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RW-1630 & RW-1630/50*

1. TRUCK TIRES D m L MN OME y O B J sss Q kl YF 8 ITEM DESCRIPTION ITEM DESCRIPTION CD A REAR FRAME MOUNTING BRACKET FLAT PLATE H REAR AXLE B 4 HOLE MOUNTING PLATE INSIDE BRACKET REAR RAIL WHEEL SPACER 5 IF REQUIRED J REAR UPPER MOUNTING PINS D REAR HYDRAULIC VALVE ASSEMBLY K REAR LOWER MOUNTING PINS E REAR UPPER LINKS 4 L REAR CYLINDER PINS F REAR LOWER LINKS 4 M REAR BRACKET SHIM S PLATE G REAR LIFT CYLINDERS 2 N SIDE PLATE Figure 4 4 2 A Diagram of Key Components 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 3 Location of Rear Railgear Position the rear Railgear as close to the rear tires as practical allowing clearance for mud flaps Table 4 4 3 A gives standard location and clearance guidelines for the rear Railgear and these dimensions are shown in Figure 4 4 4 A Generally leave a minimum of 2 clearance to any tire spring or suspension components Minimum Distance from Single Axle Tandem Axle Rear Tire to Rail Wheel Center 15 1 4 11 1 4 Min Truck Frame Extension 21 1 4 17 1 4 from rear edge of tire Minimum clearance area 24 1 4 x 19 20 1 4 x 19 from rear edge of tire Table 4 4 3 A Location of Rear Railgear 4 4 4 Location and Clearance of Railgear Th
2. ua TO TANK w NO OBSTRUCTION OR FRTERS y FROM FRONT VALVE INLET CYLINDER BLIND END CYLINDER ROD END 4 2 pl NO O O REAR VALVE TO HYDRAULIC T i u NE HYD CYL HOSES 2 a ASSY TaN LA J FRONT PTO PUMP FILTER Y fener sermo UI VALVE ASSY i 2000 psi MAX FRONT VALVE NOTE DEPENDING ON ES DIRECTION OF HANDLE UP DOWN YOU MUST RE PLUMB YOUR HOSES F 1 FROM ABOVE SEE DIAGRAM BELOW TROU VALVE MEME TOUTT PORT a al 0 pe TN NS B REAR VALVE NOTE DOES NOT HAVE TO BE RE PLUMBED DEPENDING ON PULL TO RAISE eman i DIRECTION OF HANDLES UP DOWN PUSH TO LOWER J PLUMBING FOR REVERSED HANDLE ONLY PLUMBING FOR EXTERNAL LOCKING VALVE PLUMBING FOR EXTERNAL LOCKING VALVE ISOMETRIC VIEW OF FRONT VALVE ASSY WITH T FITTINGS ON FRONT VALVE STD HANDLE W 90deg FITTINGS ON FRONT VALVE STD HANDLE FROM DIVERTER INLET CYLINDER BLIND ENDS CYLINDER ROD ENDS RELIEF SETTING 2500 psi MAX TO REAR VALVE TO FRONT VALVE ASSY IN PORT 1 TO FRONT VALVE ASSY IN PORT TO FRONT VALVE ASSY IN PORT RELIEF SETTING 2500 psi MAX FRONT L VALVE ASSY VALVE ASSY VALVE ASSY FROM FRONT VALVE ASSY OUT PORT p 1 OR REPLACE T HTTINGS W FROM FRONT VALVE ASSY OUT PORT FROM FRONT VALVE 55 OUT PORT 90deg FITTIN
3. SPRING HANGER BRACKET MOUNTING SPACER BAR 1 27 OPTIONAL Deno E ec 1 L nl 17 818128 F L CROSS TUBE DETAIL FRONT SEE SECTION 5 5 EFT NUT SLOTTED HEX 17 8 gt COTTER PIN 3 16 x 2 Rear Mounting NUT SLOTTED HEX 1 1 2 6 Pin B 12 3 4 WASHER FLAT 1 1 2 383 COTTER PIN 1 4 k 2 1 2 J CLIP 1 2 DIA FOR AIR BRAKE HOSES QTY 2 EACH SIDE INNER LONG ARM ASSEMBLY OUTER LONG ARM ASSEMBLY 818161 8 3 410 HEX NUT NOTE FOR THE 38 1 2 DIMENSION SHOWN ABOVE REF SECTION 4 5 1 FRAME EXT MEASUREMENT 25 1 DRIVER SIDE INNER PIVOT ARM 3265 1 DRVER SIDE OUTER PIVOT ARM RUBBER SPACER MUST BE INSTALLED Must have serial when ordering parts BETWEEN SPRING amp TOP FEAT BAR SPACER MOUNTING CROSS TUBES VARY ACCORDING TO TRUCK SPECS SEE SECTION 5 5 Long Arm 37 _ _ HrRAUUC_CYLNDER ASSEMBLY FRONT DRWER S 5066 Z Spring Bracket 1 HoRAULIC CYuNDER ASSEMBLY FRONT PASSENGER S SIDE 2 Height A RS INSTALL SHIM HERE SPRING HANGER BRACKETS VARY DEPENDING MAX ALLOWABLE 1 4 ON TRUCK 5 5 SEE SECTION 5 5 q CONTACT DMF IF OUTSIDE MAX RANGE NOTE SHIMS SHOULD BE PLACED ON BOTH PIVOT ARMS FOR A GIVEN SIDE OF THE TRUCK SEE SECTION 5 5 FOR PIN OFF OPTIONS NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING FRAME EXTENSIONS
4. i ceni sc irme T 81029 NOTE DMF ONLY PROVIDES HYDRAULIC HOSES FROM FRONT 8 REAR CONTROL VALVES FITTING ELBOW 3 4 x 08 JIC HYD CYL HOSES 96 qty 4 04 w 04JIC SWIVEL TO RAILGEAR CYLINDERS CUSTOMER IS RESPONSIBLE FOR ALL OTHER SYSTEM 4 51090 4 FITTING TEE 1 4 NPTx 04JICx 04JIC HYD CYL HOSES 38 qty 4 804 wi 04JIC SWIVEL COMPONENTS TANK DIVERTER PTO PUMP FILTER PRESSURE RELIEF VALVE ETC s ss 6 FITTING ELBOW 1 2 werTxso4JIC HYD CYL HOSES 62 aty 4 04 w 04JIC SWIVEL L RS s 810204 VALVE ASSEMBLY FRONT VALVE wErras 16 2402586 8 810214 8 _ Al s sm REF VALVE HANDLE REPLACEMENT ASSEMBLY 79 VALVE ASSEMBLY FRONT WIS0deg FITTINGS LOCKING VALVE DPC1 10 P 6T NOTE ON THE FRONT VALVE THE RELIEF SETTING MAY BE LOCKING LOCATED IN DIFFERENT LOCATIONS DEPENDING ON THE MANUFACTURING BRAND ALL ELSE REMAINS THE SAME WE SHOW THE TWO MOST COMMON LOCATIONS BELOW FOR THE RELIEF SETTING FRONT TIRE DIVERTER ISOMETRIC OF FRONT VALVE ASSY J ens S Reni ewer E gt TO OTHER EQUIPMENT CYLINDER BLIND ENDS N RELIEF SETTING 2500 psi MAX FROM DIVERTER TO REAR VALVE PRESSURE RELIEF VALVE
5. 2012 DMF Inc All Rights Reserved 05 02 Options doc RW 1650 2 PC WHEEL PARTS RW 1630 2 PC WHEEL PARTS ITEM NO PART NUMBER QTY DESCRIPTION ITEM PART NUMBER GTY DESCRIPTION RW 1650 FLAME HARDEN 2 PC TREAD 1 820492 RW 1630 2 PC WHEEL TREAD DETAIL FIBER RING WHEEL INSULATOR DETAIL 820482 FIBER RING WHEEL INSULATOR DETAIL 2 PC WHEEL FIBER SPACER RING 2 PC WHEEL FIBER SPACER RING RW 1650 2 PC HUB DETAIL W QTY 2 RACE BEARINGS RW 1630 2 HUB DETAIL W QTY 2 RACE BEARINGS RW 1650 2 PC WHEEL HUB DETAIL RW 1630 2 PC WHEEL HUB DETAIL RW 1650 BEARING RACE TIMKEN 6420 RW 1630 BEARING RACE TIMKEN 563 2 PC WHL HEX BOLT HHCS5 8 11 X 4 00 GR8 2 PC WHL HEX BOLT HHCS5 8 11 X 4 00 R8 FIBER BOLT COLLAR 2 PC WHEEL FIBER BOLT COLLAR 2 PC WHEEL 2 PC WHEEL HARDENED 5 8 FLAT WASHER 2 PC WHEEL HARDENED 5 8 FLAT WASHER STEEL WASHER RING 2 PIECE WHEEL STEEL WASHER RING 2 PIECE WHEEL NUT LOCK LN5 8 11 TYPE C NUT LOCK LN5 8 11 TYPE C HUBCAP BOLIS HHCS 5 16 18 X 3 4 HUBCAP BOLTS HHCS 5 16 18 X 3 4 HUBCAP LOCK WASHERS LW 5 16 HUBCAP LOCK WASHERS LW 5 16 HUBCAP 1650 7 B C FLAT HUBCAP 1650 7 B C FLAT DECAL 2 PC WHEEL RW 1 630 50 INSPECTIONS DECAL 2 PC WHEEL RW 1 630 50 INSPECTIONS KIT RW 1630 50 2 PC WHEEL 23 8MM INDICATORS 800301 KIT RW 1630 50 2 PC WHEEL 23 8MM INDICATORS P N 800021 ALL HARDWARE KIT FOR RW 1650 WHEEL see drawing M1650103 in Section 5 3 P N 800020 ALL HARDWA
6. DRVER SIDE OUTER PIVOT ARM Must have serial when ordering parts MOUNTING CROSS TUBES VARY ACCORDING TO TRUCK SPECS SEE SECTION 5 5 RUBBER SPACER MUST BE INSTALLED BETWEEN SPRING amp TOP FLAT BAR SPACER INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE NOTE SHIMS SHOULD BE PLACED ON BOTH PIVOT SPRING HANGER BRACKETS VARY DEPENDING ON TRUCK SPECS SEE SECTION 5 5 N ARMS FOR A GIVEN SIDE fe Bo AR OF THE TRUCK SEE SECTION 5 5 FOR Viu T PIN OFF OPTIONS Uus E NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING FRAME EXTENSIONS TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE e MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET LONG ARMS VARY DEPENDING ON TRUCK MODEL SEE SECTION 5 5 FOR VARIOUS LONG ARM OPTION amp DETAIL DRAWINGS FRONT CROSS TUBE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS TO TRUCK
7. ON AXLE 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NU ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL N FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND a WILL SPI b NO SIGN 6 REPEAT IF ADJUSTMENT IS NECESSARY FICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE ADJUST INNER L INSTALL TAB WASHER ITEM 7 M INSTALL OUTE N SELECT THREE TABS THAT MOST NEAR WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 R WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND O FILL OUTBOARI D CAVITY COMPLETELY P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N 800021 ALL HARDWARE KIT FOR RW 1650 amp BEHIND CAB WHEEL amp 1650 2PC WHEEL Does not include silicon for hubcap or wheel grease or bearing race LY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS Must be hardened washer PARTS Must have serial when ordering COMPLETE REAR AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEE
8. 818407 1 BRAKE BRACKET WELDMENT o Z 818455 1 civis DETAR 8 O 9 818457 1 CLEVIS PIN 1 2 x 1 1 2 w COTTER PIN 10 818470 1 COBRA BRAKE SHOE V 265 Cd 11 818431 1 BRAKE ARM CASTING gt oo y O 12 818513 1 BRAKE SHOE CLIP ASSEMBLY 14 818452 1 BRAKE SHOE PIN 15 818448 2 BOLT MOUNTING 3 8 16 x 1 Gr8 16 818450 2 WASHER LOCK 3 8 ROLL PIN 5 32 x 1 1 2 Must have serial when ordering parts j f f f c e j die sj 3 26 12 818513 WAS 818426 JI DATE DESCRIPTION TOLERANCES TITLE TOR S TE ERA COBRA AIR BRAKE ASSEMBLY SEE NOTE 1 x dE DIVERSIFIED METAL FABRICATORS INC 404 875 1512 EXE ANGULAR 1 DRAWN BY APPD BY DATE Ti DRAWING NUMBER REV d JBG 1 25 10 y M1630101 DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2012 DMF Inc All Rights Reserved 05 04 Rear Railgear Parts doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 5 1 Before Ordering Parts Front Railgear Required Information for Ordering Parts e You must have the Railgear serial number when ordering parts This uniquely identifies your Railgear as it was built to your specifications and also allows DMF to help you maintain a history of your Railgear If you are placing a parts order through a maintenance facility please inform them of the serial numbe
