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Installation and Parts & Service Manual RW-1420

Contents

1. 2 8658 05160 3NDNOL SKY 3 5 8 596581 Z 33H 2401 _ 8191 900276 313 SOV ISNT N3in Si 0000876 13 G3NDIOJVJDNVRO SOLVINSNI SINNI I 18591 FT Page 27 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Chart ication 1420 Wheels I dent ing RW Draw y A3 HIENNN ONIAVYT 5 gt 86 12 01 ow ALT 01449 A8 NAVE TIST SLSCFOFYINISYOLYIIUAYS WLIW UIIJISYIAIT LAVHI NOILVOISILN3GI T33HA 0291 8 IL 109530 LISD 133 0319105 242 03009 0 6174 y G3STIV1SNI SIOVY A GILVINSNI NON 2139 N d JWG T33HM z OztI MaD ONILSVO T33HA 338 00691 T NOLLJIUISIC ALO 1394 GSTIVLSNI 639 G3LVT0SNI 3 9 99308 34 2249 Nid SING T33HM OZY MY 900 9002 1435 OL dN 7005 1435 NOLLONGOUd O3TIVLSNI 6 GILVTNSNI G3TTV1SNI 6 YOLVINSNI 292 2891 TH33HM Or ME 4189 Nid T33HM OZY L MH KSS IES 727 C Page 28 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC GUIS SABDNSSSVd 3UI SAJAND y y v v 15 91 17 6 X
2. 2015 DMF Inc All Rights Reserved Page 59 of 80 DI VERSI FI ED METAL FABRICATORS INC RW 1420 6 5 Air Brake Connections Mechanical Installation Remove the guide wheels from the axle s to receive airbrakes Remove the electric brake assemblies The brakes are attached to the guide wheel axle tube with three one inch welds Torch or air arc the welds loose Disconnect and remove the brake controller and wiring Remove the front guide wheel steering guide bars Torch off the 1 1 4 diameter guide bars that are welded to the guide wheel axle pass over the guide wheel flange and extend out beyond the tread rim Grind the axle tube clean Operate the guide wheels into the Hi Rail position On the front axle the airbrake assemblies replace the steering guide bars The brake assembly has a 1 diameter steering guide bar built in Remove the Cobra shoe from each assembly by unbolting the shoe retainer blocks from the pivot arm weldment Refer to Drawing Air Brake Assembly Position the assembly vertically over the guide wheel axle and one inch in from the end of the axle tube Refer to Drawing Air Brake Installation Tack the mounting plates to the axle tube Refer to Drawing Air Brake Assembly On the rear axle the airbrake assemblies are mounted on the rearward side and angled slightly below horizontal Remove the Cobra shoe from each assembly by unbolting the shoe retainer blocks from the pivot arm weldment Refer
3. Aud Buou sjeauk yo s sse2Xe saeue su 2500 SHV 4090 jou 12edsu ANSA WV WALSAS 3C01N9 J WU 30 SONYNALNIVA ONY NDILLO3dSNI Page 66 of 80 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 7 0 FINAL CHECKLIST 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 Adjust the rail gear height as required Cross check the Rear Railroader to the rear axle again Weld the Mounting Plate to the Rear Frame Bracket with one 2 weld on the horizontal edges two welds per Mounting Plate Welding the plates must be done DO NOT forget it Double check all welds and fasteners and Mounting Pin cotters Tie strap all hydraulic air hoses and electrical wires away from exhausts and moving parts Insure that all hydraulic and air hoses have sufficient radius at bends Top off the hydraulic oil in the tank L Touch up the black acrylic enamel paint on the Front and Rear Railroaders Raise the Railroaders road position and install all of the pin offs Apply the Decal Kit Check tire pressures DMF RW 1420 Railroader Installation Check Sheet Front Alignment Front Mounting Pin height 23 1 2 inches Rear Mounting Pin height 10 3 4 inches Rear
4. NANO DNI8331S ONNOY IN3NTT3A HJLYT 0208 J Alo UN Lav NLI Page 55 of 80 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 NOTE There are two types of brakes available for the RW 1420 Railgear Be sure to correctly identify which brake system you will be or are currently using Read all instructions and check that all required parts and Kits are included before beginning the installation The proper installation of this equipment is solely the responsibility of you the authorized installer When in doubt contact DMF for assistance 6 4 Hydraulic Brake Connections NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance Refer to Drawing Hydraulic System Old Style and Drawing Hydraulic System New Style in section 2 3 for more information The wheels and brake assemblies are on the axles The brake valving is pre plumbed from the solenoid diverter valve through the brake relief valve e Attach the 48 braided steel hoses to the wheel cylinders the brake assemblies Run the lines along the outboard side of the pivot arms to the pivot pin Leave a little slack hose looping around
5. ION OC AJOA 4uoug 0068 ION HU IND Hee odds 43738 NNUILLOVO V VDU UD 44010435 4U043 H207 SNOLLIN LSNI ALI4VS 441008 TRAVEL 380438 3SS3139 DNILLVa dl 340 338 SUC 1198 48NIIS VWNOLLAYIV 561008 217008 SiN d 22 221008 61008 811008 911008 11008 00 SiN d r 06008 0113139534 LALO ON 1 NALI PLINY TLE gISI SZ8 Ov SUOLVOINGV4 WLIW C3LIISS3AIG Hd OG DU apu mopoa pur sepa pood pur og f k speeds Bunad Peddnbe pa 5 Won VDO ado sud SANDE up yapon FAY 0 379424 YU T siu y ad quura PAIR Y sos you guos quod A549 POSAS oq vo JA Varo GAME 7 IT9IH3IA OL Buyers aug 9 PN Wo p pes ovo K2 52 owned s sud ou bp put you od PILL 549 s
6. NAVY INGNISTITIV DNINV3H T33H 200 ANCHO NULLOnUed i eunpeooJd SIUL eg SNN UO 46 SININNOD Qep ynu uum zy NU Bugsnipe eaoge 3 dejs ul Bunes 01 8 005 0 dn Ajquiesse jepjul 40 pesn eq ue eAoqe jeJeuec AOI v ZL SI uod pee elpuldS 069 UI jou Kau Yo Bupsnipe e oqe 3 des uj Bumes 01 8 009 03 dn ye Ajquiesse jepu 10 pesn eq youe uy eJeusc MOD v 9 81 OYJ ejpuids 0E9L MU ung 9j Yo Bupsn pe 5 des uj Bupes 01 g eeuec v 7y Pupsn pe 5 uj o 9 BADGE Mojo v ZE SI Yd ELOL MU OIdID3dS Aq jo uoprsod BINDES 4 4040 9 8007 Jo eBue1 eu sj pue Bupeeq yo peg we SI WBS Ipun jeu puey Aq ueyuBp 2500 ujoq euo
7. 2015 DMF Inc All Rights Reserved Page 61 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I NC Brake Assembly Ir A Drawing ILON 335 ATENISSY AY VMEDO rli NOLL R SIT H TF9T 82 F D DNILIIJ 3Sv345 3 50818 87 G6g I I X F9 6 gt 7705 2 esete Zr B E 4907 NSHSVA 8 97 B49 X 93 0876 1708 8 Bren Nid 3088 338 1 Mona 3338 2 Er ATENISSY 4 30 5 1 92818 zr ANLISYO DUE 592 5 Drug 1 027878 oF 9 11 0 Gg T X Z2 D SIAI 1 254818 6 Pe SAW 1 seres INGA ISM lova 3948 09618 Z 2 T 1 XB D 831100 9 Nid IDAId 5 3 vug 8 5781 RP HOOT HSA r 899818 7 849 2 1 X 1 2 9 DNILNNON 1114 997818 6 caan IXY NO SINNO 370095 2 2 JLON 399 14084 J xum 7 0113139534 LALO ON WALT 301 S M3DN3SSVd AYIA W3gNvHO Dya T T9318 BOIS SAJAD AFB Svea dy 1 09818 BOIS SMIDNISSYd 14044 MIENYHO J 659818 2 AQIS SAINT 1044 H3HNVHO Sve 1 85838611 UN 194 24 ILON ATSAGISSY NELLSAS TOHLNOD DNH UV
8. SI ISOH SZ AHL SIMENISSY DVYE IHL 1437 9007 JHL NI 0319007 509909 DNIMdS JHL HLIA 54112 JHL S3SUH 03179975 AHL NDW HOV3 5871 13 08 OL I3T14d30S2 SYIHSYMXDOT ANY SLIDE 8 30 9 2 T ANOS HOYI HOVLLV 2 T1 t 58110095 3 Xv 83118 355 DIAE TIVLSNI TION SRY DNI 40 31ITESEV Page 64 of 80 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS I NC RW 1420 Drawing Air Brake Adjustment ADJUST GAP WITH f CLEVIS amp JAM NUT NI 1 8 MIN SHOE THICKNESS ADJUST TO 1 16 REPLACE SHOE IF UNABLE ADJUST TO MAX ALLOWED 1 4 2015 DMF Inc All Rights Reserved Page 65 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I Nu d Safety Decals ion an Instruct 6 6 tv NOILYDO add NI SNId 134 5 39v1d43 9 E NOLLISOG AVAHDIH TTnd E NOLLISOG Hsnd V W SAR I SO IG AWA 31VALLOV SNId 134 5 SNOILONYLSNI de AUNG S IANH IN Mbd wk ow I3DIH3A 0343103 30 30 31V UOTA FY TAY 30 SONDE 3TIH3A SHL UGHSINI4 ONY TV9 IH 40 NOLLYOTIdd 4E dA 3TIH3A A H MALSNFCY 41 SAI LAO WOLLOG LON OG BAVA isd 0002
9. TEMPORARY 6 SPACER REAR INSTALLATION RAIL EM GAP 2015 DMF Inc All Rights Reserved RW 1420 Page 31 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 4 2 Spacer Installation Before proceeding place a temporary 6 6 x 3 8 wall steel tube spacer between the truck frame and Rear Mounting Bracket see Figure 4 2 Actuate both Rear Cylinders to raise the Rear Frame Bracket up to the truck frame NOTE With the Rear Railroader in position temporarily secure clamp chain etc in place to prevent any movement during the remaining installation Then raise the Rear Mounting Bracket with temporary 6 spacer and the truck frame and lift the truck wheels up off of the rear Installation Rails Measure the Gap from the top of the rear Installation Rails to the bottom of the tire with this 6 spacer in place as shown in Figure 4 2 The truck spring and tire deflection equals 6 0 minus the measured Gap To calculate the required Spacer thickness multiply the spring and tire deflection by 60 The formula is Calculated Spacer thickness 6 0 Gap x 60 The following table shows the calculated Spacer thickness given a certain Gap This table is given as an example Actual gaps may include fractions and the Spacer thickness will need to be calculated for that specific gap NOTE Some customers require a minimum spacer fo
10. 0 09 0 82 puey Aq Aeey nu Bupsnipe ejpurds ue uBLI g pue sBuueeq payed 9 Jo ad ejquiessy SHUN uto snO JSON 01 uopppy ul 099 L Mel 069 SLOMA SIHL GASSVdNOONS ATIVHSN3O SAMENISSV SuiejsAs Bupeeg peyunoyy pepu Bupeeg II 29890 ddy 3ovsn NONNOD sBupeeg Jo Ju eunsn pV SUL 104 SPOLA usilqe s3 o1 3SOduNd seujepino ueugsn py jeeuwepino TILIL Page 78 of 80 O 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS I NC RW 1420 A 8 Hi rail Cylinder Assembly Procedure re Piston Seals P N 24 DOA T ETIBORI 2409400 415 5 5 FT 1630 RA 00 RADALL While maintaining pressure 358 Indars With oll raulic RA is FE seconde at each extent requlres replacement yasaq gonoave surface facing Inboard piston Is belaw first cylinder port with clean at 3300 Maintain mm vertical position align piston with tube bors i 2 z 8 M a to 300 foot pounds torque p on port fittings alr and fil and mainta rod seal gland OD seal and cylinder bottom areas for leakage bottom when all preceding steps have been successfully accomplishe
11. G 3 5 lt J 5 lt 5 3 G Pp sp 16 02 21 2190 L pue eu O SINTO INGAIShPCUV NDLLOVNI ma s ap ms ati ier pie J peig uo eu ON Jo ppe JO HESY yun 10 pe Bupioddns JOMOT c syoq Bugunoui 1664 g eu 2 1601 sno 2 eu uo ei SMOJO eq UBD jueunsn pe BORIGA jueseJd Jou sj JEU Juans ul jeopieA eu jo jueugsn pe e1 enba jou pue sj 1698121 1891 ou L INSNLSTIUV NOLOVaL UO SU peujejqo useq seu Jedoid souo JOAL 94 uo BLIGJELI ullus SM0JOJ Se 31 SIL 40 eunpeooud snu re9Dgeu OY uy jo jueunsn pe aouen jo eps oj ap s JUGJSJELOO 22 suopsso JUSJUSAUOD Aue eq ued SJUG LI
12. rsmm St erme T 2108 001098 660098 T 1 ezert Plor rer 1 b rer 2 9 Ord sor sre 2 ever 2 rem A 0113139534 ALDO ON 1 WALT CI PV LSA NELL 40 SINYNOdINOO V 92 VE R SION NOLLVOM del OL ANYA NYO EE 9 91 72 PELU IION O 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC m 2 lt 2 lt 4 9 5 iz ing Draw pesrils 46 0 21 ONIAVET 13144 46 NAVE 2151 68 CFO SYOLVOINdv4 TVLIW 43141543 1 3244 NIV CALVINSNI NON NADHS 1319 1 5 1 1 4 ASSY 31 3 T33HA 0291 3 ITIL 13 11 9159530 LISHI T33H GILVINSNI 242 03004 50 6174 Y SHINYA T33HM GALVINSNI 25 0180 3015 SMIONISSVd GALVINSNINON ATENISSV 3235238 IV GD 314095 1 33538 217 SYIHSYMAIOT dYJDENH Cr X 81 91 62 SLIDE dYDENH 9 TIVL3T dYDENH AINO NULLVOIlddV G3LVINSND 31 ONIN SOLVYTINSNI lt 07 1 gt X3H 37XV INN 01 2 891 3 XV 3HSVA 01616 32 31 YIHSYM Q3TIV1SNI S39VS Saved 944802 SNI NUN 133HA 002 6 1504 1311 15 S30v8 M
