheels Please confirm which wheel you need before ordering Insulated wheels can be identified by a grooved ring machined around the inside of the Rail wheel This grooved ring can been seen and felt and is located about an inch in from the outside tread Cylinders e The driver s side and passenger s side cylinders are different please see information on drawing to determine which cylinder you need to order Frame Extensions e Please call DMF for assistance The truck year and model number must be provided so that DMF can correctly identify the frame extension needed 8 2 2015 DMF Inc All Rights Reserved PART NUMBER DESCRIPTION PARTNUMBER 810453 RW 1630 CARGO PIVOTARM ASSY RIGHTHAND 818124 810452 RW 1630 CARGO PIVOTARM ASSY LEFTHAND 818149 WHEEL amp AXLE ASSEMBLY 818148 DESCRIPTION PIN ASSEMBLY FRO NTMOUNTI
150. tal spacer height to 1 dimension see figure 4 3 9 Align this first hole with the 4 hole mounting plate ensure that the mounting plate is level and then drill the additional 3 holes Once all 4 holes are drilled install four 5 8 11 Grade 5 bolts and secure them with the appropriate washers and nylock nuts Repeat this mounting bracket procedure for the other side of the Railgear Temporarily tack weld the mounting plate to the rear frame bracket If re adjustment is later needed the welds may be ground off and the rear frame bracket may be slid up or down by loosening the bolts in the slots Also temporarily tack the spacers into place so that if further adjustment is necessary the welds can easily be ground off and spacers added removed as necessary NOTE Only use Grade 5 bolts on rear Railgear 2015 DMF Inc All Rights Reserved 4 11 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 9 Mounting Plate Installation TRUCKFRAME m s OD LOCATON OF FIRST DRILLED HOLE O 1 T U 4 MOUNTING PLATE TOTAL SPACER HEIGHT T CIO ONCE THE REAR BRACKET IS CORRECTLY CENTERED VERTICALLY POSITIONED AND ALIGNED MEASURE 1 UP FROM THE BOTTOM OF THE SLOT IN THE REAR BRACKET SIDE PLATE AND DRILL FIRST 5 8 HOLE THROUGH THE SHIMS IF APPLICABLE AND TRUC K FRAME IF ANY SPAC ERS ARE INSTALLED ADD THE TOTAL SPAC ER HEIGHT TO 1 DI
151. tallation 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 Railgear e Lighting The work area should be adequately lighted e Space There should be enough space to maneuver the Railgear components into position and to safely work around other equipment 4 2 2 Truck Condition Before installation the truck should be checked in some important areas e Tires 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 rail Also the condition of the rear tires needs to be determined If the rear tires are worn they should be replaced Alignment Rear truck axle must be square with truck frame DMF recommends that a reputable alignment shop check this 0 degree thrust angle which may be different than the factory specification is required for proper Railgear operation Frame amp Suspension On a new truck these should be in good condition On a used truck the frame should be inspected to ensure 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
152. tion should include but should not be limited to the following Visually inspect Railgear for hydraulic leaks Ensure all lines and hoses are still secured and out of the way of any moving parts Ensure all hydraulic hose connections and fittings are securely in place and not broken Verify that all threaded fasteners are secure and that cotter pins are not broken Visually inspect wheels to ensure that tread and flange are not severely damaged Spin all 4 Rail wheels noting any bearing noise resistance and end play Any items noted should be repaired using specifications in the manual to ensure they are repaired to initial install standards In case of a major derailment a complete inspection should be performed including but not limited to the following Perform all inspection items as listed above in the Minor Derailment section Inspect all long arms pivot arms and links to ensure they are not bent cracked or broken Inspect and test rail brake system see Section 5 3 Ensure spring brackets are securely fastened and are not bent cracked or broken Ensure all welds are intact and show no signs of cracking or breaking Ensure all mounting hardware and brackets are securely fastened and are not bent cracked or damaged in any way A full alignment should be performed See section 4 10 Wheels should be removed and the bore bearings races and insulation if applicable should be inspected for any damage For further wheel detail