9. SEE SECTION 5 4 FOR VARIOUS LINK COMBINATIONS AND PART S AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE ENSURE SPACERS ARE PRESSED FULLY AGAINST SIDE BRACKET OR SHIMS amp ALIGNED WITH THE REAR BRACKET WELD AS INDICATED IN DETAIL ABOVE IF MULTIPLE SPACERS ARE USED ENSURE THAT THEY ARE WELDED TO ONE ANOTHER WELD AS INDICATED IN DETAIL ABOVE ENSURE BOLTS amp NUTS ARE TIGHTENED TO TORQUE SPECS 154 LBF FT WELD 4 HOLE MOUNTING PLATE TO REAR BRACKET SIDE PLATE ITEM 5 15 amp 16 ARE COMPONENTS OF ITEM 2 RESPECTIVELY REF MANUAL 5 STANDARD SEE SECTION 5 2 FOR VARIOUS OPTIONS amp U APPROPRIATE PART 5 FOR ORDERING REPLACEMENT PARTS FOR SPECIFIC PART NUMBERS OR MAJOR COMPONENTS SEE SECTION 5 4 Drawing is for illustrative purposes Your parts may not be exactly as pictured DESCRIPTION RW 1630 REAR RAILGEAR ASSY NON INSULATED MANUAL PIN OFFS FOR SPECIFIC PART NUMBERS OR Frame Extension 2 Spacer tuee PIN 3 4 SCH 40 x 7 Cd MAJOR COMPONENTS SEE SECTION 5 5 Spacer
10. 10 hex nuts per stud The top Spacer has no effect on the height of the Railgear and is only used for clamping purposes 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 6 7 The nuts should be tightened down until the Rubber Spacer begins to deform from the downward pressure Caution Do not over tighten Repeat process on passenger side Route Hydraulic lines 1 2 3 Route all hydraulic lines as shown in Section 5 3 1 Engage the PTO and allow hydraulic circuit to self bleed Inspect all connections for leaks and tighten as necessary Mounting Front Cross Tubes 1 2 Ensure that both spring bracket hangers are properly installed before attempting to install front cross tubes Remove the Front Pin Offs and set the steering tires straight ahead The front Railgear can now be actuated with the hydraulic system which will cause the Long Arms to be raised up to the Frame see Figure 4 6 5 A The cross tubes only need to be brought up to where they touch the Frame Extension or truck frame not raised all the way to lift the truck frame and raise the truck tires In order to install the front of the front Railgear at the correct height the center of the Front Mounting Pins must be located at 25 1 2 1 2 from the ground with the truck tires on the ground as shown in Figure 4 6 5 A If required shim the cross tubes to obtain this 25
11. 2 PC INSULATED WITH BRAKES 1630 amp UNDER CAB 800260 RW 1630 HUBCAP DETAIL 7 8001090 3 8 6 LOCK W D 6 18 0 1630 UNDER AXLE TUBES 1630 amp UNDER CAB BEARING RACE 800101 2 BEARING RACE TIMKEN 563 COMPONENT OF P N 820220 AXLE TUBE NO BRAKES 818308 TIMKEN 563 BEARING RACE 818101 RW 1630 AXLE STANDARD 3 1 4 X 61 29 32 BRAKE AXLE TUBE WITH BRAKES 818200 800101 L 1630 amp UNDER CAB WHEELS INSULATED 2 PIECE 1630 WHEEL w RACES 820494 NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 NOTE SPECIAL PROFILE WHEELS PLEASE CALL 6 eii elkele 1e el e n e e e i E o 5 8 11 x 4 Grade 8 Bolts Must replace bolts nuts at same time WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE G INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 l ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft lb 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT
12. 818127 4 Nur slotten Hex 7 8 0 0 y O COTTER PIN 3 16 x 2 FOR SPECIFIC PART NUMBERS OR MAJOR COMPONENTS SEE SECTION 5 5 Drawing is for illustrative purposes Your parts may not be exactly as pictured below Front Mounting Pin Spacer Top Frame Extension Truck Rubbers Must b ubber Spacer Must be F S 2 directly on top of leaf springs A O Spacer Distance Spring Bracket SS S Spring Bracket Height Rear Mounting mise 19 sie r 25 24 sse 5 Fa i 29 NUT SLOTTED HEX 1 1 2 6 WASHER FLAT 1 1 2 COTTER PIN 1 4 x 2 1 2 J CLIP 1 2 DIA FOR AIR BRAKE HOSES 2 EACH SIDE INNER LONG ARM ASSEMBLY OUTER LONG ARM ASSEMBLY 3 4 10 HEX NUT DRIVER SIDE INNER PIVOT ARM DRIVER SIDE OUTER PIVOT ARM Long Arm Pin B 12 3 4 RUBBER SPACER MUST BE INSTALLED BETWEEN SPRING amp TOP FLAT BAR SPACER Must have serial when ordering parts MOUNTING CROSS TUBES VARY ACCORDING TO TRUCK SPECS SEE SECTION 5 5 INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE NOTE SHIMS SHOULD BE PLACED ON BOTH PIVOT ARMS FOR A GIVEN SIDE OF THE TRUCK SPRING HANGER BRACKETS VARY DEPENDING ON TRUCK SPECS SEE SECTION 5 5 SEE SECTION 5 5 FOR PIN OFF OPTIONS NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING FRAME EXTENSIONS TO TRUCK FRAME NOTE 2 FI
13. REAR BRACKET CROSS TUBE 2 1 2 X 8 15 16 818235 GREASE FITTING FOR REAR LINKS 1 8 NPT 12 0 REF MUST ORDER CONPLETE BRACKET DIMENSION A SEE TABLE FRAME WIDTH 1 8 HALF A 21 5 REF _ Y 43 0 REF HOLD CENTER TO CENTER 50 0 REF Ls 1 563 REF 1 2 FILLET WELD ON BOTH SIDES TYP NO WELDS ON ENDS TYP E REVISED FRAME WIDTH TABLE ADDED ANGULAR REFERENCE 3 8 FILLET WELD OTHER PLACES TYP REV DATE DESCRIPTION APP TOLERANCES UNLESS SPECIFIED FRAC MACH t 1 32 FRAC OTHER 1 16 x DRILL SEES ANGULAR SURF FINISH TITLE REAR MOUNTING 12 FORMED BRACKET ASSY RW 1630 3 4 HEAVY DUTY PLATE DIVERSIFIED METAL FABRICATORS INC 404 875 1512 THREADS DRAWN BY APPD BY DATE DRAWING NUMBER 4 29 10 M1630117 PART NUMBER DESCRIPTION FINSHED A DIMENSION PART NO 818225 REAR BRACKET 3 4 CROSS PLATE 818793 10 3 4 REAR BRACKET GUSSETT SLOTIED PLATE FORMED 19317 34 1 8 818228 REAR BRACKET CROSS TUBE 2 1 2 X 8 15 16 818235 GREASE FITTING FOR REAR LINKS 1 8 NPT 19474 34 3 16 8 8 819315 34 1 4 819458 34 1 2 8 8 19324 34 5 8 19312 34 7 8 819313 36 11 16 Note These are the most commonly used Specia
14. REPLACED BY P N 808151 808136 PASSENGER SIDE INNER 808137 DRIVER SIDE INNER 808133 SET 808117 118 136 amp 137 EXT LONG ARM NOTCHED FOR M2 FREIGHTLINER 818117 PASSENGER SIDE OUTER 818118 DRIVER SIDE OUTER 818119 INNER 808145 SET STANDARD LONG ARM 810144 FRONT DETAIL CARGO ARM USED WITH PIVOT ARMS 810066 amp 810067 CARGO LONG ARM 808157 808158 808159 808161 PASSENGER SIDE OUTER DRIVER SIDE OUTER PASSENGER SIDE INNER DRIVER SIDE INNER EXTRA CLEARANCE EXTENDED LONG ARM LONG ARM 08VWCONST BZL 808171 808172 808173 808174 DRIVER SIDE INNER PASSENGER SIDE INNER DRIVER SIDE OUTER PASSENGER SIDE OUTER 808178 PASSENGER SIDE INNER 808179 DRIVER SIDE INNER 818196 DRIVER SIDE OUTER 818197 PASSENGER SIDE OUTER 818198 INNER 808146 SET SNUB NOSE LONG ARM 808117 PASSENGER SIDE OUTER 808118 DRIVER SIDE OUTER 808152 PASSENGER SIDE INNER 808153 DRIVER SIDE INNER 808154 INNER OUTER SET INNER LONG ARM 08 VOLVO VHD64B 808183 PASSENGER SIDE INNER 808184 DRIVER SIDE INNER XTRA CLEARANCE EXT NOTCHED INNER ONLY 808186 LH ASSY 808187 RH ASSY USED WITH PIVOT ARMS 810066 amp 810067 EXTENDED CARGO ARM STERLING W O FRAME EXT NOTE IF ORDERING DRIVER S SIDE OUTER ARM MUST HAVE SERIAL FOR A REPLACEMENT SERIAL TAG LONG ARM WILL SHIP WITH TAG ATTACHED UPDATED EXTCARGO ARM ADDED NOTES
15. Top 111 FRONT COBRA WHEEL amp AXLE sv 5 O r peemem se area P Drawing is for illustrative purposes Your esu 2 TTE PASSENGER soe INNER PIVOT au O rame I parts may not be exactly as pictured below V eo diectiy on top of leat springs 818153 2 SPRING HANGER BRACKET RUBBER MOUNTING PAD E lt 2 SPRING HANGER BRACKET ASSEMBLY Sd 818160 6 SPRING HANGER BRACKET MOUNTING SPACER BAR 1 818158 8 SPRING HANGER BRACKET MOUNTING SPACER BAR 1727 OPTIONAL a HYDRAULIC CYLINDER ASSEMBLY FRONT DRIVER S SIDE 25 1 2 HORAULIC CYLINDER ASSEMBLY FRONT PASSENGER S SIDE 2 cross TUBE DETAL FRONT SEE SECTION 56 e 818127 a wr sonwux r Front Mounting Pin Spacer Distance Spring Bracket 4 Max TUX Spring Bracket Height wa i 17 818128 COTTER PIN 3 16 27 P 12 3 4 s a wur storten 1727 6 s 3 Long Arm 618136 4 WASHER FLAT 1 1 2 9 ENS 20 818137 4 COTTER 74x 2 172 21 818487 4 u cuP 1 2 DIA FOR AIR BRAKE HOSES 2 EACH SIDE i 22 INNER LONG ARM ASSEMBLY 23 OUTER LONG ARM ASSEMBLY 24 818161 3 4 10 HEX NUT NOTE FOR THE 38 1 2 DIMENSION SHOWN ABOVE REF SECTION 4 5 1 FRAME EXT MEASUREMENT 25 1 DRVER SIDE INNER PIVOT ARM 6