13. Link Kit Position P N Short Links Upper Front Passenger 10765 10722 Upper Front Driver 10764 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10233 Lower Front Driver 10233 Lower Rear Passenger 10783 Lower Rear Driver 10782 Link Kit Position P N Long Links Upper Front Passenger 10720 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver 10230 Lower Rear Passenger 10781 Lower Rear Driver 10780 Link Kit Position P N X Short Links Upper Front Passenger 10769 10724 Upper Front Driver 10768 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10235 Link Kit Upper Rear Passenger Upper Rear Driver Position Lower Front Driver 10235 Lower Rear Passenger 10785 Lower Rear Driver 10784 Remote Pin off with Slotted Lower Links Link Kit Position P N Short Links Upper Front Passenger 10723 Upper Front Driver Long Links Upper Front Passenger 10721 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Link Kit Position P N X Short Links 10725 Upper Front Passenger Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger 2015 DMF Inc All Rights Reserved RW 1420 Page 44 of 80 DIVERSIFIED METAL FABRICATORS INC 4 6 Rear Link Variations with Tapered Links RW 1420 Manual Pin off with Standard Lower Links Link Kit Position P N Sh
14. Manual Pin off with Standard Lower Links Link Kit Position P N Short Links Upper Front Passenger 10765 10717 Upper Front Driver 10764 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10233 Lower Front Driver 10233 Lower Rear Passenger 10783 Lower Rear Driver 10782 Link Kit Position Long Links Upper Front Passenger 10715 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver 10230 Lower Rear Passenger 10781 Lower Rear Driver 10780 Link Kit Position X Short Links Upper Front Passenger 10719 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10235 Lower Front Driver 10235 Lower Rear Passenger 10785 Lower Rear Driver 10784 Manual Pin off with Slotted Lower Links Link Kit Position Short Links Upper Front Passenger 10718 Upper Front Driver Upper Rear Passenger Upper Rear Driver Link Kit Position Long Links Upper Front Passenger 10716 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Link Kit Position P N X Short Links Upper Front Passenger 10726 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger 2015 DMF Inc All Rights Reserved Page 43 of 80 DI VERSI FI ED METAL FABRICATORS INC Remote Pin off with Standard Lower Links
15. SNI Odd T33HA v002 6 DL amp 014 TC3TIVISNI 53294 4 SNI Id T33HA 5010 08 3992 ONISV38 6 0208 3 2 DNISV38 38989680 0490 15 1 35 7119134 31 104 06521 16521 26521 SaAvad SIV 94805 NO D3NI 380WN 303 12 3994 339 1 31DN NOILVLOY ILNY 1907 JIHSYA 3015 5 430 355 4 ATENISSY INVYJE NIV 95809 vOZvT NUIIVIUS IINV 3015 5 43 140 4934 ATHW3SSV 33938 219 20271 3015 5 439 355 4 3015 4 IND23 ASSY JENL 31 3015 5 3 3015 4 1 44 ASSY 3801 31 09881 AlO ON 1394 3015 SAIDNISSYd ANDY4 ATAWASSY INVJE 819 vaa 3015 SAIAIST LINDJA ATENISSY 30948 NIV 93409 NOILdIGISIT 10491 T 00251 1 ALO 1894 Wal 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Front Wheel amp Axle Assembly 1 ing Draw 3903 WHS 3 gt L6 v0 21 UA INIAVAT 3100 saz 2151 68 09 54049914493 TVLIW 43141543 1 SINE T3LVINSNI NON 3 lt NADHS CILYTNSNI 1 4 ASSY 1 3 T33HA FULL 11 9149530 SMIARNA G31V1nSNI 3018 SMIONISSVd GALVINSNINON S3 v38 NO DANI 3S0 403 2 8 3994 335 ALON WAV C3C0N3LX3 4
16. 3 0 d 034V83d0 37899 31DN39 OL 41 4 AM3IANDD OL 1494 TW SSONTSNI 31UN 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Exploded V Rear Wheel and Axle Assembly ing Draw 9 8114 gt 46 50 21 HSL ASK F HJEN N 13194 AE 1449 NAVE 2161 5 8 58019215891 WLIW I3IJISN3AIG 0319105 1 3 NADHS 031 1015 1 ASSV 31 9 T33HA NOL 534 31984 A3S ISPD T33H 03191015 242 03009 50 61 Y V 301 SUSAR IH3HA GSLVINSNI 5395 S J3IoON3SSVd T33HM G3ILVTINSNI NON EAM T FANE EN S en 119130 1390V8E D S3CINITA2 314495 31 4934 4 190 9 1113 359399 912818 96921 762818 NOLLYLOY LINY 007 YSHSVA NOLLYL08 IINY 543 59 3 1 dYDENH GP E X 81 91 6 51104 dYDENH 010 8 1 9 gt TIYLIT 49240 99521 rose 601008 801008 09521 AINO NOLLYIIddY CALVINSND 31 4019 INSNI 98521 COT N1 gt 31 INN 56521 01 AVL 3ITXV 3HSVA 86521 lt 01616 gt 3NONOL 31 YIHSYM 96521 G3TWISNI 532 4 533988 ON SNI NUN 133HA 1591 v002 6 1504 1311 15 532 4 SNI 242 133HA 11591 164 1640 00 5 002 6 01 20139 1311 15 329Va SNI 041 133HM 18591 010 08 3
17. 335 TH ALON 301 SAJAT ATENISSY Died velo SUIS SAIDNSISSYd ATHN3SSV DUE J 6001 3015 SAIDNISSYd IND ATENISSY DUE 1 3015 SAJAN IND ATENISSY IDE velar 1 7 0119149530 1 210 ON 1899 N11 Page 62 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC Brake Control System Assembly Ir A ing Draw ATHN3SSV WALSAS TOMINID PWA AY VEDO LIL NOILJINOS 31 ATENESSY W3LSAS Divdad UV HO br 8 JOVd 335 Died INNOW IATYA 567818 02 DUE Ay INIRII INNON 168818 6 L s 3015 SAMSDNISSYd NV3N 3HWVHO Drug 19988 ZI 301 SAJAN NV3N Dive NIV 97 301 SAEDNSSSYd INON W3HWVHJ Dive 657818 57 3015 SAJA IND 3HWvHO Dive 7 857818 r I g9 9 012 DE DNILLIJ 9 669818 9 Nd518 3TddIN Bereta T AL ON 1394 NAL 375 89 9 01702 LHDIVMIS DNILLI4 GGS X 90690 gt AYIA IINIT ly ISOH GL X 90690 gt DNI3dS 14044 1 MIY 35 29 X 90690H gt 9 DNISdS K 1 1ND334 3S0H CDDSBZNA ONY IID AVT3B8 ATA QZOTENDI OLY ND 9 lt 00 184 8 5 gt TIVE 55784 GATYA IV
18. ADI WSS 922192 Nid 41 0180 2015 DMF Inc All Rights Reserved RW 1420 DI VERSI FI ED METAL FABRICATORS I NC Cylinders I I IC Rear Hydrauli ing Draw 10619213 pg 4 3 nm AE TYYENYLS gt JUS 5 439 355 3015 SAGAD IIRILSB 56 X 2 1 1 3085 15 ATHN3SSV W3INITAO or 1 un NOILJINOS 30 9 1089 181 491 6 X MADE T3SNILLEd ldN 48 7 3SYIND 2 1 1 18 355 63015 SAMIDNISSYD 2 7 2 IATENISSY TIYAYA 3018 SAJAD 2 1 2 ATENISSY TIYAYA UEE B d I IOVE INF NIS D DEE Z 012 2 NOLSId 0 1 076 0057 0052 04 Was 0002 0052 NOLSId Was 91 8 75 LNN tr 1 81 1 Deere rere wo T omg oF 1 vere 1 sme 1 2 3 some 9 T some 5 T 48 1 8 7 20992 2 8 1 2 NOLSId 7 7 0113159534 LALO ON 1 NALI 391 00519214 N d 9 9 719130 9 9 119130 ACIS SAIDNISSYd 10817214 4404 3598 698 9 9 p 9a SSQNTONI Ty3S ADI WSS 922192 Nid 42 0180 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 4 5 Rear Link Variations
19. Inc All Rights Reserved Page 5 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Il ABS Brake System Trucks Equipped With ABS Brake System 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 Anti Lock Brake System The system is designed to prevent wheel lock up and jackknifing during braking It also provides increased vehicle stability and driver control The ABS consists of wheel speed sensors an ECU electronic control unit and all wiring and airlines that link the ABS components to the brakes and the truck s electrical system During braking the sensors will detect if one or more of the wheels are locking and automatically engage the ABS The ECU then signals the system to apply and release brake pressure as much as 15 times per second allowing the wheel s to turn just enough to maintain optimum traction Vehicles equipped with WABCO or 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
20. Proper clearances will allow the rail gear to move up and down with the truck front suspension As the truck tire hits bumps in the road the truck spring allows the front axle to move upward see Figure 3 4 Since the rail gear is attached to the spring just in front of the axle sufficient clearance must be allowed to prevent interference with other parts on the truck i e frame steering boxes shocks oil filters spring hangers hydraulic lines etc The Front Mounting Pin does not move in relation to the vehicle frame because it is fastened through the Frame Extension or directly to the truck frame As the Front Mounting Pin does not move and the Rear Mounting Pin at the axle does the rail gear effectively rotates about the Front Mounting Pin Therefore the part of the rail gear near the Rear Mounting Pin moves more than the part near the Front Mounting Pin and attention needs to be paid to the possible clearance problems that can be caused by this movement O 2015 DMF Inc All Rights Reserved Page 20 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 3 2 Align Front Railgear The front Railroaders now are ready to be squared up and aligned Three measurements need to be taken to insure that everything is aligned properly To align the Long Arms check 1 That they are parallel with each other and the truck frame The outside Long Arms should be the same distance apart at the Rear Mounting Pin as they are at the Front M
21. possible for a relief to be adjusted much higher than it s valve can withstand To ensure correct system pressure check with a gauge e Fill the Power Unit tank with Dextron II ATF e Hold the front push button down while spooling the front valve Operate the front railgear to fill the cylinders with fluid remember to re fill the tank e Repeat the procedure for the rear railgear 2015 DMF Inc All Rights Reserved Page 13 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS INC System Old Style Ic Hydrauli Drawing SOLVOIONI 437 SONS T3AIAS 370 N33 14 00 39 DI DNIENN Id G8 3NIT DWNT CCIE 7331 55314 15 9 T 0827 1540 1370901 HOLIMS T zwo 81 06006 x3s3H 3700 NOLLINGHSNd 1 89 01 e UZ 8F N dg HgE BUBd 43738 pied 1 2660 8 081 05 42 92 01 3 43113 INOA AWA 1 vero 2 5081 482 09 80 5 101043705 Svea AWA 1 9 dH k k dS NISMS mv SANA 1 oee S Z T 002 VA2 AD33N3 NOMS AWA 1 rooe 20 8 926 MINN 1 _ 25207 301 SMIDNISSYd VSN AO 7 ATIS SAJAN AO 1 00582 92 3015 5 355 4 INDY MO 1 301 SAMIART 14094 AI J 00098 vr AL ON NAL LD TH3HM NI
22. Alignment Single Axle Tandem Axle Tire to Rail Wheel center 13 1 4 inches 9 1 4 inches Minimum Truck Frame extension 19 1 4 inches 15 1 4 inches Calculated Spacer thickness w 6 spacer 6 0 GAP x 60 Check overall measurements Rear Truck Axle to Rear Railroader Axle straight A Rear Truck Axle to Rear Railroader Axle diagonal G B within 1 16 D within 1 8 F H Front Railroader to Rear Railroader straight Front Railroader to Rear Railroader diagonal within 1 8 within 1 4 2015 DMF Inc All Rights Reserved Page 67 of 80 DIVERSI FI ED METAL FABRICATORS I NC RW 1420 8 0 ENGAGING THE RAIL 8 1 Getting On the Rail Lower rear guide wheels first At the track crossing drive past the track then back the vehicle onto the rails Engage the truck s parking brake to prevent the truck from rolling If the railgear has brakes turn brake switch on Engage the PTO Remove the safety pin off pins one each side Push Pull valve handle to lower wheels to engage rail When both wheels are fully down and properly engaging rail replace safety pin off pins NOTE Rear end can be articulated to facilitate alignment by operating one spool at a time Lower front guide wheels If necessary drive the truck into position to line up the front guide wheels with the rail Engage the PTO Remove the safety pin off pins one each side
23. CIRD 91818 ES 31UN 335 GP E ASSV 430 14 334 ESIBIB ET 2 1 3 431103 862618 T T 15 gt 0311075 INN 952818 1 0 1914 SH3HSVA 688818 OT ze X 9 E Nid 31100 8 8 2616 6 zT 15 0311075 174 221818 8 DNIINNOW AJADI AVAA ASSY Nid 2 _ 15001 Z ASSY _ 05201 9 Nid 31914 1332938 ONTINNOW ava 2 _ 2700 f att 335 ASSV 130Vad avaa 439 1 ALON 335 55 142 _ 50407 2 ASSV IXY 3 T33HA T PZBPT I Z WALI 40 SIN3NOdWOO JYV 1 EL 88 NAL 3LON Page 36 of 80 O 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Pin offs cc K z 2 cc cc 3 G a 8 41 152 03110715 LAN ONILNNOW 83M07 ASSY Nid 11 130 319719 13920088 3933 121818 8 Z WALI JO SIN3NOdWOO SUV EL S4 WSL ILON Page 37 of 80 2015 DMF Inc All Rights Reserved RW 1420 Brackets ing Rear Mounti ing ate 0222114 20 20 01 ENON DNI VMI e AYT N ZIST C ABChOrY NI