153. truck axle Four measurements shown in Figure 4 3 7 need to be taken to ensure this requirement 1 The distance from the truck axle to the Rear Railgear Axle at each end In Figure 4 3 7 distance A must be equal to B within 1 8 This is an important alignment check 2 The diagonal from the truck axle to the opposite Rear Rail Wheel In Figure 4 3 7 distance C must be equal to D within 1 4 410 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 7 Squaring up Rear Railgear to Truck Frame REAR TRUCK AXLE ALIGNMENT CHECK A B within 1 8 C D within 1 4 REAR RAILGEAR AXLE REAR Figure 4 3 7 Squaring Rear Railgear NOTE Although the previous mounting conditions and alignment may be met be certain that enough room exists between the Rear Railgear and other equipment In general this should include a 2 clearance around the Railgear more clearance will be needed if Remote Pin offs are installed Also ensure that there is clearance to remove the Pin Offs from their holes 4 3 8 Temporarily Securing Rear Bracket Now that the rear bracket is correctly centered vertically positioned and aligned measure 1 up from the bottom of the slot in the rear bracket slide plate and drill your first 5 8 hole through the shims if applicable and truck frame If any spacers are installed add the to
154. ts After the Railgear has been installed the frame mounted truck equipment may be re mounted partially over the Railgear frame brackets or farther down the truck frame NOTE Accessibility to the Railgear must be maintained for pin offs normal maintenance and or repairs 4 9 3 Installation The behind cab unit has been shipped disassembled for ease of installation Using floor jacks raise each bracket approximately 23 1 2 from the bottom of the box assembly to the ground up against the pre determined frame location both sides see figure 4 9 3 This should allow for the proper height of 9 of ground clearance Clamp the brackets securely to the truck while allowing access for a frame drill and platform Align the boxes to be square with the frame as well as each other Once aligned drill a minimum of six 5 8 diameter holes in a balanced pattern through each bracket assembly and frame member and cross member gusset where applicable Attach each frame bracket assembly to the truck with 5 8 11 Grade 8 bolts and 5 8 11 Type C lock nuts I 34 7 8 E d T d pa cd b dB cd TRUCK FRAME di cH h f db Alb
155. ts and washers See above forthe type of hardware required and the torque specifications A sam UPDATED TO CURRENT MANUAL REVISON JDI REV DATE DESCRIPTION BY APP TOLERANCES Nuts bolts and washers may only be used once If the wheel is disassembled all of the nuts 08 mE bolts and washersmust be replaced RW 1630 50 RW 1630 50 INSULA TED 2 PC WHEEL ASSY FRAC OTHER 1 16 x 063 A pe DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL 925 DRAWING NUMBER ANGULAR 9 SURF FINISH THREADS wo 4 6 2010 M1630106 ALT VIEW FRONT ALT VIEW REAR DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 5 16 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 6 0 HYDRAULIC SYSTEM 6 1 HYDRAULIC 5 5 6 2 6 1 1 New Hydraulic System for Vehicle without Hydraulic System 6 2 6 1 2 Hydraulic System for Multiple Uses Railgear and other Application s 6 2 6 1 3 Hydraulic System Installation Continued 6 3 6 2 VALVE ASSEMBLIES AND HYDRAULIC SCHEMATICS 6 4 6 3 RW
156. y 5 15 Troubleshooting On Track Problems 3 5 Manufacturer Equivalent Welding Rod 4 5 Location of Rear Railgear 4 9 Shimmling Chart sete merece pie 4 10 Cylindrical Tank Spacing Under Cab 4 26 Squared Tank Spacing Under 4 26 2015 DMF Inc All Rights Reserved RW 1630 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1630 SECTION 1 0 GENERAL INFORMATION 1 1 GENERAL 1 2 1 2 FRONT 1 3 1 2 1 Standard Front Railgear 5 1 3 1 2 2 Behind Cab Front Railgear 1 4 1 2 3 Under Cab Front Railgear 1 4 1 3 REAR 1 5 1 3 1 Rear Railgear Components Including RW 1630 and RW 1650 1 5 2015 DMF Inc All Rights Reserved 1 1 DIVERSIFIED METAL FABRICATORS INC RW 1630 1 1 GENERAL DESCRIPTION DMF s RW 1630 Railgear is our original and very successful Railgear for large trucks The front guide wheel as
157. zation Number 5 No labor will be reimbursed without an SA The SA must be included on your request for reimbursement e Please use driver s side passenger s side terminology instead of left right side when describing issues with your Railgear This ensures that everyone involved is clear about where the issue is occurring Other Considerations for Ordering Parts This is a list of considerations to make before placing a parts order with DMF There are many variations and customer requirements that we strive to accommodate and as a result the more information you can provide to us when placing an order the more likely that we will be able to help you quickly and efficiently Wheels e f you are a customer using special wheel profiles this is especially prevalent in Metros please be sure to inform the DMF Parts Department that there may be a special wheel profile involved in your order DMF offers both insulated and non insulated wheels Please confirm which wheel you need before ordering Insulated wheels can be identified by a grooved ring machined around the inside of the Rail wheel This grooved ring can been seen and felt and is located about an inch in from the outside tread Links e DMF s links come in 3 sizes x short short and long The sizes cannot be mixed between upper and lower links i e Long upper link can only be used with long lower link Each link has a slotted version as well e Links are sold in

RW-1630 & RW-1630/50*

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RW-1630 &amp; RW-1630/50*

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RW-1630 & RW-1630/50*