16. for long links no matter what pin off option you have LONG SLOTTED LINKS MANUAL LONG MANUAL LONG SLOTTED 210 P N 819208 P N 819 Truck Front Truck Rear AIR REMOTE LONG AIR REMOTE LONG SLOTTED 15 P N 819213 P N 8192 Truck Front 818652 n d Truck Rear 818284 818230 Truck Front gt f Y 818653 hw 818659 Truck Rear 818550 CABLE REMOTE LO IN 8192 CABLE REMOTE LONG P N P N 819212 818563 LONG STANDARD amp SLOTTED LINKS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER 7 26 2010 M1630109 NG SLOTTED 14 Truck Front 818652 d Truck Rear M1630109 Wheel Bearing Grease Mystik JT 6 Lo Temp Extreme Grease PARTS Must have serial when ordering Bx y SO REAR ALE WELOMENT TUBE WDE BRAKES foctory stondord preferred for colder climotes COMPLETE REAR AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS 800100 4 630 BEARING CO 6 INSULATED NO BRAKES 1630 amp UNDER CAB 800204 WEF 2 Ad 1630 WHL ASSY NON INS W RACES NOTE DRAWING amp PART NUMBERS ARE APPLICABLE FOR INSULATED WITH BRAKES d amp UNDER CAB ed RW 163 R D NON INSULATED NO BRAKES 1630 amp UNDER CAB 800202 800107 2 630 WA oc D BOTH 1630 AND UNDER CAB REAR NON INSULATED WITH BRAKES 1630 amp UNDER CAB 800206 2 PC INSULATED NO BRAKES 1630 amp UNDER CAB 8002384
17. it is your responsibility to take corrective action before any use of the vehicle 2 2 Highway Operation Before operating a Railgear equipped vehicle on the highway 1 Verify Railgear is in highway position 2 Verify pins are properly and fully inserted in both front and rear Railgear even if the Railgear on your truck is equipped with a locking valve system you MUST verify that the pins are correctly inserted 3 Steering wheel lock has been removed if applicable 4 Verify that Railgear brakes have been disengaged if applicable 5 Verify PTO has been disengaged and that the indicator light is OFF 2 3 Getting on the Rail 2 3 1 Getting onto the Rail 1 At the track crossing drive past the track then back the vehicle onto the rails Engaging the rear Railgear first will allow your vehicle to side shift and align itself to the rail making it easier to engage the front Railgear 2 Engage the truck s parking brake to prevent the truck from rolling 2 3 2 Lower Rear Guide Wheels 3 If the Railgear has brakes turn brake switch on 4 Engage the PTO leave the truck running and the transmission in neutral gear 5 Remove the safety pin off pins 4 pins 2 front and 2 rear on both driver and passenger sides If pins are too tight to be easily removed verify that Railgear is fully raised by briefly pulling bumping the valve handle toward you 6 Push valve handles to lower wheels and engage rail 7 To assist with alig
18. mee TS 1389 ies 1 3 8 12 1675 1255 2710 2035 2440 1830 1 3 8 6 1470 1100 2580 1780 2315 1735 11 2 12 2195 1645 3560 2670 3275 2455 1 1 2 6 1950 1460 169 2370 3040 2280 COMMENTS A Torque values specified are for bolts with residual oils or no special lubricants applied If special lubricants of high stress capacity such as Never Seez graphite and oil molybdenum disulphite colloidal copper or white lead are applied A 12 20 09 ADDED RECOMMENDED TORQUE CHART multiply the torque values in charts by 0 90 The use of Loctite does not affect the REV DATE DESCRIPTION torque values in charts ue TON P B All values are in Foot Pounds FTLB Multiply by 12 for Inch Pounds 122 SEG 5 Flat washers of equal strength must be used D Bolt manufacturer s specs should be used when available E Plated values in charts are for Cadmium Multiply by 1 87 for Zinc F Never re use highly stressed torqued fastener IT MAY FAIL DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2012 DMF Inc All Rights Reserved 05 O1 Installation Drawings doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 2 1 Rail Sweeps The components that make up the standard Front and Rear Rail Sweeps for Railgear without any brakes are different than Rail Sweeps for Railgear with Cobra Air Brakes For Rail Sweeps provided with Cobra Air Brakes the
19. 16 C HEX END CAP 1 27 13 HEX NUT SAME AS OPPOSITE SIDE INSTALLATION NOTES INSERT AIR CYLINDER THROUGH PLATE AND SCREW INTO P O SLIDE WELDMENT P O ASSEMBLY MUST BE PARALLEL TO LINK AND STUDS SHOULD BE FLUSH WITH THE OUTER HEX NUTS LOCATE AIR CONTRL VALVE P N 818593 FOR CONVENIENCE AND CONNECT TO A PROTECTED AIR SUPPLY CONNECT LEFT VAVLE TO THE LEFT P O CYLINDER WITH TWO OF THE HOSES AND FITTINGS SUPPLIED REPEAT THE SAME PROCEDURE FOR THE RIGHT P O ASSEMBLY P O SHOULD DISENGAGE WHEN VAVLE IS PULLED 8 11 10 REMOVED NOTE 42 AND REMOTE RETRO KIT CHART REVISED PER NEW BRAZIL MANUAL amp 5 DESCRIPTION OLE TITLE RW 1630 REMOTE CABLE PIN OFF ASSY REAR NOTE 2 RETO FIT KIT GENERIC DRAWING FINSHED PART NO A DIMENSION 19442 33 1 2 19444 33 5 8 19446 33 3 4 19448 33 7 8 19450 34 19501 34 1 8 19454 34 1 4 19455 34 5 16 19456 34 3 8 19503 34 1 2 9460 34 5 8 19462 34 3 4 19464 34 7 8 19466 35 19468 35 1 8 19469 35 1 4 19471 35 5 8 19487 35 3 4 19484 36 19491 36 1 2 8 8 8 8 8 8 8 8 8 8 81 8 8 8 8 8 8 8 8 8 8 19482 43 1 8 PART NUMBER DESCRIPTION 818225 REAR BRACKET 3 4 CROSS PLATE 818792 12 REAR BRACKET GUSSETT SLOTTED PLATE FORMED 818228
20. 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 TRUCK FRAME TRUCK FRAME SPACER REAR SIDE TACK WELD REAR FRAME BRACKET REAR FRAME BRACKET ENSURE ALL SPACERS ARE FIRMLY AGAINST SIDE BRACKET amp ALIGNED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO MOUNTING BRACKET AS SHOWN IF MULTIPLE SPACERS ARE USED SPACERS NEED TO BE WELDED TO ONE ANOTHER AT THE REAR amp TACK WELDED ON THE SIDES IF POSSIBLE IF SHIMMING IS REQ D BRACKET MUST BE EQUAL ON BOTH SIDES SPACERS MIN 1 2 MAX 3 IF OUTSIDE OF THIS RANGE ON FINAL INSTALLATION CONTACT DMF 5 8 11 NYLOCK NUTS amp 5 8 FLAT WASHERS NOT PROV D 5 8 11 NC HEX CAP BOLTS NOT PROV D MUST BE GRADE 5 FOR REAR ONLY LENGTH TO BE DETERMINED ONCE BRACKET MOUNTED amp SHIMMED BRAKES NOT SHOWN SEE SECTION 5 2 OPTIONS REF MANUAL PIN OFFS STANDARD SEE SECTION 5 2 FOR VARIOUS OPTIONS amp SEE SECTION 5 4 FOR APPROPRIATE PART S FOR ORDERING REPLACEMENT PARTS VARIOUS LINK COMBINATIONS AND PART S Pa r WE amp ARE ASSY REAR RW 1630 2 REAR LINK ASSY LONG SLOTTED SEE SECTION 8 3 RE MOUNTNG BRACKET ASSEMBLY SS s 818250 2 PN assy REAR UPPER s sse s SLOHED GUN 1 1 52 s 818248 8 comer
21. 875 1512 DATE DRAWING NUMBER REV 241303 DS 9 11 09 241304 PS B m vor x o a ac lt a lt o NOTE DMF LINKS COME IN 3 SIZES X SHORT STD SHORT amp LONG THE SIZES CAN NOT BE MIXED BETWEEN UPPER amp LOWER LINKS EXAMPLE LONG UPPER LINK CAN ONLY BE USED WITH LONG LOWER LINK EACH LINK HAS A SLOTTED VERSION SLOTTED DESCRIPTION BY RW 1630 50 DRAWN BY APPD BY JBG TITLE RW 1630 50 REAR LINK OPTIONS amp DIMENSIONS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV 9 18 09 M1630111 X SHORT LINKS 818661 Truck Front T Truck Rear MANUAL XSHORT P N 819220 Note Links are sold individually unless you want a full set of all 8 Please refer to full set p n s shown below The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same for x short links no matter what pin off option you have MANUAL XSHORT SLOTTED P N 819222 X SHORT SLOTTED LINKS Truck Front d Truck Rear 818661 Truck Front i Truck Rear 818531 818595 AIR REMOTE XSHORT P N 819224 AIR REMOTE XSHORT SLOTTED P N 819225 Truck Front Pd Truck Front Tue Truck Rear 818541 818563 CABLE REMOTE XSHORT P N 81
22. A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP UNLESS SPECT mz CYLINDER REAR SAE PORT L VLV 3 1 2 BORE x AC oW ue 9 1 2 STROKE LH DRIVER SIDE x on H DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES DRAWN BY APPD BY DATE DRAWING NUMBER ANGULAR SURF FINISH 125 MICRO THREADS 2A AND 2B BJF 10 7 09 240256 PART NO DESCRIPTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 240208 O RING GLAND 2 338 240209 BACKUP RING GLAND 8 338 240255 WELD ASSY 3 1 2 TUBE SAE PORT LOCKING VALVE RR RH 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 NPT STRAIGHT 240258 90 DEGREE ELBOW 4 MJIC x SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 DMF P N 240225 SEAL KIT TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO BASE OF CYLINDER IF THE TUBES ARE FACING YOU SR CLOSEST TO Y
23. C D within 1 4 REAR RAILGEAR AXLE Figure 4 4 7 A Squaring Rear Railgear NOTE Although the previous mounting conditions and alignment may be met be certain that enough room exists between the Rear Railgear and other equipment In general this should include a 2 clearance around the Railgear more clearance will be needed if Remote Pin offs are installed Also ensure that there is clearance to remove the Pin Offs from their holes 4 4 8 Temporarily Securing Rear Bracket Now that the rear bracket is correctly centered vertically positioned and aligned measure 1 up from the bottom of the slot in the rear bracket slide plate and drill your first 5 8 hole through the shims if applicable and truck frame Align this first hole with the 4 hole mounting plate ensure that the mounting plate is level then drill the additional 3 holes Once all 4 holes are drilled install four 5 8 11 Grade 5 bolts and secure them with the appropriate washers and nylock nuts Repeat this mounting bracket procedure for the other side of the Railgear Temporarily tack weld the mounting plate to the rear frame bracket If re adjustment is later needed the welds may be ground off and the rear frame bracket may be slid up or down by loosening the bolts in the slots Also temporarily tack the spacers into place so that if further adjustment is necessary the welds can easily be ground off and spac