24. Rights Reserved Page 11 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 2 0 HYDRAULIC SYSTEM CONNECTION 2 1 New Hydraulic System If only DMF Railroaders are to be installed and there is not an existing hydraulic system outfit the truck with the supplied 12 Volt DC power unit This unit will be used to actuate the railgear raise and lower cylinders only Refer to schematics on the following pages Mount the Power Unit Assembly in the desired location This might be under the hood behind the cab under behind the steps to the cab or another location that will provide suitable vandal protection Connect the large stud on the Power Unit solenoid to the battery with the supplied 1 0 cable Connect the grounding control terminal on the solenoid to an ignition switch energized push button switch to be located near each manual valve When either push button is held down the power unit should function The hoses that connect the directional valves to the cylinders are supplied in the kit All hoses to from the Power Unit and between the valves are to be supplied by the installer All hoses are to be SAE 10021 1 wire braid 4 with female swivel JIC 4 ends Using a pair of 38 hoses supplied loose in the kit connect the rod end of each front cylinder to one working port on the front manual directional valve with a 4 JIC tee Use the other pair of 38 hoses to connect the blind ends of the cylinders to the other work port The rear valve is
25. S T33HM NOLLINOI DU HALVE DA ACh HO UMS DIVYA JO AVALSNI TOHLNOO Diva ATIVA DINOMLOFTA 0170 ISN 50404 NO Page 14 of 80 O 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC System New Style IC Hydrauli Drawing NOLL THOS isd 0081 isd 022 0091 049 mi 431734 431734 NL LU JH awed 14049 INE 5938 K Fases 24 THA LHDIT SOLYOIGNI C31 SUN3 T3AIAS ITYNIS 001 395 LA DNIENN TA CBH INIT 3 13315 5531 1 15 1540 1370901 HILI S 81 0 006 3700 NOLLNEHSNd HOLI S 1884 NADHS LOND DYSE TIOHINV caray INDAD N DHS gt YUE T H13IN9I 45 NGS3ND 934 SATA 8 1 002 ADN3N3 UNONA AWA 926 LINN 341 SMIDNISSYd 3015 SAARC 142 3015 SAIDNISSYd INDYA MO T ET 301 SAMIART 14094 AI J 00098 vr AL ON NAL 1551 39 241 141 ANO SDIVHE INOM NMOHS LON Q7OJINVIN DAVAYA 2601 ALON SDIvUE LNOU NMOHS DivuE PEPOL N d 3LON NOLLINOI DU YALL DA ATI Divua JO AVALSNI TOHLNOO DIVHE DINOMLOSTA 0120 TYNINH
26. Spring Hanger Bracket as shown in Figure 3 1 For Spring Hanger Brackets other than the 4 or 6 please call DMF See the following table to determine the number of Spacers The number of Spacers shown in this table does not include the top Spacer that is used above the truck springs The top Spacer has no effect on the height of the rail gear and is only used for clamping purposes Table A Spacers Required RW 1420 w 4 Spring Hanger Bracket 2 7 8 c top w 6 Spring Hanger Bracket 5 1 2 c top Spacer A 14 5 8 3t of Spacers Spacer A 17 1 4 14 5 8 15 1 8 0 to 1 2 15 1 4 to 16 1 8 16 1 4 to 17 1 8 17 1 4 to 18 1 8 18 1 4 to 19 1 8 Figure 3 1 FRONT PI RW 1630 RW 1420 RW 1212 5 8 to 1 1 2 1 5 8 to 2 1 2 2 5 8 to 3 1 2 Use 6 Spring Hanger Bracket TRUCK FRAME FRAME EXTENSION MN d N HEIGHT Z 25 172 is 2 ze 24 12 23 1 2 s r PIN RW 1420 11 3747 1 RW 1212 10 374 RAIL LS eus 22 7 5 Oy SPRING HANGER Use 4 Spring Hanger Bracket Use 4 Spring Hanger Bracket 0 0 to 7 8 1 to 1 7 8 1 SPACERS 4 OR 6 5 8 SPRING HANGER r BRACKET DAL COMMONLY REFERED TO AS THE 4 OT 6 BRACKET 2 7 8 OR 5 172 SPRING HANGER 1 REAR PIN HEIGHT RW 1630 12 3 4 2015 DMF Inc All Rights
27. 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 Rail Operation of Trucks with ABS Brake System Active While operating on track with the railgear down the ABS becomes ineffective in brake application at lower speeds If the ABS is active and the truck moving on rail with front wheels elevated the amber dash light may come on Since the front wheels are not rotating the motion sensors may transmit a fault indication to the ABS which signals the dash lamp to illuminate inadvertently This will not affect rear truck braking or rail wheel braking if applicable When the truck is returned to road operation the ABS fault must be cleared by turning the engine off and re starting At this time the diagnostic check will repeat as stated above NOTE This procedure is applicable only to WABCO and Allied Bendix ABS Brake Systems For any other ABS Brake System contact DMF for assistance 2015 DMF Inc All Rights Reserved Page 6 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 III Initial Instructions Work Area The area in which the Railgear installation is to occur should meet minimum requirements in order to facilitate the process and prov
28. and stow in provided storage tubes Check and make sure that the front guide wheels line up with the rail then engage wheels NOTE The front guide wheel assembly is an over center design and does not require safety pin off pins engaged in the rail mode On the tracks Do not exceed 30 MPH while on the track All railroad speed rules should be observed Be aware that some high rail gear is insulated and will not operate the crossing gate circuits e Reduce speed at all crossings curves branch lines switches and frogs e Traction is reduced on the track especially wet conditions Tire damage may result from spinning wheels on track e Braking distance is increased on the track especially in wet conditions Do not slide tires or guide wheels on the tracks 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 with the front wheels elevated This will not effect rear truck braking or rail wheel braking 8 2 Getting Off the Rail Removing truck from track Engage the PTO and the truck parking brakes Leave the truck running and the transmission in neutral gear Lift both sets of railgear there is no preference for removal order Engage the safety pin off pins in highway position Disengage the switch that controls the railgear brakes if applicable Disengage the PTO before moving the truck If the
29. pre plumbed to the cylinders and mounted on the rear mounting bracket This may be relocated as required Plumb from the pressure port on the Power Unit to the inlet of the front directional valve Plumb from the outlet of the front directional valve to the inlet of the rear directional valve and from the outlet of the rear directional valve to the tank return fitting on the Power Unit Be certain that the front and rear valves are plumbed correctly Each valve port is marked IN or OUT Plumbing the valves backward will cause an unsafe condition possible injury and or damage 2015 DMF Inc All Rights Reserved Page 12 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 2 2 Hydraulic System with Brakes NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance Kits supplied with guidewheel brakes have the Power Unit plumbed to the braking valves The Power Unit Assembly will be used to operate the railgear to raise and lower functions and operate the guidewheel brakes Refer to schematics on the following pages e Install the hydraulic system as the basic system above however Plumb from the pressure port on the Power Unit to port P on the solenoid diverter brak
30. specifically referring to warranty coverage are not followed Equipment or parts not manufactured by this company but which are furnished in connection with DMF products are covered directly and solely by the warranty of the manufacturer supplying them This warranty is in lieu of other warranties expressed or implied including any implied warranties of merchantability or fitness for a particular purpose and any liability for special or consequential damages All warranty claims must reference a serial number Returns must reference a RMA number 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 2015 DMF Inc All Rights Reserved Page 80 of 80
31. to Drawing Air Brake Assembly Position the brake assembly one inch from the end of the axle tube and leave 1 8 clearance between the chamber and the lower scissors link Refer to DWG 818402 Tack the mounting plates to the axle tube Refer to Drawing Air Brake Assembly Weld the mounting plates to the axle tubes with 1 8 to 3 16 fillets Install the guide wheels Check for clearance On the front axle the brake assembly should be located vertically over the axle and vertically behind the wheel The assembly should be roughly 1 4 clear of all parts of the wheel On the rear axle the assembly is angled slightly down from horizontal so that the chamber will clear the scissors link by 1 8 All other clearances to the wheel should be roughly 1 4 Replace the Cobra shoes in the brake assemblies Adjust the chamber clevis until the shoe is just clear of the wheel Plumbing Installation An air toggle valve labeled brakes on off is 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 Near the front and rear if equipped guide wheel axle 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 vehicle supply system or directly from the main air tanks There is a ball valve a
32. 1 3 Railgear Installation RaIISuu u u usay a meme mense emen messen enn 10 1 4 Preliminary Installation cesses III me messen n enne 11 2 0 Hydraulic System Connection arasnarnnnnvnnnnvnnnnnnnnnvnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 12 2 1 New Hydraulic es e nen enne nns 12 2 2 Hydraulic System with ese he esee eres 13 2 3 Brakes cot es aa de eR ebd are ange 13 Drawing Hydraulic System Old 14 Drawing Hydraulic System New Style 15 Drawing Brake Valve Manifold 16 Drawing Valve Assemblies amp Hydraulic 17 3 0 Front Railgear Installation asrarnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnn 18 3 1 Front Railgear eir ieee ide ened pe x Pe eee eee re 18 3 2 Align FrONtiRAll Cal teneo trente e t 21 3 3 FinalFront nstallatlo mesg u ua endet per Eee ERE uapa cee a baa ede de eed aa 23 Drawing Front Railgear Assembly 24 Drawing Front Wheel amp Axle Assembly 1 25 Drawing Front Wheel amp Axle Assembly lI sss mes 26 Drawing RW 1420 Wheel Exploded 27 Drawing RW
33. 1420 Wheels Identification 28 Drawing Front Hydraulic meme hens 29 4 0 Rear Railgear Installation a arannnnnnnnnnnnnnnnnnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnnn 30 4 1 Location of Rear ene hehe s ag 30 4 2 Spacer Nstallation u AW Elec aes eel ote ches wed Speake ee 32 4 3 Square Rear Railroader with Truck 34 4 4 Final Rear Installation u u u ususi anis III eee tese nnn 35 Drawing Rear Railgear Assembly with Manual Pin offs 36 Drawing Rear Railgear Assembly with Remote Pin offs 37 Drawing Rear Mounting 5 38 Drawing Manual amp Remote Pin offs and 39 Drawing Rear Wheel and Axle Assembly Exploded View 40 Drawing Rear Hydraulic Cylinders 41 Drawing Rear Hydraulic Cylinders 42 4 5 Link Variations cao 43 4 6 Rear Link Variations with Tapered Links 45 Drawing Rear Link 2 2 070 0 4 4 47 5 0 Front To Rear Alignment sannnnnnnnnnnnnnnnnnnnnnnnnnnnnn
34. 379501 503 440 NOD 31773 UN3531 ZE0ZE0SA gt WIV 319901 JAWA 07 84 145 9 6 0 NOLLOSLONd MSI JAWA 0119139530 268818 verste e r rere e r 9 seree 5 888818 r severe 16 serere 2 serere 7 PALO UN 1svd NLT Page 63 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Brake I nstallat ir A ing Draw 2905 10981888 iR 0997 148 N VIND NOLLYTIVLSNI 33998 MIV DETAY CIND NOLLYTTYLSNI BIY DETAR NOILJINOS 3 341 HOVA 35974 SdITO 341 30974 54 764818 N d AV139 IDOYA OL 3ATYA AYTAY LNNOW HIDIH3A 3Hl 30 3931N39 YYIY IHL 139088 DNILNNON SHL YIONN 034 907 3A WA AVTIY JHL OL HOWLLY S3SDH yuq NOT 465 349 SSSOH JHL SdITO 1 5 IHL HOVE 587 14 08 Dl SNOYOL 5 5 ONY 51708 8 IYAD 3 1 ANDA HOWE H YLLY 5310095 3Y SIAO SAMANISSY 33948 TIVISNI ITN N d INNON AYTAY HLIA 31914 04 ASSY 3ATWA HIOIH3A 3Hl 30 31N39 3H1 315714 DNLINNON SHL S3UND 03449 07 JAWA AYTAY IHL OL HOWLLY SASOH Divad 1431 SI 3SUH 29 3HL
35. 6 6 Instruction and Safety Decals 0 20 66 7 0 Final CheckliSt annannnnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnnnnnnvannnvannnvnnnnvannnvannnnnvnnnnvnnnnvnnnnvnnnnvnnnnner 67 DMF RW 1420 Railroader Installation Check 5 67 8 0 Engaging the Rail 68 8 1 Getting On the 68 8 2 Getting Off the sense estes a Esa asa sa nnns 68 9 0 Routine U U U U 70 9 1 Inspection amp 70 9 2 Lubricatiori SpeciIfiGatIOnk u u a cece eee eee eee nena e 71 Drawing Grease Point Locations 2 72 Appendix A Technical Data aanannannnnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnner 73 Working Pressure Ratings for SAE Hose and 5 73 2 Welding Information east peed ende pe 73 SAE O ring Fitting Installation sss mnm mens eee enne 74 A 4 NPT Pipe Thread Fitting Installation 75 A 5 SAE JIC 37 Deg Flare Fitting Installation 2 2 1 2 2 2 2 77 2 2 22 4 76 A 6 Purchased Fastener Torque Sp
36. 992 ONISV38 06521 6 0408 WH SNI3V38 16521 898 6422 UYVANYIS WIS 26521 19130 31 ALNG AAV3H 50921 530944 ON UNINTTIM 3934 ASSY 3401 9 31 06821 2530 UN 1394 Page 40 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS INC Cylinders Ic Rear Hydrauli ing Draw 10919213 4 HSE AE CONOD GUIS S 839N3SSVd 30 SANNO IDIRLSB 2 01 X mBZ T T X 2 1 355 SGUNITAD DZFT AM En NOILJINOS 3U N3d 035079 8 2 H 9 r AN T089 181 9176 X DE T3 Z 90092 EF ldN 8 T NILA SRD T ezoa zr ve2 1 18 355 CM 7 verne T C3UIS SAIDNISSYD 2 1 8 IMTENISSY 134499848 T 3015 SAAND Z T 2 AISN3SSY 134494 T 07 0 d I OIOVE ONRI O T 60892 6 DEE 2 UNV 0 1 80686 0 2 2 molsid 7 zome Z Ov UIN 1 9ome 9 0061 0052 Iwas 1 somre 5 0008 0052 NOLSId was 892 9T F 8 MODAN UMN T FT 20889 8 Wusid 7 CNT TOSS ALD UN 1 04 JUIS ACIS SAIDNISSYd DOFIF2Z14 N d 10919214 1904 ISVE 9 9 719130 9 9 119130 4404 IN3 3598 698 9 9 p 9a SSIONTONI 7739
37. 9VS NOAWOO SURYA ojneipAH eunsseig 017 IVS JO eu L 404 SPORAN YSJIGEISF 01 3SOdUNd Bug ZE OIN SVS JIL 0119139534 LALO ON 1894 Page 76 of 80 O 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC ARININ SEYO uj AE Odd 48 E ee g NULLVOLJIO3dS 1 NINILSV m zy Aq uj 90D INTIMA NOLLONEOYG Se i idi N me teens Lx A polltide Jaddoo ep HUF una Ip pus SE PNS Aedes 5594 JO SJUEIPGN J pejjdde sjueopqni ou 510 syjeq GJE peppeds senpa enbJo V S INSNNOS sere sser szor Ses PET PT me Fus o erate eet 09 ozz sn ost 8 5 en en o us el 2 in 5 r o Q EY 2 91 2 r2 8 E 7 9 6 dl VID 1NN SNTHVA33d 4 esl M 8 M9 MJ y 1 vS c
38. AL ISN 50404 NO ALON S T33HM 15 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC fold Assembly Brake Valve Mani ing Draw ASSY UDJINYN DWAL 0291 2181 6101 ILL NUILLdISUS 30 241 HI fdl N d 492 WYASDVIC LINDEN 90719 3 14 3AUW33 3501312179 TIYLSNI ALIAYD 3 AUW38 Orid N 0E B0d9 I S 9 1 19 80 5 00 07 80 E NE 0DIS 081 05 0 1 8055 20721 40 1D 1935 L ON TON A10 ON HALI Y 6F0TUH 33974 NAHL r8 0 EM Zdl HI U399flld 31DN ONY 1804 JAWA Syed AND ANOMS gt TIOSINYN 3A7wA yaa va v 0113159534 1 410 DN NLT a99N 1d T3499 1d ALON 26 0 Jaw 51 0 10 119 8 1 IDNILSLId Page 16 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I Nu IC Schemati IC amp Hydrauli res Valve Assembli ing Draw OILVN3HOS OITDWSAH SAMENISSY NOILJINOS 30 AG 3SUH LINDI TAH oroo re cimo 06908 69 case 989018 ee eaaa 18 Se3I
39. DIVERSIFIED METAL FABRICATORS I NC S SEQYQY O Installation and Parts amp Service Manual RW 1420 May 2015 SERIAL NUMBER FRONT SERIAL NUMBER REAR NOTE Please refer to the serial numbers when ordering parts or inquiring about warranty items DMF 665 Pylant Street Atlanta Georgia 30306 Parts 404 607 1684 Parts Fax 404 879 7888 parts dmfatlanta com Service Department 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com DIVERSIFIED METAL FABRICATORS INC RW 1420 TABLE OF CONTENTS Table of Contents 2 dens 4 ua s aetna aren decent idest desees adonde nis 4 Il ABS Brake System uras asua re date XE ne EE n bere eve ev dea erp eka nee 6 HERE SEFUCTIONS Sick 7 1 0 Railgear Components amp General Information 8 Led JEront Rallgear 5o ade en dus ved Asa paya Siga a uya qayasqa pusu 8 1 2 Rear Railgear etx ede sex ey xe re 9
40. G JNSBS LU 9894 9 ON eq ue pue 1801 O JUOY JEL 08 01 GU 0 GUI fe PUUBLP JO je e PUB uo Z 10 Jo UINUJUJLU eu peyeyul eq pinoys su saup uj eunsseud Peyo uopoedsu Jo dous sejdde eanpeocud eu g dous juewubje peyenb Aq eq Pinoys sju enp 0 o EUOBEIP eu uo 9 L ULM eu exenbs eq pinous eje B PP Z JeuoBejp uo 8 UM ezenbs eq uer amp 1n290 BujBuey gu JO JUGLIUBIE pessauppe eq Ajo pinoys pue suopeaypeds eq oj POLUNSSS ul enu z pue Sd3LS v INSNNOTTYV iti Page 50 of 80 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 6 0 INSTALLATION OF OPTIONS 6 1 Rail Sweeps The components that make up the standard Front and Rear Rail Sweeps are the same for Railroaders without any brakes For Rail Sweeps provided with Cobra Brakes the mounting brackets are shorter Installation of Rail Sweeps is done while the Railgear is in the rail position For standard Rail Sweeps without brakes weld the Mounting Bracket directly to the Railgear Axle Tube ori
41. Inc All Rights Reserved Page 54 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I NC res Wheel Lock Assembl ing Steering Draw 4 DNIA VMI 81 1 228 909 554 1 WLAN 5 AE Udd SNOLLYISYA SASSY MOI TASHA 43315 NOILJINOS JU ODI N AYO JU 214 5 V ISN SI SMONYL LSOW 114 OL X907 733HM SNIN331S V SVH ANT 021208 N d TAIHA DNIdOOSITIL 0 14 YINITLHDIISH 291208 N d 0082 289 061208 N d LSIAGN ALN 83S 0504 Bu 091208 N d CHOOSE 007808 N d MISNS Taos 091808 N d T X TIYSNOO DL X907 133HM 3315 va pereo va va eros 733HM va 095208 9 JAHM 15 3 114 133 45315 3 097208 114 114 va v3 voee owe F9 DK 803 1 T33H SNRI3IS 1 997208 OT Cz 0Ho UNN 8 __ 6 C y 8 X 1708 3 207008 8 ipovad 20108 Aas 9 DNINdS 50408 6 1 Nid INSHOTGA T 27108 Po 7 sere 2 NAN OO SNINS3IS 1914 INSKOTIA HOLYT 1900
42. MMON USAGE 2015 DMF Inc All Rights Reserved Page 79 of 80 DIVERSIFIED METAL FABRICATORS I NC RW 1420 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 manufacturer to be free of defects in material and workmanship under normal use and service for a period of ONE CALENDAR YEAR DMF s obligation under this warranty is limited to repairing or 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 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
43. N INON AWA 908018 159 0008 8 do 53 S DNILSIXI gt Camp 6 amp gt 5 RAL Page 17 of 80 2015 DMF Inc All Rights Reserved DIVERSI FI ED METAL FABRICATORS I NC RW 1420 3 0 FRONT RAILGEAR I NSTALLATION 3 1 Front Railgear NOTE The Railroader unit that we have shipped to you has been designed for your specific truck However before starting the front Railroader installation check the vehicle s front tire spacing The front rail gear operates between the front steering tires therefore you must have a minimum of 65 between the tires If this is not the case contact DMF With the front Railroader under the truck frame Spacer thickness can be determined Spacers may be required to place the front rail gear at the proper height Measure the ground clearance of the front spring just in front of the front axle beam A as shown in Figure 3 1 The correct distance from the ground to the center of the Rear Mounting Pin with the front truck tires on the ground should be 11 3 4 In order to obtain this 11 3 4 distance 1 Spacers should be used between the spring and the Spring Bracket Spacer distance is dependent on the Spring Hanger Bracket supplied Nominal 4 or 6 c top dimension 2 7 8 or 5 1 2 To determine which Spring Hanger Bracket is supplied measure the distance from the Rear Mounting Pin center to the top of the
44. N 231111 YY Im 75 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC Flare Fitting Installation A 5 SAE JIC 37 Deg e 13179 AG 148 NAVY NOLLYTIVISNI DNILLL4 500 3MNNTIIDOYd NOILONCOYd 142531 21 8 4 21 8 5 21 91 5 21 91 1 1 9I E 81 91 6 02 91 Z 13334 221 2 aan S6un 4 14 94014 ZE OIM 395 jo JEL snuju sj uo LUN e Jo LIS L 0 enbe sj xeu e uo Jey euo 8U Bunsim o BuuejyBn yueuiuBire u esou ey pjou pu0998 esf 141474 8je 4 popu jnu O 3nu esou Bujdwep nu uo Apog jo esou 3sujeBe eqm Aue suing JO ere sued ensue o sjueuoduioo Joedsul v spu3 pe1e eeJBeq 6 017 IVS sPumiJ peseyoung SIHL GASSVdWOONA ATIVHIN3O SAYVd jueuoduog 10 184 000p saInsseld IV pesegr unejoned uM suiejs s 3
45. N TI vert S3 vaE BIV M 3015 SAIINISSYd 1043 d33As T 6 SDKA NIV 3015 SAJANI INU33 43385194 T IXY 2 gt qav NVIS AdgN3sSv I 7 0119199534 A19 UN 18yd WALT 52 of 80 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 6 2 Remote Pin Off Pins Reference Drawing Manual amp Remote Pin offs and Cables in section 4 4 Cable operated Pin Offs are available on the Front Single 3 4 or Rear Dual 1 The Front Cable Remote Pin Offs weld onto either the outer or preferably inner Long Arms The Rear Remote Pin Offs components are shown in the Pin Off Drawing The Rear Remote Pin offs can be operated with a manual cable assembly or air actuated Remove the 1 4 20 hex nut 7 16 14 hex end cap and the internal tooth lock washer Slide the cable through the fixed pin off plate Replace the internal tooth lock washer 7 16 14 hex end cap and the 1 4 20 hex nut Add a 1 4 lock washer on the end of the cable and screw the cable into the sliding pin plate Tighten the 1 4 20 hex nut on to the lock washer and pin plate Mount two cable handle mounting plates not supplied These plates should have a 3 4 hole to attach the handle end of the cable to This plate should be securely located near the rear rail wheel valve Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate an
46. N VMI AG Gddv 21 o ACO SIYAR ON 5 AT HISSY AYIDA 1044 OgrT AM NOILJINOS JU 3190 A38 1 re gt CD O9 yo C 04 Page 24 of 80 Igear Assembly Front Ra ing DIVERSIFIED METAL FABRICATORS I N lt Draw X Dr HOS r E NId SIL INL 3095 DNOT ATENISSVY JIL CARD 3015 SAMIDNISSYd ATENISSY 440 NId CARD 301 S M3ATIMC ATENISSY 41 14 GP M3OVdS ONTLNNOW 1339938 DNISMdS ANOS ATENISSY 1339738 DNIBMdS yd DNLINNON 4384414 1329938 DNTIMdS 2 1 2 431105 2 1 1814 9 8 17 CALLOS LAN GZ 91 62 NId 531109 B P 9344075 LON 341155049 INLINNON 14043 301 AMIDNISSYd LINDVSE DNLINDDON 14044 301 SAJAT LI0V8E DNLINNON 14041 3015 SAMIDNISSYd 14044 ATEMISSY YICNITAD OMNYYTAH 3015 SAJAT IND ATEHISSY YICNITAD OMNVATAH SIAYA ON SNI NOND 14134 ATHW3SSV 38nl ITXY 53013 HIDE YANNI 14043 ATEAISSY NEW 3015 S M3ON3SSVd YALNO 14044 ATENISSY N ONT 3015 SAJAT S3LNO 14044 5 KAY 3015 SAMIDNISSYd 14044 ATEKISSY WAY LOAId 3015 S MJAIMI 14043 1 355 082 SI3CNIAD INDR44 AIOVAS GZ X 0r HOS F E JIL 3600 430995 Way LOAId ATENISSY JIL ONILNNON 14043 ATEN3SSV NId Or 0506 Zz T esters 2 091878 581818 esters 91878 verre 881818 2 281818
47. NITAO SNW3INITAO 14044 S3SUH TAQ ONS N3INDAO P INIA KOMA ONITE JINTAO SONILLLJT M 001 5 435340 MILNIAIT SATA SONILLI4P E 5 5 INISI i31N3AIT AWA 59 11114 2 1 8 06 5 IN3S3MD MILNIAIT AWA ADMINI IINGW3OV d3M LINOYSE 3 7l NVH JA NA ANID N3S329D FININIDYTIdIN 310 9 THA 370NYH N3s38D lIN3N3Ov 14339 3T NSH JAWA AJHN3SSV ADBGN3 LIN3N3OV7Id3N ITONYH 3A NA ANITZA 35345 IN3N3OV 1434 3T1UNVH SONILLLJ SA NA N3S3MD fuv ATHAGSSV SONILLLJ JAWA ADW3N3 INOS ATHW3SSV Bd DNILL3S 431734 camo ve cas oezo 6 aD orzo ur steore Zr Boe Cap 218018 57 Cap stos r case 8018 430 roere TT 0119139534 1 410 DN 1 CL3IND M3IMSATU NUM 154 0052 _ DNILL3S 43734 SUNS UNIT MIUNIUD C SUNE UM X Ld x 016018 o 144 71 X LAN 2 1 gt DNIHSNE 906018 COIT 0 X FD X LAN 331 BOEDTE 4 ADET DNILLL4 05078 DNIN H 395 90 X DH AD amp ET3 DNILLLS 50012 CONIISIXD NOLLONS MEL Camp 5 gt 35349 N31N3AIT SATA 018 dH b dS 5353802 MINIS GAWA 8 1 008 YAI ADNA