24. FABRICATORS INC RW 1630 amp RW 1630 50 1 0 GENERAL INFORMATION General Information E B HU HH How to Use this Manual 1 Operation 2 Installation Routine Maintenance 4 Repair General Description Front Railgear 1 Standard Front Railgear Components 2 Behind Cab Front Railgear Components 3 Under Cab Front Railgear Components Rear Railgear 4 1 Rear Railgear Components Including RW 1630 and RW 1650 Anti Lock Brake System ABS 1 Trucks Equipped with ABS 2 Rail Operation of Trucks with ABS Active HG WWW Ui Ul 2012 DMF Inc All Rights Reserved 01 00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 1 How to Use this Manual No matter what your job function is Operation Installation Maintenance or Repair it is your responsibility to familiarize yourself with the entire manual Once you have read the entire manual there are some specific sections that you will want to pay special attention to depending on your role For purposes of this manual we will refer to RW 1630 when discussing either RW 1630 or RW1630 50 and we will explicitly call out any differences when appropriate If you find anything missing incorrect or unclear in this manual please contact us We are always trying to improve our manuals We reserve the right to update our manuals without notice You can download a current manu
25. FOR T0 CARGO LONG ARM AND EXTCARGO ARM ADDED PART 5 FOR EXTENDED CARGO ARM DESCRIPTION TE A 1 16 12 AN 5 26 11 REV DATE aa JUNLESSPECTES VARIOUS RW 1630 LONG ARMS DIVERSIFIED METAL FABRICA TORSINC 404 875 1512 DATE DRAWING NUMBER 3 16 10 M1630116 DESCRIPTION 3001C 4 A4 RW 1650 BEARING TIMKEN 502 21 RW 1630 SEAL STANDARD CR ps T 2 RW 1630 WASHER AXLE TAB PUCLID 5 500125 2 1520 NUT INNER En 6 1800106 2 RW 1650 NUT OUTER WHE 7 8007 2 R A UR 2 RW 1630 HUBCAP DETA DIA 12 NE PROT AR NNER DRIVER SIDE ARM 13 OUTER 1 OUTER DRIVER SIDE 14 INNER PIVOT ARM 1 INNER PASSENGER SIDE PIVOT ARM 2 pR PTM L SUL UNS 16 FE T 2 Rm R BRAK MUST WELDED RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT AND WEIGHTS ARE SET 5 8 11 x 4 Grade 8 Bolts WHEEL ASSEMBLY PROCEDURE Must replace bolts nuts at same time A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UN
26. FRAME OR FRAME EXTENSIONS ALL THE WAY AROUND e IF SHIMS REQUIRED FULLY WELD ALL SHIMS IN ALL LOCATIONS IN PLACE ONCE ALIGNMENT IS ACHIEVED IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED AT LOCATION SHOULD NOTE 3 BE WELDED TO ONE ANOTHER e ONCE SPRING BRACKET IS FINALLY SET WHERE CLEARANCE ALLOWS LEAVE 1 THREADED ROD EXPOSED ABOVE NUT 2 THREADS MIN SEE ABOVE ILLUSTRATION ITEM 5 5 6 25 amp 26 ARE COMPONENTS OF ITEM 4 RESPECTIVELY TOP VIEW 5 a DESCRIPTION MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE TITLE unes SPEED OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER RW 1630 FRONT RAILGEAR ASSY SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS FRAG REF P N 4801192 ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET FOR DETAIL DWG S OF THIS CYLINDER amp OTHER VARIOUS CYLINDERS SEE SECTION 5 5 DRAWN BY APPD BY DATE 1 25 10 BREAK SHARP EDGES UPPER ARM ASSEMBLY PASSENGERS SIDE LOWER ARM ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY 4 1 2 WHEEL amp AXLE ASSY w COBRA AIR BRAKES COBRA AIR BRAKE ASSEMBLY DRIVER S SIDE 6 110035 2 NUT SPRING 1 8 COBRA AIR BRAKE ASSEMBLY PASSENGER S SIDE BOLT FRAME MOUNTING 5 8 11 x 2 1 2 Gr5 NUT SLOTTED HEX 1 8 a 11045 16 FRAME MOUNTING 5 8 11 TYPE C 21 812266 4 NUT SLOTTED HEX 1 147 110050 16 LOC
27. IND Driver Side MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT AND WEIGHTS ARE SET 5 8 11 x 4 Grade 8 Bolts Must replace bolts nuts at same time WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE G INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft lb Wheel Bearing Grease Mystik 6 Lo Temp Extreme Grease factory standard preferred for colder climates NOTE ALL PARTS ARE NOT THE SAME BETWEEN 1630 FRONT amp UNDER FRONT SEE DRAWING UC110005 FOR SPECIFIC UNDER CAB PARTS IN SECTION 5 1 Possenger Side 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT ITEM 5 APPROXIMATELY 1 8 1 4 OF A TURN THIS WILL PRODUCE 0 005 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp R
28. ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL NSIDE AND OUT Must be hardened lt s washer RC Torque to 120 ft Ibs 5 8 11 Type C prevailing Torque Nut 2 pc wheel uses 1650 hubcap Decal 800300 apply to hubcap cover when using 2 pc wheel Must replace bolts nuts at same time 80 89 P N 820494 2 PC INSULATED 1630 WHEEL W RACES REPLACES ITEMS WILL SPIN FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND a 4 amp 12 ABOVE KEEP ALL OTHER PARTS b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT Cm 2 P N 4800300 DECAL 2 PC WHL INSPECTION 6 REPEAT ADJUSTMENT IS NECESSARY EXCEPT HUBCAP dE P N 4800301 KIT 2 WHL TORQUE INDICATORS J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE ADJUST INNER WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 1 630 amp U N D ER CAB REAR AXLE L INSTALL TAB WASHER ITEM 7 A TD M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND SELECT THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS C
29. NO BRAKES 1630 amp UNDER CAB 800204 INSULATED WITH BRAKES 1630 amp UNDER CAB 800208 NON INSULATED NO BRAKES 1630 amp UNDER CAB 800202 NON INSULATED WITH BRAKES 1630 amp UNDER CAB 800206 2 PC INSULATED NO BRAKES 1630 amp UNDER CAB 800238 2 PC INSULATED WITH BRAKES 1630 amp UNDER CAB 800260 1630 amp UNDER CAB AXLE TUBES AXLE TUBE NO BRAKES 818308 AXLE TUBE WITH BRAKES 818200 1630 amp UNDER CAB BEARING RACE TIMKEN 565 BEARING RACE 800101 1630 amp UNDER CAB WHEELS INSULATED 2 PIECE 1630 WHEEL w RACES 820494 NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 NOTE SPECIAL PROFILE WHEELS PLEASE CALL Torque to 120 ft Ibs NEL Een 5 8 11 Type C prevailing Torque Nut 2 pc wheel uses Must replace bolts nuts at same time 1650 hubcap Y Ng c7 6 Decal 800300 9 0 apply to hubcap cover Um when using 2 pc wheel amp 7 6 so diii 1630 WHEEL W RACES REPLACES ITEMS PARIS Uo P N 4800300 DECAL 2 WHL INSPECTION N SELECT THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS O FILL OUTBOARD CAVITY COMPLETELY P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N 800020 ALL HARDWARE KIT FOR RW 1630 amp UNDER CAB WHEEL Does not include s
30. POSITION THE INBOARD SIDE TITLE UNLESS SPECIFIED OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER RW 1630 FRONT RAILGEAR ASSY SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS Bia REF PIN 4801192 ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET DIVERSIFIED METAL FABRICATORS INC 404 875 1512 FOR DETAIL DWG S OF THIS CYLINDER NA DATE DRAWING NUMBER REV THER VARI YLINDERS SECTION 5 amp OTHE OUS CYLINDERS SEE SECTION 5 5 1 25 10 1850304 A ITEM PART NO DESCRIPTION 1 240101 1 PISTON 4 172 DMF P N 240125 SEAL KIT 240102 GLAND 4 1 2 a i SEAL KIT INCLUDES ITEM Z s 4 5 6 7 8 amp 9 240104 SEAL PISTON 3120 3875 5 240105 1 SEAL ROD 3750 2000 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE a 240106 1 WIPER 859 271 DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE 240107 31 O RING PISTON 2 214 FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER WITH la 240108 1 O RING GLAND 2 346 FITTINGS POINTED UP AS IF YOU WERE HOLDING THE BASE SEE PP008 FOR CYLINDER o 240109 1 O RING GLAND BACK UP 6 346 END IN YOUR ED 5 ASS Y amp TEST PROCEDURE 10 240110 BARREL ASSEMBLY 4 1 2 DRIVER S SIDE HAND WITH IT POSITIONED AS SUCH LOOKING AT THE ACTUAL ENSEM 7 M 240115 1 BARREL ASSEMBLY 4 1 2 PASSENGER S SIDE FITTING ON THE BASE END 1 245125 1 RoDp ASSEMBLY 2 THE FITTING ITSELF IS