48. ONNVETAH ASSV INVEE 314095 33938 31 SYIHSYMAIOT dYJDENH Cr X 81 91 62 SLIDE dYDENH 81 6 91 601008 91 SI 9 119131 dYDENH AINO NUILVOIlddV G3LVINSND 31 ONIN SOLVYINSNI 01 2 37XV INN 01 2 891 3 XV 3HSVA 01616 32 31 YIHSYM cseszi et gesar Q3TIV1SNI S39VS 530944 SNI NUN 133HA 002 6 1504 GATWISNI S30v8 M SNI 242 T33HA v002 6 DL amp 014 TC3TIVISNI S30v8 M SNI Id T33HA 010 08 3992 ONISV38 6 0208 3 2 DNISV38 38989680 0490 15 1 35 7119134 31 104 o6ser 8 16681 2 26521 9 NOILVLOY ILNY 1907 JIHSYA NUIIVIUS IINV 3015 5 439 355 4 3015 4 IND23 ASSY JENL 31 3015 5 3 3015 4 1 44 ASSY 3801 31 14 143 ALO ON 18394 WILI Page 26 of 80 2015 DMF Inc All Rights Reserved RW 1420 Drawing RW 1420 Wheel Exploded View DIVERSIFIED METAL FABRICATORS INC G3TW1SNI S3A331S HOLVTNSNI 9 13316 HLOG M 12591 Nid CATIVLSNI 5 1289 Nid 9 2189 N d HLOG 3LON v002 6 33139 4 YOLVINSNI 30319 2 002 6 01 dn 35149049 JAIITS SOLVINSNI 30319 T GA IND NOVOTNY 319 0SND 3V ONIN MOLVINSNI 0 01 98621 or POND INN 2 6658 6 GVA
49. PRING Item Description 1 5 BR E 2 SPACERS if required ON FRONT TRUCK SP t Top required AXLE 4 RUBBER SPACER 5 RE MOUNTING PIN 6 FR RAIL WHEEL 7 PIVOT ARM 8 FRO CYLINDER 3 LONG ARM 10 FR MOUNTING PIN 11 FRAME MOUNTING BRACKET 12 FRO EXTENSION if required 13 STEERING WHEEL GUIDE Figure 1 2 2015 DMF Inc All Rights Reserved Page 8 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 1 2 Rear Railgear Figure 1 3 shows the individual parts of the installed rear Railgear with the Rail Wheels in the rail position down The item descriptions will be used throughout this installation manual Figure 1 3 TRUCK FRAME TRUCK TIRE 1 5 1 da 4 a ED o 23 1 1 Item Description 6 FRAME BRACKET 3 MOUNTING PLATE inside Bracket C SPACER if required D VALVE ASSEMBLY UPPER LINK F LOWER LINK Figure 1 4 2015 DMF Inc All Rights Reserved Page 9 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 1 3 Railgear Install
50. Reserved Page 18 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Figure 3 2 Frame Extension 4 Frame Mounting Bracket If they are required per Table A the 1 x 2 flat bar Spacers are placed between the Spring Bracket and the underside of the truck spring Use the 8 bar to lever the Long Arms and Spring Brackets up to the springs as in Figure 2 1 After lifting the Long Arms attach each Spring Bracket to the truck spring using a Rubber Spacer directly above the spring a 1 x 2 flat bar Spacer on top of the Rubber Spacer and two 3 4 10 hex nuts per stud Push the Spring Brackets back against the axle beam and tighten the hex nuts two per stud onto the top Spacer to cage the springs The nuts should be tightened down until the Rubber Spacer begins to deform from the downward pressure squeezes out between the top Spacer and spring Remove the Front Pin Offs and set the steering tires straight ahead The front Railgear can now be actuated with the hydraulic system which will cause the Long Arms to be raised up to the Frame Extension see Figure 3 2 The Cross Tube Mounting Bracket only needs to be brought up to where it touches the Frame Extension or truck frame not raised all the way to lift the truck frame and raise the truck tires In order to install the front of the front Rail Gear at the correct height the center of the Front Mounting Pins must be located at 24 1 2 from the ground w
51. SAOLYOINEY4A TWLIN OIL3ISMIAIT SLISSND DIG MVONV IS A THN3SSV 1 DNILNNON 0291 NDILdISOS3I ddv AG E ou 48 1 4 iH 113559 v re 5 9 XDI X B E 31979 0311075 8 2 2 X TAPPE X 2 38nl SSON eb 8 L X 2 1 X B T VE YIOYdS 1 91 TE S 1 TE sYa 58007 e i se 8 E rE 82221 18001 86221 9v amp rE 25821 08007 8 L v amp 96821 se 9222 9 6 96 680 Seggi 48 56 26221 vezzi 2 1 OCTET NOISNAWIC ON Lavd 458 NG 03654 3135510 GUVONVLS S300 1d tiHHLD TEM LITH E NO ON 93089 NO TEM LITH 7 0 271 37991 339 V X E T X B T ye w39vds B L L X TIY YTE X 2 55045 2 4 8 X g T 1135510 28001 01 X 6 X B E 1315719 0311075 2 Page 38 of 80 DI VERSI FI ED METAL FABRICATORS I NC Draw X 8 E IAH ALYT AWA 05 0 X B E MIAH 131979 veg DOLL 97805 30 PALO UN 0119140530 110 UN 1894 H311 O 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC offs and Cabl
52. SIFIED METAL FABRICATORS INC RW 1420 4 3 Square Rear Railroader with Truck Axle Once the proper height and tire to rail gear location has been achieved the Rear Railroader needs to be made absolutely square with the rear truck axle Four measurements shown in Figure 4 4 need to be taken to insure this requirement 1 The distance from the truck axle to the Rear Railroader Axle at each end In Figure 4 4 distance A must be equal to within 1 16 This is an important alignment check 2 The diagonal from the truck axle to the opposite Rear Rail Wheel In Figure 4 4 distance C must be equal to D within 1 8 NOTE Although the previous mounting conditions and alignment may be met be certain that enough room exists between the Rear Railroader and other equipment In general this should include a 2 clearance around the rail gear more clearance will be needed if Remote Pin offs are installed Also insure that there is clearance to remove the Pin Offs from their holes 2015 DMF Inc All Rights Reserved Page 34 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 4 4 Final Rear Installation NOTE If more than 1 16 inch of space exists between the truck frame and the Rear Frame Bracket on each side it will be necessary to install shim plates to center the Railroaders These should be 12 x 12 shims of the proper thickness with equal thickness used on each side These can be fabricated
53. TOM X INDG G T gt ATHN3SSV RGUNITAO 14043 0891 HSL ee SER 66009214 TP gore Wa gru ras AN EA 66009214 N d 00109214 N d LLL NUILLdISUS 30 led 10d laid T 1 ANI 3578 NG UN3 904 904 UN3 5 390 91 11 02 0350719 Ic 9 AN 10B9 BI 91 6 X QIF p T ADETA 2 EF ldN 8 T ONILLIJ asyo 1 Goa T GUS SAEDNISSYD Z T r 385 1355498 T smog ais SAND 2 1 AlENISSY lave T 07 41 30 8 UNV ONRI O 1 6 9rE 2 UNV 0 1 2 101519 ONA 3 Zoe 2 ee z s s y NALI SACMTONI LD Twas Te 656 1 somre 9 JD TWAS SING 0002 0525 1009 Iwas T somre 5 5286 0216 NOLSId was 8 FIT MOOTAN INN 7 60 9 __ 7 801098 8 2 7 T c Cc AL 1 UN i d SLT Front Hydraul ing Draw Page 29 of 80 O 2015 DMF Inc All Rights Reserved DIVERSI FI ED METAL FABRICATORS I NC RW 1420 4 0 REAR RAILGEAR I NSTALLATION NOTE It is important that the truck tire pressure especially the rear tires be checked and brought to the manufacturers recommended level With the truck on the rear Installation Rails position the Re
54. Transverse Torque Rods On vehicles that will regularly experience high center of gravity loads on rail e g spray trucks material loaders it is advisable to install rear tandem control rods to limit transverse axle displacement This is also necessary of long wheel base vehicles to limit front tandem walking off in curves Front and Rear Installation Rails In order to install the Railroader to get proper tire traction on the rail it is necessary that standard gauge rails or Installation Rails be fabricated from 3 square tubing per Figure 1 5 Drive the truck into the work area pulling forward and back several times to align the axles and up onto the Rear Installation Rails The rear inside tires should be on the rails with the rear outside tires off the floor The Front Installation Rails are not needed at this point NOTE Before proceeding be certain that the front truck tires are chocked and the brakes are set 2015 DMF Inc All Rights Reserved Page 7 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 1 0 RAILGEAR COMPONENTS amp GENERAL I NFORMATION 1 1 Front Railgear Figure 1 1 shows the individual parts of the installed front Railgear with the Rail Wheels in the rail position down The item descriptions will be used throughout this installation manual DMF Railgear assemblies are also referred to as guide wheels rail wheels or railroaders Figure 1 1 FRONT TRUCK 4 S
55. amber ABS dash light remains on during rail operation the truck engine must be turned off and restarted after returning to highway operation This will clear the ABS after a few seconds If the amber light remains on during road operation the truck s brake 2015 DMF Inc All Rights Reserved Page 68 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 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 Page 69 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 9 0 ROUTINE MAINTENANCE 9 1 Inspection amp Maintenance If your hi rail vehicle is high use or operated under extreme conditions such as operating in mountainous regions or extreme temperatures the levels of inspections listed below may need to be performed more frequently than stated The following are instructions for routine inspections recommended by Diversified Metal Fabricators In some circumstances government or corporate regulations may require additional inspections be performed Please ensure that you are aware of any inspection requirements that pertain to your rail gear and that you abide by all local and national laws regarding rail gear maintenance and safety Daily Maintenance e Visually inspect for hydraulic fluid leaks e Check and make sure that all threaded fasteners are secured NOTE All hex nuts are either nylon insert or slotted hex nuts
56. ar Railgear as close to the rear tires as practical allowing clearance for mud flaps The following table gives standard location and clearance guidelines for the rear rail gear and these dimensions are shown in Figure 4 1 Generally leave a minimum of 2 clearance to any tire spring or suspension components Minimum Distance from Single Axle Tandem Axle Tire to Rail Wheel Center 13 1 4 9 1 4 Min Truck Frame Extension from tire 19 1 4 15 1 4 Overall Rail Gear Clearance from tire 20 1 4 x 19 16 1 4 x 19 If the truck frame does not extend the minimum of 19 1 4 for single axle or 15 1 4 for tandem axle trucks it should be properly lengthened to provide the necessary mounting clearance for the rail gear In addition because the rail gear typically drops straight down but it can also articulate from side to side to allow alignment of the vehicle with the rail a clear space of 19 inches must extend outward from each side of the frame in this area to allow for proper articulation see Figure 4 1 It is important that nothing encroach upon this space i e outriggers lift gates body tie down bolts Figure 4 1 SINGLE AXLE TRUCK TANDEM AXLE TRUCK FRAME INE 3 1 4 1 4 19 20 1 47 E 52 2015 DMF Inc All Rights Reserved Page 30 of 80 DIVERSIFIED METAL FABRICATORS INC Figure 4 2 CLAMPS TRUCK FRAME TRUCK TIRE
57. ar guidewheel axle is set parallel to the rear drive axle first see Drawing Alignment Procedure amp Traction Adjustment With the guidewheels in the rail position recheck the side and diagonal measurements to the drive axle housing The side measurements should be within 1 16 and the diagonals within 1 8 Loosen the mounting bolts and slide the mounting bracket as necessary Tighten the bolts The front guidewheel axle must be set square to the rear guidewheel axle diagonally measure from the right front guidewheel to the left rear guidewheel D 1 then from the left front guidewheel to the right rear guidewheel D 2 These measurements must be within 1 4 inch Measure from the left front guidewheel to the left rear guidewheel C 1 then from the right front guidewheel to the right rear guidewheel C 2 These measurements must be within 1 8 inch If D 1 and C 2 are shorter than D 2 and C 1 shim the right front railwheel forward The left front guidewheel should be shimmed forward in the opposite case These shims can be flat bar located between the bottom of the long arms and the welded stop block on the pivot arms If the C dimensions are equal and the D dimensions are not the front guidewheel axle can be slid to the side within space limitations to help equalize these dimensions Maintain a minimum 1 4 gap between the guidewheel and the inside of the steering tire Start with a 1 8th inch shim and pla