31. SCREW 10 24 X 1 00 12 818497 2 FITTING STRAIGHT 0104 6 68 SAE 818499 6 FITTING 902 2104 6 68 14 818458 1 AIR BRAKE CHAMBER FRONT DRIVER S SIDE Lis 818459 1 AIR BRAKE CHAMBER FRONT PASSENGER S SIDE Note Items 5 6 7 8 amp 13 shipped ossembled Note Items 5 6 7 8 Rear Kit p n 818415 amp 13 shipped assembled FROM VEHICLE AIR BRAKE Front Kit p n 818413 CONTROL CIRCUIT KIT 4818441 INSTALLER S SUPPLY LINE 1 INSTALLER S SUPPLY LINE FRONT AXLE Item 1 p n 818485 only qty 1 included w front brakes 16 10 09 REVISED ITEM 1 TO QTY 1 AND ADDED NOTES KIT 818413 FRONT INCLUDE ITEMS 5 6 7 8 amp 13 ADDED TANKS nus KIT 818415 REAR INCLUDE ITEMS 5 6 7 8 amp 13 _ KIT 818437 INCLUDE ITEMS 2 3 4 22 23 24 25 amp 26 fee Xx KIT 818438 INCLUDE ITEMS 18 20 2x amp 21 2x KIT 818441 INCLUDE ITEMS 19 20 2x amp 21 2x 1 818483 1 VALVE PRESSURE PROTECTION BW103976 SPL PR 4 2 818484 1 MTG ANGLE BRKT AIR BRAKE VALVE OPTIONAL 3 818485 1 TOGGLE AIR 0352037 4 818486 1 LEGEND PLATE ON OFF FOR TOGGLE AIR VALVE 5 818488 2 VALVE BRASS BALL 3 8 5 6 6 818498 3 FITTING NIPPLE 215PN 6 gt 0 O 7 818489 1 REGULATOR AIR MIDLAND KN31070 1 8 818490 2 VALVE AIR R
32. Short Links Short Links Long Links RW 1630 Wheel amp Rear Axle Assembly Detail RW 1650 Wheel amp Rear Axle Assembly Detail Manual Pin Offs Rear Remote Pin Offs Rear Mounting Bracket 12 Rear Mounting Bracket 10 3 4 Cobra Air Brake Assembly 5 5 Front Railgear Parts 5 5 1 5 5 2 5 5 3 5 5 4 5 5 5 5 5 6 5 5 7 5 5 8 5 5 9 5 5 10 2012 DMF Inc All Rights Reserved Doc M1630104 240099 100 M1630116 M1630102 M1630100 M1630112 MGENN101 MGENN100 M1630101 Before Ordering Parts Front Railgear Front Installation Detail Drawing RW 1630 Front Hydraulic Cylinder Assembly Long Arm Variations RW 1630 Wheel amp Front Axle Assembly Detail Manual Pin Offs Front Remote Pin Offs RW 1630 Mounting Tube Variations RW 1630 Spring Hanger Variations Cobra Air Brake Assembly 05 00 RW 1630 Technical Details doc TRUCK FRAME 1 1 WHEEL AXLE ASSY REAR RW 1630 2 REAR LINK assy LONG SLOTTED SEE SECTION 55 3 REAR MOUNTING BRACKET ASSEMBLY CENTER 4 818221 2 REAR MOUNTING BRACKET PLATE TOP amp BOTTOM 5 818240 2 DETAIL CYLINDER ACER 6 818250 2 ASSY REAR UPPER MOUNTING REAR SIDE 7 818257 2 ASSY REAR LOWER MOUNTING W HEAD FOR SLOTTED LINKS 818256 8 NUT SLOTTED HEX SLHN 1 1 4 7 TACK WELD 9 818248 COTTER PIN 3 16 2 REAR FRAME BRA
33. at each end to the IN port of the rear Railgear valve Lastly run a hydraulic line from the OUT port of the rear Railgear to the tank ensuring that there no obstructions such as filters or other equipment The remaining ports on the front and rear valve assemblies connect to the Railgear cylinders with SAE 100R1 4 hose and 4 JIC swivels The rear cylinder hydraulic hoses are pre installed at the factory Check that proper hose clearance is obtained to avoid chafing and shield hoses if necessary See detailed Hydraulic System drawings in Section 5 3 WARNING Be certain that the front and rear valves are plumbed correctly Each valve port is marked IN or OUT Plumbing the valves backward will cause an unsafe condition resulting in possible injury and or damage See Section 5 3 for additional Hydraulic System Drawings 2012 DMF Inc All Rights Reserved 04_00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 Installation of Rear Railgear NOTE Only use GRADE 5 bolts when attaching rear bracket on the truck frame The rear bracket should break away from the truck frame in an accident otherwise it will damage your truck frame 4 4 1 General Information There are several items to note before you begin the installation of the rear Railgear Before you begin Railgear installation please read installation instructions for the options you have ordered Some options may affec
34. be sure to inform the DMF Parts Department that there may be a special wheel profile involved in your order e DMF offers both insulated and non insulated wheels Please confirm which wheel you need before ordering Insulated wheels can be identified by a grooved ring machined around the inside of the Rail wheel This grooved ring can been seen and felt and is located about an inch in from the outside tread Cylinders e The driver s side and passenger s side cylinders are different please see information on drawing to determine which cylinder you need to order Frame Extensions e Please call DMF for assistance The truck year and model number must be provided so that DMF can correctly identify the frame extension needed 2012 DMF Inc All Rights Reserved 05 05 01 Before Ordering Parts Front Railgear doc 81124 4 PINASSEMBLY FRONTMOUNTING gawo ooo 2 ss 2 meemasswmvevorame 4 0 0 0 FOR SPECIFIC PART NUMBERS OR Frame Extension 3 818148 2 SPACER TUBE PN 3 4 scHh 40 x 7 MAJOR COMPONENTS SEE SECTION 5 5 Spacer Top L 1 FRONT COBRA WHEEL amp AXLE assy 1 PASSENGER SIDE OUTER Por ARM 0 0 j Drawing is for illustrative purposes Your Ll zoe eue e _ 818153 L 818160 818158 Front Mounting Pin Rubber Spacer Must be parts may not be exactly as pictured below reciy on top of leaf springs Spacer Distance Spring Bracket 74
35. boxes shocks oil filters spring hangers hydraulic lines etc The Front Mounting Pin does not move in relation to the vehicle frame because it is fastened through the Frame Extension or directly to the truck frame As the Front Mounting Pin does not move and the Rear Mounting Pin at the axle does the Railgear effectively rotates about the Front Mounting Pin Therefore the part of the Railgear near the Rear Mounting Pin moves more than the part near the Front Mounting Pin and attention needs to be paid to the possible clearance problems that can be caused by this movement 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 47 Cargo Arm Front Assembly Installation 4 7 1 Front Cargo Arms In some applications the front Railgear long arms that extend beyond the front of the truck to frame extensions cannot be used due to possible interference with other truck components If this is the case DMF supplies a front Railgear unit that includes much shorter long arms Referred to as Cargo Arms With some modifications that will be detailed further the rear of the arms mount to the truck springs in the same manner as a standard set of long arms while the front of the arms mounts further forward on the leaf springs thus utilizing the suspension of the chassis 4 7 2 Diagram of Key Components Front Mounting Dimensions Figure 4 7 2 A shows the individual parts o
36. onto the road If the amber ABS dash light remains on during rail operation the truck engine must be turned off and restarted after returning to highway operation This will clear the ABS light after a few seconds If the amber light remains on during road operation the truck s brake system may have an active fault and should be checked out Please refer to the truck s operation manual 2012 DMF Inc All Rights Reserved 02 00 RW 1630 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2012 DMF Inc All Rights Reserved 02 00 RW 1630 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 0 ROUTINE MAINTENANCE 3 0 Routine Maintenance 3 1 Inspection and Maintenance 1 Daily 2 Weekly Bi annually 4 Annual Maintenance or as required Lubrication Specification Troubleshooting Troubleshooting On track Problems Derailment Drawings amp Illustrations 1 Brake Adjustment Diagram 2 Grease Point Locations WW Ww WWURWWNWWW Q N QJ CJ CJ m Ui Ul 3 1 Inspection and Maintenance If your Railgear vehicle is high use or operated under extreme conditions such as material handlers or weed spraying vehicles or such as operating in mountainous regions or extreme temperatures the levels of inspections listed below may need to be performed more frequently than stated The following are instructions for routine inspections recommended by Diversified Metal Fabricators In s
37. order through a maintenance facility please inform them of the serial number so that they can relay the information when placing your order Returns DMF has a Return Authorization Procedure You must contact DMF for RA before returning any parts for any reason Parts will not be credited without an RA Labor In extremely rare situations on a discretionary basis and with prior approval DMF will reimburse certain specific labor costs If you feel this may apply in your situation you must contact DMF s Service Department for a Service Authorization Number SA No labor will be reimbursed without an SA SA must be included on your request for reimbursement Please use driver s side passenger s side terminology instead of left right side when describing issues with your Railgear This ensures that everyone involved is clear about where the issue is occurring Other Considerations for Ordering Parts This is a list of considerations to make before placing a parts order with DMF There are many variations and customer requirements that we strive to accommodate and as a result the more information you can provide to us when placing an order the more likely that we will be able to help you quickly and efficiently Wheels Links If you are a customer using special wheel profiles this is especially prevalent in Metros please be sure to inform the DMF Parts Department that there may be a special wheel profile inv
38. should be checked for the manufacturer s recommended inflation and for consistent pressure readings from all the tires This will ensure correct traction of the tires on the rail Also the condition of the rear tires needs to be determined If the rear tires are worn they should be replaced Alignment Rear truck axle must be square with truck frame DMF recommends that a reputable alignment shop check this O degree thrust angle which be different than the factory specification is required for proper Railgear operation e Frame amp Suspension On a new truck these should be in good condition a used truck the frame should be inspected to ensure that it has not been damaged or bent The suspension bushings should also be examined for excessive wear and replaced if necessary If any problems in these areas are not corrected it will cause difficulties aligning and operating the Railgear e Transverse Torque Rods On vehicles that will regularly experience high center of gravity loads on rail e g spray trucks material loaders it is advisable to install rear tandem control rods to limit transverse axle displacement This is also necessary on long wheelbase vehicles to prevent front tandem walking off in curves 4 2 3 Front and Rear Installation Rails In order to install the Railgear to get proper tire traction on the rail it is necessary that standard gauge rails or Installation Rails be fabricated from 3 square tubin
39. should have a 3 4 hole to attach the handle end of the cable to 1 4 20 HEX NUT Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex end cap Replace the T handle on the cable 1 2 13 HEX NUT 7 16 LOCK WASHER 7 16 FLAT WASHER 7 16 C HEX JAM NUT UPPER REAR LINK 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK WASHER SEAL 7 16 INTERNA K WASHER 5 8 C HEX END CAP 16 ERNAL LOC SHE 7 16 C HEX END CAP 1 2 13 HEX NUT NOTE 3 818587 REM AIR P O FITTING P N 818589 CONVERTS REMOTE CABLE PIN OFFS 818593 REM P O AIR CTRL VALVE TO REMOTE AIR OPERATED PIN OFF ASSEMBLY 11 TRUCK SUPPLY N L P N 818596 5 8 18 JAM NUT SAME AS OPPOSITE SIDE E P N 818765 AIR CYLINDER THE OUTER HEX NUTS l 818591 1 4 TUBE LOCATE AIR CONTRL VALVE P N 818593 FOR CONVENIENCE AND CONNECT TO A PROTECTED AIR SUPPLY CONNECT LEFT VAVLE TO THE LEFT P O CYLINDER WITH TWO OF THE HOSES AND FITTINGS SUPPLIED REPEAT THE SAME PROCEDURE FOR THE RIGHT P O ASSEMBLY P O SHOULD DISENGAGE WHEN VAVLE IS PULLED REMOVED NOTE 2 AND REMOTE RETRO KIT CHART uc 1 27 13 HEX NUT 4 PLCS REVISED PER NEW BRAZIL MANUAL KIT 4 5 vec REV AT RIPTION Y APP KIT P N 818613 AIR REMOTE ASSY LESS PIN OFFS REV DATE _ DESCRIPTIO LEY APP P N 818595 MOUNTING PLATE TITLE P N 818599 5 16 24 JAM HEX NUT INCLUDES 800136 D
40. st2 REF VALVE HANDLE REPLACEMENT wUNKKT 78 s 610215 REF VALVE HANDLE REPLACEMENT ASSEMBLY 19 51028 1 VALVE ASSEMBLY FRONT W 30deg FITTINGS VALVE HANDLE REPLACEMENT HANDLE ONLY LOCKING VALVE DPC1 10 P 6T 21 21 600606 REF LOCKING VALVE W FITTINGS DIVERTER lt 3 i I L i OTHER EQUIPMENT im ee PRESSURE RELIEF VALVE RETURN TO TANK W N TRUCTI FILTER RETURN TO TANK ETURN TO 1 NO OBSTRUCTION OR FILTERS 25 2 a i De TO HYDRAULIC PTO PUMP FILTER RELIEF SETTING x 1 2000 psi REAR VALVE NOTE DOES NOT HAVE TO BE RE PLUMBED DEPENDING ON foem m DIRECTION OF HANDLES UP DOWN PLUMBING FOR EXTERNAL LOCKING VALVE PLUMBING FOR EXTERNAL LOCKING VALVE WITH T FITTINGS ON FRONT VALVE STD HANDLE W 90deg FITTINGS ON FRONT VALVE STD HANDLE TO FRONT VALVE ASSY IN PORT TO FRONT VALVE ASSY IN PORT f OUT VALVE ASSY VALVE ASSY OR REPLACE T FITTINGS W FROM FRONT VALVE ASSY OUT PORT 90460 FITTINGS FRONT TIRE A TP 5 9 11 CORRECTED SECTION REFERENCE 9 20 10 DELETED P N S 810311 810312 amp 810313 amp ADDED 240258 9 09 09 REVISED SCHEMATIC LAYOUT AND B O M PER AS BUILT NOW SEE SECTION 4 3 OF MANUAL WHICH SPECIFIES HYDRAULIC SYSTEM REQUIREMENTS REVISED BY REMOVING TYPE OF VALVES ENERGY GRESEN LUBRICATION SPECIFICATIONS HYDRAULIC ASTM D6158 HM UNAX R
41. the pressure relief valve and before any existing equipment One diverter outlet routes to the existing equipment s valves the other diverter outlet routes to the front Railgear See Detailed Drawing in Section 5 3 for additional information on installation of the pressure relief valve and diverter valve Once both are installed proceed to section 4 3 3 for continued installation of hydraulic system WARNING Railgear control valves have built in pressure reliefs and the hydraulic working pressure of the system is 2500 psi The front valve should be set to 2250 psi at the relief The rear valves should be set to 2000 psi and all other parts supplied by DMF are rated to 2500 psi Care must be exercised that the relief in any of the valves is not inadvertently exceeded It is possible for a relief to be adjusted much higher than its valve can withstand To ensure correct system pressure check with a gauge 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 3 Hydraulic System Installation Continued From the output side of the Pressure Relief valve or the Diverter valve if appropriate route a pressure line SAE 100R2 8 and 8 JIC swivels at each end to the center of the front bumper Connect the pressure line to the IN port of the front Railgear valve From the OUT port of the front Railgear valve route a pressure line SAE 100R2 8 and 8 JIC swivels
42. they can be used in any BEST FITS YOUR APPLICATION combination The two different types are REPLACEMENT CABLES Cable operated Air operated LENGTH 818581 Remote pin offs are not installed at the factory to prevent damage during shipment 818577 818576 EE Note Remote Front Pin Offs Shown wl amp w o Air Cylinder 818575 Once cables are installed to pins route cables to easily accessible location for operator use preferably as near as possible to 818578 the front Railgear control valve In this location mount two cable handle mounting plates not supplied These plates should BIBS have a 3 4 hole to attach the handle end of the cable to 818580 P N 818700 FRONT CABLE PIN OFF ASSY Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex P N 818757 FIN OFF HOUSING WELDMENT end cap Replace the T handle on the cable 1 4 FENDER FLAT WASHER 5 16 HEX NUT P N 818709 CABLE 5 8 HEX NUT HANDLE MOUNT 7 16 LOCK WASHER 7 16 FLAT WASHER P N 818758 7 16 C HEX JAM NUT PIN OFF PIN SEAL 4 x 3 4 DIA w 1 4 20 1 4 C HEX NUT L 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK WASHER SEAL 5 8 C HEX END CAP 7 16 INTERNAL WASHER 7 16 C HEX END CAP KIT P N 818763 CABLE P O 3 4 PIN FOR BRAZIL INCLUDES 818576 CABLE ASSY QTY 2 818759 3 4 PIN QTY 2 amp 818767 WASHER QTY 2 MOUNT INSIDE FOR BRAZIL 81858
43. whole wheel must be carefully serviced To install a torque indicator place it over the nut with the raised collar resting against the wheel Push with both thumbs or a socket flush ALT VIEW FRONT ALT VIEW REAR to the wheel 2 Most of the inspection stations know this systemand will realize that the driver is aware of the loose nut and will pass him through fo go to a maintenance shop 5 If the torque indicators have not moved this means that the nuts are secure DESCRIPTION BY APP and safe No torquing is required which means less tear on the nut and valuable time money is saved RW 1630 50 RW 1630 50 INSULATED 2 PC WHEEL ASSY If a replacement bolt is needed DMF requires that you replace both bolt and ar s nut at the same time Replace broken bolt with a 5 8 11 x 4 grade 8 bolt and replace SE A nut with 5 8 11 Type C Prevailing Torque Nut A hardened washer must be used beneath the nut TN HM oo ME Sow neat SS kana The bolts that hold the rail wheel tread to the Hub should be torqued to 120 foot pounds aosi DA AND 22 4 6 2010 qu M1630106 DIVERSIFIED METAL FABRICATORS INC RW 1630 5 2 7 Options Velcro Steering Wheel Lock Installation Instructions for The DMF Velcro Steering Wheel Lock Overview The DMF Velcro steering wheel lock consists of two 2 wide adhesive backed hook strips and a 4 wide piece of loop fabric A piece of adh