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59. ation Rails In order to install the Railroader to get proper tire traction on the rail it is necessary that standard gauge rails or Installation Rails be fabricated from 3 standard channel per Figure 1 5 Drive the truck into the work area pulling forward and back several times to align the axles and up onto the Rear Installation Rails The rear inside tires should be on the rails with the rear outside tires off the floor The Front Installation Rails are not needed at this point NOTE Before proceeding be certain that the front truck tires are chocked and the brakes are set Figure 1 5 Sa Inside to Inside 56 1 2 1 2 x 3 HRFB Front Installation Rails Rear Installation Rails 10 Cap ends of rails on 45 Figure 1 6 O 2015 DMF Inc All Rights Reserved Page 10 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 1 4 Preliminary Installation Remove the truck front bumper Bolt the Frame Extension to the truck frame refer to Figure 1 1 amp Figure 1 2 Make sure that tilt cabs of hoods will clear the Frame Extensions Trim the brackets and re gusset them if necessary All truck Frame Extensions that are bolt on brackets must use 5 8 18 fine thread bolts hardened steel washers and Grade 8 prevailing torque locknuts All of the 5 8 18 Gr 8 fasteners should be tightened per Purchased Fastener Torque Specification Table Dwg PP006 in Appendix A Check that the Frame Exten
60. c hoses and fittings meet these pressures ratings and that they conform to SAE J517 Hydraulic Hoses and SAE J 516 Hydraulic Fittings NOTE The SAE ratings for hoses can be found stamped on the hose outer surface A 2 Welding Information e Dual Shield Wire spec gt AWS E71T 1 e Low Hydrogen spec gt AWS E 7018 Low Hydrogen Electrodes AWS E 7018 Manufacturer Equivalent 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 2015 DMF Inc All Rights Reserved Page 73 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I NC ring Fitting Installation A 3 SAE O m E JM3ENDN DNI VHI NOLLYTIVISNI ONILLIS DNIS D 200 NOLLONEOY 13444 221 Paull 213 2215 222 4409 375 Sun 3404 35 59 11114 318 15 0 59 11114 3 8V1Shf V uod jo uo syees dn pue 81 jeu ensue 9 ung Jo Yep p7 snumu JO snid uejuBp uo eoueJejo JO ujg enbe sj xey uo je SuO mojeq mp UON ELD osten pv ul 1444 146 3301 Ip
61. ce it between the stop block welded to the pivot arm and bottom of the stationary arm near the axle mounting bracket All four pivot arms have stop blocks Add shims as required so the load is carried by all blocks When the proper spacer thickness has been found to square the guidewheels tack each shim to the top of its stop block per drawing below If equipped with railsweeps rotate each front axle tube half until the railsweep rubber is vertical Weld three 1 2 tacks each axle tube half to its outside pivot arm The inside pivot arms are not welded allowing cylinder removal After the Front and Rear Railroaders have been properly aligned complete structural welds may be applied at these locations that were previously only tacked o On the Front Railroader between the Frame Mounting Bracket and Frame or Frame Extensions if required the Front Railroader between the Axle Tube and outside Pivot Arms a continuous weld on the inboard side of the outside Pivot Arm is required NOTE For all structural welds either low hydrogen rod or dual shield Mig wire should be used refer to Appendix 2015 DMF Inc All Rights Reserved Page 48 of 80 DIVERSIFIED METAL FABRICATORS I NC RW 1420 Figure 5 1 INSTALL SHIM 0 AR HERE 2015 DMF Inc All Rights Reserved Page 49 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS INC P d rw 5 2 J u G
62. d rau Cring facing O ring In Step E Be certaln that O ring seats In 3 threads and no burrs Deburr as neccassary outboard side facing the rod end and bore and blow out with shop air as and dings sert side facing tha closer piston face rp edges Deburr as neccessary bly alr ule ke rod end with hammer unti g per dal pa 6 Pcr end of rod assem In tube bore engage rdraulle power nger through Inder to full exten ona Inspect n each e Disconnect ES facing inboard In assemb wit fading oi on Ss alr p 4 2 to cylinder ly Inspect unit and to ad with sho ic oll to ald Ming in bore with I with lip o ri assem sh rts for minimum three blow off win y seals with each o ring D and bore for shai blow p ul geal da on In ng for Inder nier d Nr LE 325 EES i inm nimi moa lt OT tube ID th tir All Models PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE D Impression 3 z i B COMMENTS 5 assembly Instructions on prints are performed with preference over this procedure ROD ASSEMBLY 5 5 5 5 2 o PISTON PURPOSE To Establish Production Methods For The Assembly Of Cylinders TITLE Cylinder Assembly CO
63. d replace the 5 8 11 hex end cap Replace the T handle on the cable 2015 DMF Inc All Rights Reserved Page 53 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 6 3 Steering Wheel Locks Carefully remove the face cover from the steering wheel Position the Lock Bracket at the 12 o clock position on the steering wheel hub The U should be facing the speedometer and at the lower edge of the steering wheel The Lock Bracket should not interfere with any other part of the truck as the steering wheel is turned Mark the hole locations and drill 2 3 16 holes Using the 10 24 flat socket head screws and the 10 24 nuts attach the Lock Bracket Strap the Latch Weldment around the column and tighten until the clamp starts to grip With the latch in the down position move the Latch Pin into line with the Lock Bracket There should be a 1 2 gap between the Lock Bracket and the Latch Weldment Tighten the Latch Weldment hose clamp securely NOTE Check to be sure that nothing interferes with the normal operation of the steering wheel Check the operation of the latch for fit and operation with the Lock Bracket After making all necessary adjustments drill a 125 hole through the column strap at the loose end near the truck s turn signal Use a 1 8 x 3 4 pop rivet to secure the column strap and the Latch Weldment into place Replace steering wheel cover For more information see the Steering Wheel Lock Drawing 2015 DMF
64. distance from the inside of the Rail Wheel to the truck frame If the measurements are off slide the Rail Wheels and Axle assembly to one side the Axle Tube will slide through the holes in the Pivot Arms Depending on the brake configuration used the Axle Tube will need to be rotated in order to locate front Railroader components in the right position The possible configurations are Without Brakes If the rail gear is not supplied with any brakes the Steering Wheel Locks must be aligned as shown in Figure 3 5 When the front Railroaders are down in the rail position these Steering Wheel Locks prevent the front truck wheel from interfering with the rail gear operation With Cobra Hydraulic Brakes If the rail gear is supplied with Cobra Hydraulic Brakes factory installed then they need to be rotated around so that they are oriented in the correct position see Figure 6 4 For the rest of the Brake installation see Section 6 3 O 2015 DMF Inc All Rights Reserved Page 21 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Figure 3 5 With the Axle Tubes now centered and brake configuration determined the Axle Tubes should be tacked to each outside Pivot Arm The inside Pivot Arms should not be welded to the Axle Tube to facilitate ease of disassembly for repair or future maintenance Final welding is performed after alignment in Section 5 0 The front Railroaders are ready to be lowered o
65. e power unit the same one that the push button switches are wired to The last terminal is wired out to the tab terminal on the brake solenoid diverter valve e When the control panel is properly wired the indicator lamp will illuminate the solenoid valve will spool the coil will get warm and the power unit will operate when the switch is 2015 DMF Inc All Rights Reserved Page 56 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 in the on position and the brake pedal is depressed far enough to trip the stop lamp switch While an assistant depresses the brake pedal loosen the bleeder fitting at each brake until the air is expelled As the system is bled keep fluid in the reservoir to prevent pumping air back into the lines Bleed each wheel once then repeat to make certain that all the air is bled out 2015 DMF Inc All Rights Reserved Page 57 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS INC Drawing Hydraulic Brake Assemblies ASSV TAI zpival 01281 C33eb 58 of 80 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRICATORS INC RW 1420 Drawing Hydraulic Brake Adjustment 1 8 MIN SHOE TO ADJUST REMOVE ROD END PIN AND THREAD ADAPTER gt DESIRED LENGTH TIGHTEN JAM NUT TO CYLINDER BODY REINSERT ROD END PIN O ADJUST TO 1 16 REPLACE SHOE IF UNABLE TO ADJUST TO MAX ALLOWED 1 4 4
66. e uou ejqejsnipe ynu uoy 4 3465 Inun ese od o umop Meg Uonisod PJOY 0 youe esn euo uey Aq weosun Bumy ejqejsnipe ue 3 Aresseoeu eq Buluoue uw JUBIT pod Jpejuoo pinoys pe uou e98 xeu ejqejsn pe 1 dn peg pun pod mers o dn peysnd si osoo 8 dn peq ons eye ejqissod se se 490 ejqejsn pe 104 2 Jo Jo BURJ O 8 seppied uBjeJoj Aue JO 05 pju suing JO eey ee sped poq JEU ensue ju amp iens IVS spes SHUMI peseyoind 3 SIHL GASSVdWOONS ATIVHSNSO SLYWd JO ISd 0007 ojeg Jy spiniJ Bupesedo suejs s 35VSN NONNOD eunsseJg uBIH puy tunip N JO SUL 404 uoponpoud usiiqe sd 01 ASOdYNd uogejejsu 3 1LLL 0113139534 LALO ON 1 Page 74 of 80 O 2015 DMF Inc All Rights Reserved RW 1420 DI VERSI FI ED METAL FABRICATORS I NC A 4 NPT Pipe Thread Fitting In
67. e valve Plumb from port DH on the solenoid diverter brake valve to the inlet of the front directional valve 2 3 Hydraulic Brakes Only NOTE The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail mode As the vehicle rear tires are in contact with the railhead the primary braking effort is derived from the rubber tires Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance e If the chassis has been outfitted with a PTO hydraulic system The railgear raise and lower function may be plumbed into that system Using an appropriately sized manual diverter valve such as a Gresen S 50 the railgear may be tapped into the loop and plumbed as in section 2 1 above To operate the railgear brakes the 12 Volt DC Power Unit may be used to operate the braking circuit only This prevents having to run the PTO circuit while traveling down the rail e Install the Power Unit and connect to the battery as above Plumb from the outlet of the brake system pressure control valve to the brakes per the OPTIONS section that follows Railroader valves have built in pressure reliefs and the hydraulic working pressure of the system is 2000 psi The front valve is preset to 2000 psi at the relief The rear valves are preset to 1500 psi and all other parts supplied by DMF are rated to 2500 psi Care must be exercised that the relief in any of the valves is not inadvertently exceeded It is
68. ecification r r 77 A 7 Railwheel Bearing Adjustment 00 1 78 A 8 Hi rail Cylinder Assembly 79 DMF Limited Warranty Policy arannannnnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnvannnunnnnvannnvannnvannnvannnvnnnnvnnnnner 80 2015 DMF Inc All Rights Reserved Page 3 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 SET UP NOTE Read all instructions and check that all required parts and Kits are included before beginning the installation The proper installation of this equipment is solely the responsibility of you the authorized installer When in doubt contact DMF for assistance Tools Required for I nstallation e Electric Welder Arc or Mig e General Mechanic Tools e Cutting Torch e Hoist or Floor J ack e 8 Lx 1 1 2 dia Tube or Bar e Hand Grinder e Frame Drill w 5 8 Drill Bit e Protective Clothing Goggles Supplied Parts Check List Part Qty Manuals P amp S and Install Including Decal Package 1 Front RW 1420 Rail Gear 1 Rear RW 1420 Rail Gear 1 Rear Mounting Plates 4 6 X 1 2 w 4 Holes 2 Front Frame Extensions if Required 2 Front Valve Plate Assembly w Hydraulic Hoses amp 2 Push Button Switch 1 1 Installed Monarch Hydraulic Power Unit Assembly 1 1 0 Power Cable X 86 w lugs 1 Optional Parts Check List Part Qty Rail Sw
69. eeps Front Right or Left or Axle Set 1 each Rail Sweeps Rear Right or Left or Axle Set 1 each Remote Pin Off Assembly on Rear Rail Gear 2 each Remote Pin Off Cable w T Handle 2 each Hydraulic Brake Assembly Front or Rear Right or Left 1 each Hydraulic Brake Control System Front and or Rear 1 each Air Brake Assembly Front or Rear Right or Left 1 each Air Brake Control System Front and or Rear 1 each Steering Wheel Lock Kit 1 each Shim Kit for Rear Bracket 12 12 2 1 8 1 4 amp 3 8 1 kit 2015 DMF Inc All Rights Reserved Page 4 of 80 DI VERSI FI ED METAL FABRICATORS INC RW 1420 Additional Material that may be Required Item Qty Hydraulic Hose Appropriate Size amp Rating for System As Required Swivel Hose Ends Appropriate Size amp Rating for System As Required Diverter Valve Appropriate Size amp Rating for System As Required Hydraulic Oil Unax RX 46 or Equivalent As Required Bolts amp Lock Nuts 5 8 18 Gr 8 if Frame Extensions are Required As Required Bolts amp Nylock Nuts 5 8 11 Gr 5 Rear Mounting Bracket Plates 8 each Steel Channel 3 wide x 4 long for Front Installation Rails 2 each Steel Channel 3 wide x 10 long for Front Installation Rails 2 each Steel Flat Bar 1 2 x 3 x 56 1 2 long for Installation Rails 4 each Steel Square Tube 6 6 3 8 12 long Temporary Spacer 2 each 2015 DMF
70. ented so that the Rubber is flush with the rail as shown in the Railsweep Drawing For Rail Sweeps with Cobra Hydraulic Brakes bolt the shorter Mounting Bracket directly to the Brake structure on the front bolt on the side facing forward on the rear bolt to the top of the Air Brake which faces backward For more information see the Railsweep Drawing 2015 DMF Inc All Rights Reserved Page 51 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I NC ions iat d Var G 2 Isweep Assembli ing Rai Draw 3 E Ode 4g SNOLLVINYA P SINENISSY d33 STIVM 0891 ILL NUILLdISUS 30 SPAWN NO 59 03103135 ISDW ERT 4 WALT ILON CONN 97 8 8 gt INN 125818 07 B E X901 MIHSV vesere 6 B E W3HSV r 80588 0 2 1 1 X 9 SOHH gt 9 1708 F Z 19130 3845 iva 1 506818 9 19130 31719 ONLINNOA da3As 7 6818 5 1708 SIAE SIY S N3ON3SSVd 1332V38 DNIINDUN 7 08997 NO 1708 Sayeed WIV M TINS 1 ONTLNNOW 407 2 NO O7GM TXYONVLS INS 13N0V8E ONTINNOW 14291 T NT TOSS 110 nu Ld ALT opm NOTE ATENSSSV dSMSTIVE AVTA SNULLVIMVA ATENISSY d33MS Iva WIV IIS SMIDNISSYd AYI d33As 1 6 SDE NIV 301 SAJAT d3a sTv
71. es Pin Manual amp Remote ing Draw 86 90 01 13190 Oddy N ONI VMU OIN3N39 LIM 140438 28 i 4 ATENASSY 440 NId 31879 02 7 Y LIL Sve NULLdINOS3U Aza k t lad SA33D NId TYNNYN ANN X3H 992 329 ATENISSY 440 NId 31DW38 W3HSVA MIDT TYNNILNI 91 LAN Det T N 52 M3HSVA 1708 073 X3H 2 1 5 X 81 2 1 126818 285818 essere 318VO 430 Nid 3lDW38 TIN 7935 LON NET MN3HSV 1914 91 L XOU 97 2 US wes _ sem wmm er meme HET Wa S3 VO 1438 NOILYOTTddY S114 1538 LYHL 31899 3Hl A3I93dS XH O T 866818 N d ANN WYP 9 8 5 966818 N d MOI TYNNILNI 8 5 G65B1BH m WJENITAI 022618 N d Page 39 of 80 31979 9 5668798 N d 82714 gt LON 8I 2 1 8214 2 YIHSYMMIDT 2 ATEKISSY 440 NId 1 AY SLOWSY OL S440 Nid 37890 SLONFY SLYGANOO ZFS8I8 N d 164 ILON ONS DB G MIHSY X907 TYNAILNI B S WYP 2 8 6 LOT 94 SrZ0T 3780 6 S gt NIT LYOHS 0 318 2 9 4 SANIT DNOT Zt LOT 37840 8Z SANIT DNOT 3118929 2674 SANT ONT gt o SAD 0138 33DNId ILONIG
72. ide adequate conditions in which the work can be completed safely accurately and in a timely manner e Floor The floor should be level in order to provide good measurements required to check the alignment of the Railroader e Lighting The work area should be adequately lighted e Space There should be enough space to maneuver the Railroader components into position and to safely work around other equipment Truck Condition Before installation the truck should be checked in some important areas e Tires The tire pressure should be checked the manufacturer s recommended inflation and for consistent pressure readings from all the tires This will ensure correct traction of the tires on the rails Also the condition of the rear tires needs to be determined If the rear tires are worn they should be replaced e Alignment Rear truck axle must be square with truck frame DMF recommends that a reputable alignment shop check this 0 degree thrust angle which can be different than the factory specification is required for proper Railroader operation e Frame amp Suspension On a new truck these should be in good condition On a used truck the frame should be inspected to insure that it has not been damaged or bent The suspension bushings should also be examined for excessive wear and replaced if necessary If any problems in these areas are not corrected it will cause difficulties aligning and operating the rail gear
73. ith the truck tires on the ground as shown in Figure 3 1 If required shim the Cross Tube Mounting Bracket to obtain this 24 1 2 Any shims used should be load bearing members no thin wall tubing If necessary a different Frame Mounting Bracket can be used to obtain the desired height of the Front Mounting Pin Check for truck frame spring steering gear or other truck component interference with the Railroader equipment particularly the Long Arms see CLEARANCE NOTE in this section Front Mounting Pin ground clearance may be reduced to as low as 22 to provide for proper fit NOTE If the vehicle is supplied with an integral extended front frame or a set back front axle the Frame Extension will not be required The Frame Mounting Bracket can be brought up to the extended frame as shown in Figure 3 3 Follow all instructions for finding the Front Mounting Pin height with the Frame Extensions Solid or load bearing Spacers may be required between the bracket amp the bottom of the frame to obtain the desired 24 1 2 from ground to Front Mounting Pin 2015 DMF Inc All Rights Reserved Page 19 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Figure 3 3 Front Mounting Pir Integral Extended Truck Frame or set back front axle CHECK FOR INTERFERENCE N TH IS AREA CLEARANCE NOTE
74. n the Installation Rails As the rail gear is lowered check the clearance from the truck tire to the Rail Wheels If there is interference stop lowering the wheels and retrace the installation steps to fix the problem When the Railroaders are completely lowered the front truck tires should be approximately 2 inches above the Installation Rails If rail gear will not lift the truck check that the cylinders are not cross plumbed that the system pressure relief valve if present is set high enough and that the pressure relief on the Front Railroader Valve is set high enough Re check the center alignment of the Rail Wheels to the truck frame If it is off break the tacks between the outside Pivot Arms and Axle Tube and slide the Axle Tube to the correct position and re tack in place 2015 DMF Inc All Rights Reserved Page 22 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 3 3 Final Front Installation If the Spring Bracket location had to be adjusted make sure that the hex nuts two per stud on both 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 3 4 in section 3 1 Remount the truck front bumper or use 8 std channel welded onto the ends of the Frame Extensions O 2015 DMF Inc All Rights Reserved Page 23 of 80 RW 1420 IT
75. nd 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 set to be set so that the guide wheels do not lockup and slide The guide wheel brake chambers are connected to the SERVICE ports on the guide wheel air brake relay valve Install the airlines and valves per DMF instructions Make certain that the valve assembly for the front indicates that it has been preset to 75 psi 2015 DMF Inc All Rights Reserved Page 60 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Testing Put the vehicle on a test track With the on off toggle valve on and the ball valve s open check that The guide wheel brakes tightly clamp the rail wheel when the vehicle brake pedal 15 depressed The brakes properly release when the brake pedal is released The guide wheels do not slide when the guide wheel brakes are applied 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
76. nnnnnnnnnnnnannnvannnvannnvannnvnnnnvannnvannnnnver 48 5 1 Final Align mente bade Gs de steere dre a 48 Drawing Alignment Procedure and Traction 50 2015 DMF Inc All Rights Reserved Page 2 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 6 0 Installation of Options 51 6 1 RallSWeeps epi ete Sed iis ceeded eevee xin Dx Pe eines Xr Pg De DE YR 51 Drawing Railsweep Assemblies and 5 52 6 2 Remote Pin OPE PINS ur nasa kresne ree Ee Er Ear SU rat 53 6 3 Steering Wheel Locks reae px gaa ae 54 Drawing Steering Wheel Lock Assemblies csse mmn 55 6 4 Hydraulic Brake 5 56 Drawing Hydraulic Brake 0 58 Drawing Hydraulic Brake Adjustment 59 6 5 Air Connections coe eR RUE 60 Drawing Air Brake 2 2 24 0 07 0 s eme shes ee eren nn 62 Drawing Air Brake Control System Assembly mmn 63 Drawing Air Brake lt 2 2 1 1 11 6 64 Drawing Air Brake eren nnns 65
77. on P N Long Links Upper Front Passenger 10720 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger Lower Front Driver 10230 Lower Rear Passenger 10781 Lower Rear Driver 10780 Link Kit Position P N X Short Links Upper Front Passenger 10769 10724 Upper Front Driver 10768 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10235 Link Kit Upper Rear Passenger Upper Rear Driver Position Lower Front Driver 10235 Lower Rear Passenger 10785 Lower Rear Driver 10784 Remote Pin off with Slotted Lower Links Link Kit Position P N Short Links Upper Front Passenger 10723 Upper Front Driver Long Links Upper Front Passenger 10721 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Link Kit Position P N X Short Links 10725 Upper Front Passenger Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger 2015 DMF Inc All Rights Reserved RW 1420 Page 46 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I NC 90620714 5 ec 5 0 SNHISN3NIG ANIT 0O2grI 21g1 6101 Page 47 of 80 491 11 9 9T T 01 SNOISNSWIG ANT AVY 0 1 121 6101 9 2015 DMF Inc All Rights Reserved DI VERSI FI ED METAL FABRICATORS INC RW 1420 5 0 FRONT TO REAR ALIGNMENT 5 1 Final Alignment The re