44. 0 Railgear Installation 4 1 Pre Install 4 1 1 Safety Statements 4 1 2 Installation Order 4 1 3 Installation Sheets 4 1 4 Required Tools amp Materials 4 1 5 Welding Information 4 1 6 Purchased Fastener Torque Specifications 4 2 Initial Instructions 4 2 1 Work Area 4 2 2 Truck Condition 4 2 3 Front and Rear Installation Rails 4 2 4 Installation Rails 4 3 Hydraulic System 4 3 1 New Hydraulic System for Vehicle without Hydraulic System 4 3 2 Hydraulic System for Multiple Uses Railgear and other application s 4 3 3 Hydraulic System Installation Continued 4 4 Installation of Rear Railgear General Information Diagram of Key Components Location of Rear Railgear Location and Clearance of Railgear Shimming and Temporarily Spacing Rear Bracket Square Rear Railgear with Truck Axle Squaring up Rear Railgear to Truck Frame Temporarily Securing Rear Bracket 4 4 9 Mounting Plate Installation 4 4 10 Welding of Spacer 4 4 11 Final Rear Railgear Alignment and Weight Settings APP LA SAP Pe ee P 4 5 Varying Front Railgear Configurations 4 5 1 Traditional Long Arm Assembly 4 5 2 Cargo Arm Assembly 4 5 3 Mid Mount Assembly 4 6 Traditional Long Arm Assembly Installation 4 6 1 General Information 4 6 2 Diagram of Key Components 4 6 3 Frame Extension Installation 4 6 4 Bridge Kit Information 4 6 5 Front Mounting Dimensions 4 6 6 Mount Front Railgear 4 6 7 Front Railgear Clearance 4 7 Cargo Arm Front Assembl
45. 0264 5 00 CROSS TUBE P N 810270 VOLVO OFFSET CROSS TUBE P N S BELOW DRIVER SIDE SHOWN P N 810388 PASSENGER SIDE U HAND P N 810389 Af Af REV DATE DESCRIPTION BY APP UNLESS SPECIFIED FRAC MACI FRAC OTHER eine X t O XX DRILL SIZES IGULAR SURF FINISH TITLE VARIOUS CROSS TUBE DETAILS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER REV JBG 8 11 2010 MGENN101 6 5 8 OFFSET SPRING HANGER P N 818172 9 1 2 OFFSET SPRING HANGER P N 810136 DESCRIPTION TITLE VARIOUS SPRING HANGER BRACKETS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 m DRAWN BY APPD BY DATE DRAWING NUMBER REV 9 SPRING HANGER P N 4818142 et 4 01 10 MGENNIOO COBRA AIR BRAKE ASSEMBLY FRONT PASSENGER S SIDE COBRA AIR BRAKE ASSEMBLY REAR DRIVER S SIDE COBRA AIR BRAKE ASSEMBLY REAR PASSENGER S SIDE COBRA AIR BRAKE ASSEMBLY FRONT RETRO FIT KIT COBRA AIR BRAKE ASSEMBLY REAR RETRO FIT KIT COBRA AIR BRAKE ASSEMBLY COMPLETE RETRO FIT KIT F amp R NOTE 1 KIT P N 818445 AIR BRAKE PIVOT PIN w 2 ROLL PINS INCLUDES 5 818454 BRAKE SHOE PIVOT PIN QTY 1 amp 17 818509 ROLL PIN QTY 2 NOTE 2 1 NOTE 2 1 AIR BRAKE CHAMBER FRONT SEE NOTE 2 BOLT MOUNTING 1 2 13 1 1 2 Gr8
46. 08 JIC HYD CYL HOSES 96 qty 4 04 w 04JIC SWIVEL TO RAILGEAR CYLINDERS CUSTOMER IS RESPONSIBLE FOR ALL OTHER SYSTEM FITTING TEE 1 4 NPT x 04 JIC x 04 JIC HYD CYL HOSES 38 qty 4 04 wi 04JIC SWIVEL COMPONENTS TANK DIVERTER PTO PUMP FILTER PRESSURE RELIEF VALVE ETC 5 810310 6 FITTING ELBOW 1 2 MPT x 04 JIC HYD CYL HOSES 62 qty 4 04 w 04JIC SWIVEL NOTE ON THE FRONT VALVE THE RELIEF SETTING MAY BE LOCATED IN DIFFERENT LOCATIONS DEPENDING ON THE MANUFACTURING BRAND ALL ELSE REMAINS THE SAME WE SHOW THE TWO MOST COMMON LOCATIONS BELOW FOR THE RELIEF SETTING ISOMETRIC VIEW OF FRONT VALVE ASSY UN ENDS CYLINDER BLIND ENDS FROM DIVERTER INLET RELIEF SETTING 2500 psi MAX VALVE ASSY FRONT VALVE NOTE DEPENDING ON DIRECTION OF HANDLE UP DOWN YOU MUST RE PLUMB YOUR HOSES OPPOSITE FROM ABOVE SEE DIAGRAM BELOW EROM FRONT VALVE ASSY OUT PORT PULL TO RAISE PUSH TO LOWER PLUMBING FOR REVERSED HANDLE ONLY ISOMETRIC VIEW OF FRONT VALVE ASSY 9 2 FROM DIVERTER INLET CYLINDER BLIND ENDS CYLINDER ROD ENDS RELIEF SETTING 2500 psi MAX TO REAR VALVE TO FRONT VALVE ASSY IN PORT RELIEF SETTING 2500 psi MAX FRONT VALVE ASSY IF HANDLE REVERSED FRONT VALVE PLUMBING erone MUST BE REVERSED s 810204 REF 4 X 8 MORB 90 DEG ELBOW G80 04 05 NWO FG 7 s
47. 1 2 Any shims used should be load bearing members no thin wall tubing If necessary a different cross tube can be used to obtain the desired height of the Front Mounting Pin up to a maximum of 3 of shims If you need more than 3 of shims a change of cross tubes mounting block may be required see section 5 6 for information Contact DMF for assistance Once properly shimmed the hydraulic system should already be properly positioned to hold the shims in place until alignment can be completed Check for truck frame spring steering gear or other truck component interference with the Railgear particularly the Long Arms see CLEARANCE NOTE in section 4 6 7 Front Mounting Pin ground clearance may be reduced to as low as 24 to provide for proper fit Repeat process on passenger side 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 6 7 Front Railgear Clearance CHECK FOR INTERFERENCE IN THIS AREA Figure 4 6 7 A Front Railgear Clearance CLEARANCE NOTE Proper clearances will allow the Railgear to move up and down with the truck front suspension As the truck tire hits bumps in the road the truck spring allows the front axle to move upward see Figure 4 6 7 A Since the Railgear is attached to the spring just in front of the axle sufficient clearance must be allowed to prevent interference with other parts on the truck i e frame steering
48. 105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 240208 O RING GLAND 2 338 240209 BACKUP RING GLAND 8 338 240255 WELD ASSY 3 1 2 TUBE SAE PORT LOCKING VALVE RR RH 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 NPT STRAIGHT 240258 90 DEGREE ELBOW 4 MJIC x SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 DMF P N 240225 SEAL KIT TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO BASE OF CYLINDER IF THE TUBES ARE FACING YOU SR CLOSEST TO YOU THEN IT IS A DRIVER SIDE CYLINDER DS PART 240232 IF THE TUBES ARE FACING AWAY FROM YOU THEN IT IS PASSENGER SIDE CYLINDER PS PART 240231 SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE o o o s o m o x Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123 A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP TOLERANCES TITLE BEEN CYLINDER REAR SAE
49. 3 Torque 300 ft Ibs THE TUBES ARE FACING AWAY FROM YOU THEN IT IS PASSENGER SIDE CYLINDER PS PART 241304 SEE PPOO08 FOR CYLINDER ASS Y amp TEST PROCEDURE 1 240246 1 HYD CYL PISTON 5 7 2 240202 1 GLAND 3 1 722 3 240103 1 Nur NYLOCK 1 14 5 240105 1 SEAL ROD 3750 2000 6 240106 1 WIPER ROD 59 7 7 4 7 240107 1 O RING PISTON 2 214 8 240208 1 O RING GLAND 2 338 9 240209 1 O RING GLAND BACK UP 8 338 10 241318 1 or ASSY 3 1 2 TUBE LVALVE RR PASSENGER SIDE 241319 1 ASSY 3 1 2 TUBE LVALVE RR DRIVER SIDE 11 240229 1 HYD CYL REAR ROD ASSEMBLY LVL 818235 1 GREASE FITTING 1 8 NPT STRAIGHT 241016 1 PARKER LOCKING VALVE 45 DEG FITTING FOR LVL TUBES REAR 2504 06 04 FG AQP FITTING NUT FC2875 06S 16 810313 2 AQP FITTING FERRULE FF9605 065 13 750 REF ROD END PORT ROD END PORT DETAIL A A P N 241303 PASSENGER S SIDE DETAIL P N 241304 DRIVER S SIDE BASE END PORT 1630 REAR EXTRA SHORT CYLINDER A 4 16 12 818235 WAS 240123 12 1 11 241016 was 241013 DATE DESCRIPTION SPECIFIED _ TITLE COMMON SENSE PREVAILS RW 1630 REAR EXTRA SHORT DS PS L VLV CYLINDER ASSEMBLY 3 1 2 BORE x 2 ROD x 9 1 2 STROKE DIVERSIFIED METAL FABRICATORS INC 404
50. 4 washer FLAT 1 1 27 COTTER PIN 1 4 x 2 1 2 J CLIP 1 2 DIA FOR AIR BRAKE HOSES QTY 2 EACH SIDE 22 INNER LONG ARM ASSEMBLY 23 OUTER LONG ARM ASSEMBLY 24 Eme 8 3 amp 10 HEX NUT 95 1 DRVER SIDE INNER PIVOT ARM 96 1 DRIVER SIDE OUTER PIVOT ARM Must have serial when ordering parts MOUNTING CROSS TUBES VARY ACCORDING TO TRUCK SPECS SEE SECTION 5 5 FOR SPECIFIC PART NUMBERS OR MAJOR COMPONENTS SEE SECTION 5 5 Drawing is for illustrative purposes Your parts may not be exactly as pictured below SEE SECTION 5 5 FOR OPTIONS LONG ARMS VARY DEPENDING ON TRUCK MODEL SEE SECTION 5 5 FOR VARIOUS LONG ARM OPTION amp DETAIL DRAWINGS TOP VIEW S U MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET FOR DETAIL DWG S OF THIS CYLINDER amp OTHER VARIOUS CYLINDERS SEE SECTION 5 5 RUBBER SPACER MUST BE INSTALLED BETWEEN SPRING amp TOP FLAT BAR SPACER SPRING HANGER BRACKETS VARY DEPENDING ON TRUCK SPECS SEE SECTION 5 5 NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING FRAME EXTENSIONS TO TRUCK FRAME Front Mounting Pin Frame Extension L Spacer Rubber Spacer Must be directly on top of