78. or DMF shim plates may be used Using the Mounting Plate as a drill template drill four 5 8 holes through the truck frame Locate the Mounting Plate so as to allow for maximum adjustment of the Rear Frame Bracket see Figure 4 5 Bolt the Mounting Plate to the Rear Frame Bracket through the shims if required and truck frame with 5 8 11 Grade 5 bolts amp nylock nuts Tack weld the Mounting Plate to the Rear Frame Bracket If re adjustment is later needed the welds may be ground off amp the Rear Frame Bracket slid up or down by loosening the bolts in the slots Also tack the Spacer into place as shown in Figure 4 6 Figure 4 5 TRUCK FRAME V 2 WELD CENTER TOP amp BOTTOM De ae re Hex Head Bolt 4x 5 5 8 11 Grade 5 e 5 MOUNTING PLATE N 1 N 3 REAR FRAME BRACKET Figure 4 6 TRUCK FRAME SPACER 2 gt CRM TACK WELD 1 vA 4 REAR FRAME BRACKET 2015 DMF Inc All Rights Reserved Page 35 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS I Nu offs 75 gt lt c z a 2161 5648 POP NI SHOULVODIEV I WLM T3LAISHSATT 440 NId WONVH SVIN IWOIdAL ATGM3SSV SVIN 0Ogy Au RENN SNIAVtXI Ad 4 6105 TIM Eis 335 Gb E ASSV JJO Nid
79. ort Links Upper Front Passenger 10765 10735 Upper Front Driver 10764 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10733 Lower Front Driver 10733 Lower Rear Passenger 10787 Lower Rear Driver 10786 Link Kit Position Long Links Upper Front Passenger 10695 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Links Link Kit Position X Short Links Upper Front Passenger 10797 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Links 10737 Manual Pin off with Slotted Lower Links Link Kit Position P N Short Links Upper Front Passenger 10736 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Link Kit Position P N Long Links Upper Front Passenger 10697 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Link Kit Position P N X Short Links Upper Front Passenger 10799 Upper Front Driver Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10738 2015 DMF Inc All Rights Reserved Page 45 of 80 DI VERSI FI ED METAL FABRICATORS INC Remote Pin off with Standard Lower Links Link Kit Position P N Short Links Upper Front Passenger 10765 10722 Upper Front Driver 10764 Upper Rear Passenger Upper Rear Driver Lower Front Passenger 10233 Lower Front Driver 10233 Lower Rear Passenger 10783 Lower Rear Driver 10782 Link Kit Positi
80. ounting Pin This prevents the mechanism from binding during up down operation of the rail gear Also the distance from the Long Arms to the truck frame should be the same on each side 2 That they are the same distance forward Measure the distance from the Front Mounting Pin to a common point in the truck frame i e a grease fitting on the Spring Hanger If the measurements are off square the Railroaders by loosening the nuts on one spring hanger and moving forward on the truck spring and re tighten To check the Spring Bracket location check 3 That the Spring Bracket to truck axle distance is same on both sides Measure the distance from each Spring Bracket back to the truck axle Since the forward position of the Long Arms has been verified Check 2 an off measurement here probably means the front truck axle is mis aligned and needs to be corrected After these alignment checks and after insuring there are sufficient clearances the Frame Mounting Brackets can be tack welded to the Frame Extensions NOTE Do not attach the welding machine ground clamp onto the Rail Wheels This will cause arcing across the bearings inside the wheels and lead to premature bearing failure Raise the front Rail Wheels just above the floor enough to slide the front Installation Rails into place under the Rail Wheels Because the Railroader Axle assembly is not fixed to the Pivot Arms the Rail Wheels need to be centered To center measure the
81. procedure Rail test for proper traction and braking If abnormal adjust properly see traction procedure 2015 DMF Inc All Rights Reserved Page 70 of 80 DI VERSI FI ED METAL FABRICATORS INC RW 1420 Annual Maintenance or as required In addition to the items listed in Daily Maintenance Weekly Maintenance and Bi annual Maintenance perform the following e Disassemble inspect repack and reassemble Rail Wheel Bearings as shown in Section 5 5 4 11 5 4 12 amp 5 5 5 9 2 Lubrication Specification Hydraulic oil e Unax RX 46 hydraulic oil or equal Wheel bearings Grease Fittings e Factory Standard Citgo Syndurance Premium Synthetic 460 2 e Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 or equivalent 2015 DMF Inc All Rights Reserved Page 71 of 80 RW 1420 DIVERSIFIED METAL FABRICATORS INC int Locati Grease Po ing Draw SNOILYOOT LNIOd 389349 NOILJINOS JU Page 72 of 80 2015 DMF Inc All Rights Reserved DIVERSIFIED METAL FABRICATORS INC RW 1420 APPENDIX A TECHNICAL DATA A 1 Working Pressure Ratings for SAE Hose and Fittings The following table gives the recommended working pressures for SAE J517 Hose and SAE J516 Fittings Hose Diameter 100 R1 100 R2 4 2750 psi 5000 psi 6 2250 psi 4000 psi 8 2000 psi 3500 psi 12 1250 psi 2250 psi Contact hose supplier to confirm that the hydrauli
82. r future adjustability Contact your customer to determine his requirements Spring amp Tire Deflection Calculated Spacer thickness p 6 0 Gap 6 0 Gap x 60 Release the clamps holding the Rear Frame Bracket to the truck frame Collapse the Rear Railroader to the folded position which will lower the truck wheels back down on the Installation Rails Replace the temporary 6 spacers with the permanent Calculated Spacers and tack in place onto the Rear Frame Bracket These permanent Spacers should be solid steel pieces because they will experience the full structural load seen by the rear frame Extend the Rear Railroader to the rail position which will raise the truck frame The truck inner duals should be flat to slightly cupping the installation rails Too much weight on these tires truck frame too low will cause rapid tire wear Not enough weight truck frame too high will cause wheel spin and poor braking see Fig 4 3 If necessary adjust the Spacer thickness to achieve the proper tire cap on the Installation Rails 2015 DMF Inc All Rights Reserved Page 32 of 80 DIVERSIFIED METAL FABRICATORS INC RW 1420 Figure 4 3 Frame Frame Too Frame Too Properly Set High Low Figure 4 4 REAR TRUCK AXLE ALIGNMENT CHECK A B within within 1 REAR REAR RAILROADER AXLE 2015 DMF Inc All Rights Reserved Page 33 of 80 DIVER
83. sion tubes are level front to rear and side to side with the frame NOTE DMF front frame extensions are designed to support the front hi rail gear only It is the installer s responsibility to properly engineer bracketry for rail racks boom rests etc In normal applications mount the Front Valve Plate Assembly between the Frame Extensions with the Energy Valve on the underside and the handle facing forward and weld in place In case this is not possible mount Valve Assembly in the most appropriate and easily accessible location NOTE If the vehicle has been supplied with an integral extended front frame or set back front axle the Frame Extensions will not be required The Front Valve Plate can be attached directly to the extended truck frame Roll the Rear Railgear up on the Rear Installation Rails under the truck frame in the back The rear rail gear is usually installed with the Safety Pin Offs either manual cable or air operated towards the rear However truck body work may dictate locating the Pin Offs on the front side If the Rear Pin Offs must be located toward the front and the Railgear is supplied with insulated Rail Wheels make sure to swap the left and right Rail Wheels The insulated Rail Wheels should always be on the driver s side of the rail gear The unit can be leaned upright against the truck frame block the wheels to prevent movement during the hydraulic system connection 2015 DMF Inc All
84. stallation HSL MIEKON SNIAYYUT Ode 48 NOLLYTTYLSNI 700 INTON NOCLONEOY LL Sesp 9 JO euo 01 peyur sI Bun edid suopenys ul pesn eg Aej ede 1 SLNIWWOD ldN ezis SONILII4 IV3elHL 1 13315 Aiquiesse esou Jo eqn Bujuoo eAjeoe oj peuBije sj pedeus jo pue Jeu ens exe Mojeq HELD uj 1 3 4 1 M LL eBuj4 wos SUN ejepdoudde eu 94 uejuBg uoueJM q uonisod 1408 JeBuy ey 0 edid Bunu mens 7 uopeujurgjuoo ujejs s Ye eq JSNLU 64 jenbe peAcudde Jo ejsed uoje UM JUEJE9S PEOULLL Ajo esp edid Addy g Suing JO pue GJEL jeu ensue o sjueuoduioo pod y speeq edid peJede UUM peseuoung zsnaaoosd SIHL Ag GISSYdNODNA ATIVHSNSO SLuVd Bugey jueuodwog 10 84 0006 ojeg senssejd SPIN4 peseg unejoned Bugeredo suejs s 39VS n NOWNOO eunsseig LAN JO uopeljejsu 104 spoujSIN usiqejs3 01 3sOdad Bum LAN pessy L edid euone
85. the front side of the pivot pin and run the hose up along the outboard side of the outboard long arms and over the top of each pair of long arms to the center of the vehicle The hoses are attached to the long arms with J clips just above the pivot pins These hoses are joined at the center of the vehicle above the railgear with a brass tee Connect the brake relief valve port marked FB to this tee with a 48 braided steel hose Four wheel brake kits only e Connect the rear pressure reducing port RB to the rear braided steel hose tee with the supplied 25 steel line Shorten or coil the excess of this line as necessary Tie strap the upper end of the rear braided hose to the center of the rear mounting bracket All Units with Optional Brakes The brake control panel consists of a double pole single throw switch and an indicator lamp The lamp is connected to the switch by the red lead and is to be grounded by the black lead Locate a suitable spot for the control panel e Connect the lamp ground to a location under the instrument panel Connect the center terminals of the switch the ones with the jumper wire to the cold side of the stop lamp switch at the brake pedal with a wire tap connector NOTE On Fords connect the center terminals of the brake switch to the C210 terminal under the instrument panel One of the two remaining terminals of the switch is wired out to the grounding control terminal on th
86. 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 difference in wear between wheels on the same axle or diagonally If abnormal pattern is noted check railgear alignment see alignment procedure Weekly Maintenance In addition to the items listed in Daily Maintenance perform the following e Grease and lubricate all grease fittings on front and rear railgear and guidewheel assemblies NOTE There are six 6 locations on front assemblies and fourteen 14 locations on rear assemblies e Check level of hydraulic oil and all other fluids e Check air pressure in tires and inflate to proper inflation pressure if necessary Bi annual Maintenance or as required In addition to the items listed in Daily Maintenance and Weekly Maintenance perform the following e Remove the hubcaps from the railwheels and inspect for deterioration or loss of wheel bearing grease Unless there is a problem the cavity may be topped off with the recommended grease without removing and or re packing the bearings e Clean the hubcap and mating surfaces and apply a bead of silicone gasket and re attach securely e Clean the strainer filter in the hydraulic power unit tank e Inspect wheel flanges for excessive wear If abnormal pattern is noted check railgear alignment see alignment
87. x 3noN0L GC3IN3WNUO 3 SANN 81108 3SHvOO 219 nbio MOY JO JO UMOG ezis ssouoy 3 JO SI JG WE JO O pervers ul eyepdoddy ales Spes awe 9245 64 8 mojeg eyeudouddy PESILLL 881800 JO Jeu SV Jeugjse 719 JO Puy 9 6297 IVS JO 5925 J50N SIHL GASSVdWOONS 819 uogueye Ajquiessy yed JO JSON 3DVSN NONWOO sIeuejse POSEAN JO 104 SPORAN 1 OL ASOdYNd uopeoypeds enbo j JEUEJSE4 JILIL 0119139534 LALO ON Lyd 5 J i 0n 5 F G lt lt 77 of 80 2015 DMF Inc All Rights Reserved RW 1420 DIVERSIFIED METAL FABRICATORS I NC 2 J 5 lt 0 lt E ec gt lt e 13179

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