51. 5 4 16 or 5 5 10 While the Front and Rear Railgear is in the rail position the front Cobra Air Brake assembly should be located as shown below The rear Cobra Brake assembly is oriented at the factory and will not need to be changed Cobra Air Brake Location FRONT of VEHICLE AIR BRAKE Figure 5 2 4 A Cobra Air Brake Location 2012 DMF Inc All Rights Reserved 05 02 Options doc DIVERSIFIED METAL FABRICATORS INC RW 1630 Front Air Brake Installation 44 1 02 Maximum widths of Long Arms NOTES Run the supplied hoses through the J clips with the spring guards located in the loops left at the Brake Assemblies The 75 Hose is for the passenger side amp the 62 Hose is for the driver side Mount Air Brake Valve Assembly to an appropriate place near the Front Railgear usually on the Front Valve Assembly Plate with supplied Relay Brake Hoses attach to the Front Valve Assembly Figure 5 2 4 B Front Air Brake Installation Rear Air Brake Installation RW 1630 J clips 4 places each side Run the supplied hoses through the J clips Rear Hoses are 59 long Mount Air Brake Valve Assembly to an appropriate place near the Rear Railgear usually on the Rear Frame Bracket with supplied Relay Mount Attach Brake Hoses to the Air Brake Valve Assembly Figure 5 2 4 C Rear Air Brake Installation 2012 DMF Inc All Rights Reserved 05 02 Options doc D
52. 6 818456 1 COTTER 1 8 x 1 1 2 7 818407 1 BRAKE BRACKET WELDMENT o Z 818455 1 civis DETAR 8 O 9 818457 1 CLEVIS PIN 1 2 x 1 1 2 w COTTER PIN 10 818470 1 COBRA BRAKE SHOE V 265 Cd 11 818431 1 BRAKE ARM CASTING gt oo y O 12 818513 1 BRAKE SHOE CLIP ASSEMBLY 14 818452 1 BRAKE SHOE PIN 15 818448 2 BOLT MOUNTING 3 8 16 x 1 Gr8 16 818450 2 WASHER LOCK 3 8 ROLL PIN 5 32 x 1 1 2 Must have serial when ordering parts j f f f c e j die sj 3 26 12 818513 WAS 818426 JI DATE DESCRIPTION TOLERANCES TITLE TOR S TE ERA COBRA AIR BRAKE ASSEMBLY SEE NOTE 1 x dE DIVERSIFIED METAL FABRICATORS INC 404 875 1512 EXE ANGULAR 1 DRAWN BY APPD BY DATE Ti DRAWING NUMBER REV d JBG 1 25 10 y M1630101 DIVERSIFIED METAL FABRICATORS I NC RW 1630 DMF LIMITED WARRANTY POLICY Diversified Metal Fabricators DMF products are designed to provide the utmost service and reliability Competent workmen guided by stringent quality standards manufacture the products from high grade material DMF warrants products of its manufacture to be free of defects in material and workmanship under normal use and service for a period of ONE CALENDAR YEAR DMF s obligation under this warranty is limited to repairing or replacing at its factory or other location
53. 7 REM AIR P O FITTING 818593 REM P O AIR CTRL VALVE pm TRUCK SUPPLY P N 818758 PIN OFF PIN 2 7 8 x 3 4 DIA w 5 16 24 an ES P N 818785 PIN OFF HOUSING WELDMENT Truck DS 1 4 FENDER FLAT WASHER P N 818599 5 16 24 JAM HEX NUT P N 818596 5 8 18 HEX NUT P N 818755 AIR CYLINDER DRIVER SIDE P N 818785 PIN OFF HOUSING WELDMENT 1 4 FENDER FLAT WASHER P N 818599 5 16 24 HEX NUT 5 8 HEX NUT P N 818755 AIR CYLINDER PASSENGER SIDE Al P N 818758 PIN OFF PIN 2 7 8 x 3 4 DIA w 5 16 24 9 03 09 REVISED PER NEW BRAZIL MANUAL amp KIT 4 5 DESCRIPTION TITL TOLERANCES UNLESS SPECIFIED KIT P N 818774 FRONT REMOTE AIR KIT ASSY LESS PIN OFFS ME SPEEDY INCLUDES 800136 DECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 818593 QTY 1 FRAC OTHER 1 16 818596 QTY 2 818599 QTY 2 818755 QTY 2 818758 QTY 2 amp FW1 4 QTY 2 x 1650 REMOTE CABLE ASSY FRONT NOTE 2 RETO FIT KIT GENERIC DRAWING Xx OR XXXX per SIZES ANGULAR SURF FINISH THREADS
54. 800021 ALL HARDWARE KIT FOR RW 1650 amp BEHIND CAB WHEEL amp 1650 2PC WHEEL Does not Must be hardened P N 820496 2 PC INSULATED 1650 WHEEL W RACES REPLACES ITEMS 4 amp 5 ABOVE KEEP ALL OTHER PARTS washer PARTS Must have serial when ordering COMPLETE REAR AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS NON INSULATED WITH BRAKES 1650 amp BEHIND CAB 800213 NON INSULATED NO BRAKES 1650 amp BEHIND CAB 800214 INSULATED NO BRAKES 1650 BEHIND CAB 800216 INSULATED WITH BRAKES 1650 amp BEHIND CAB 800227 INSULATED NO BRAKES 1650 BEHIND CAB 800215 2 PC WHEEL NO BRAKES 1650 amp BEHIND CAB 800218 2 PC WHEEL WITH BRAKES 1650 amp BEHIND CAB 800261 1650 amp BEHIND CAB AXLE TUBES 1650 amp BEHIND CAB BEARING RACE AXLE TUBE WITH BRAKES 818203 TIMKEN 6420 BEARING RACE AXLE TUBE NO BRAKES 818210 800125 1650 amp BEHIND CAB WHEELS NON INSULATED 1650 WHEEL w RACES 800015 INSULATED 1650 WHEEL w RACES 800016 INSULATED 2 PIECE 1650 WHEEL w RACES 820496 NOTE SPECIAL PROFILE WHEELS PLEASE CALL 9 include silicon for hubcap or wheel grease or bearing race Never Re Use Previously Bent Tabs Torque to 120 ft Ibs 5 8 11 Type C prevailing Torque Nut Must replacebolts nuts at same time Q 2 a dr Decal 800300 apply to hubcap cover when using 2 pc wheel P N 800300 DEC
55. 818425 4 10 LOCK WASHER LW 10 9 818492 1 HOSE AIR LINE FRONT LH w SPRING GUARD HO6906 x 62 24 Fw 10 2 8 FLAT WASHER 10 818494 1 HOSE AIR LINE FRONT RH w SPRING GUARD 06906 x 75 25 818427 2 10 24 HEX NUT 11 818496 2 HOSE AIR LINE REAR HO6906 x 59 n 26 510 24 1 2 RD HEAD MACHINE SCREW 10 24 X 1 00 12 818497 2 FITTING STRAIGHT 0104 6 68 SAE 818499 6 FITTING 902 2104 6 68 14 818458 1 AIR BRAKE CHAMBER FRONT DRIVER S SIDE Lis 818459 1 AIR BRAKE CHAMBER FRONT PASSENGER S SIDE Note Items 5 6 7 8 amp 13 shipped ossembled Note Items 5 6 7 8 Rear Kit p n 818415 amp 13 shipped assembled FROM VEHICLE AIR BRAKE Front Kit p n 818413 CONTROL CIRCUIT KIT 4818441 INSTALLER S SUPPLY LINE 1 INSTALLER S SUPPLY LINE FRONT AXLE Item 1 p n 818485 only qty 1 included w front brakes 16 10 09 REVISED ITEM 1 TO QTY 1 AND ADDED NOTES KIT 818413 FRONT INCLUDE ITEMS 5 6 7 8 amp 13 ADDED TANKS nus KIT 818415 REAR INCLUDE ITEMS 5 6 7 8 amp 13 _ KIT 818437 INCLUDE ITEMS 2 3 4 22 23 24 25 amp 26 fee Xx KIT 818438 INCLUDE ITEMS 18 20 2x amp 21 2x KIT 818441 INCLUDE ITEMS 19 20 2x amp 21 2x PARTNO DESCRIPTION 3 mer PUMP EXISTING 6 to 7 gom 2000 ps MINIMUM FITTING ELBOW 3 4 MPT x 4
56. 9221 CABLE REMOTE XSHORT SLOTTED P N 819223 X SHORT STANDARD amp SLOTTED LINKS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE 7 26 2010 DRAWING NUMBER M1630107 Truck Front Truck Rear M1630107 SHORT LINKS Note Links are sold individually unless SHORT SLOTTED LINKS you want a full set of all 8 Please refer to full set p n s shown below 818264 The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same for short links no matter what pin off option you have MANUAL SHORT MANUAL SHORT SLOTTED P N 819200 P N 819202 818285 818243 Truck Front Truck Front 818266 d Bw Truck Rear Truck Rear 818264 AIR REMOTE SHORT AIR REMOTE SHORT SLOTTED P N 819205 P N 819207 818285 818243 Truck Front Truck Front Tue Truck Rear CABLE REMOTE SHORT CABLE REMOTE SHORT SLOTTED P N 819204 P N 819206 818551 SHORT STANDARD amp SLOTTED LINKS Truck Front e D Truck Front UM RIO D DIVERSIFIED METAL FABRICATORS INC 404 875 1512 818654 DATE DRAWING NUMBER d 7 26 2010 M1630108 M1630108 Truck Rear Note Links are sold individually unless you want a full set of all 8 Please refer to full set p n s shown below The Rear Set of Rear Links differ in p n s according to pin off option Your Front Set of Rear Links are the same
57. AL 2 WHL INSPECTION cg P N 800301 KIT 2 PC WHL TORQUE INDICATORS 1650 amp BEHIND CAB REAR AXLE 800261 WAS 800245 wo REV DATE DESCRIPTION ev APP TITLE RW 1650 REAR WHEEL amp AXLE ASSY EXPLODED DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER REV JBG 1 25 10 M1650103 A NOTE 1 Note Remote Rear Pin Offs PART NO DESCRIPTION SPECIFY THE CABLE THAT There are two different types of remote pin offs available for both front and rear 1 NOTE 1 REF REMOTE PIN OFF CABLE MORSE BEST FITS YOUR APPLICATION Railgear and they can be used in any combination The two different types 818563 REMOTE MOUNTING PLATE are 818550 REMOTE ASSY for w LONG LINKS 7 3 4 C to C REPLACEMENT CABLES Cable operated 4 818551 REF REMOTE ASSY for w SHORT LINKS 5 3 4 C to C Cable operated with air REMOTE PIN OFF T HANDLE MORSE 818581 Remote pin offs are not installed at the factory to prevent damage during SS 08185771 shi pment 818576 Note Remote Rear Pin Offs 97 818578 Once cables are installed to pins route cables to easily accessible location for 818579 operator use preferably as near as possible to the rear Railgear control valves 1 27 13 x 5 1 2 HEX HEAD BOLT 818580 In this location mount two cable handle mounting plates not supplied These plates
58. ARD MOUNTING CONFIG WHICH WAY THE PIN OFFS ARE FACING IF THEY ARE FACING TRUCK FRONT PASSENGER TOWARD THE REAR OF THE TRUCK THEN THIS IS CONSIDERED SIDE OF TRUCK OUR STANDARD MOUNTING CONFIGURATION THEN DRIVER S SIDE amp PASSENGER S SIDE TERMINOLOGY IS CONSISTENT WITH THE LAYOUT OF THE VEHICLE HOWEVER IF THE PIN OFFS ARE FACING TOWARD THE FRONT OF THE TRUCK IE UNDERNEATH THE TRUCK WHICH IS USUALLY DONE TO ACCOMMODATE THE CLEARANCE ISSUES WHEN INSTALLING AIR REMOTE PIN OFFS IE THE DRIVER S SIDE CYLINDER IS ACTUALLY ON THE PASSENGER S SIDE OF THE VEHICLE amp SHOULD BE ORDERED PASSENGER SIDE AS THE DRIVER S SIDE THE REVERSE APPLIES FOR THE OTHER OF RAILGEAR SIDE OF THE VEHICLE NOTE ALL OTHER REAR PARTS ARE NOT DS DRIVER SIDE OR PS PASSENGER SIDE SPECIFIC DRIVER SIDE PLEASE NOTE THAT IF YOU HAVE INSULATED RAILGEAR amp YOU OF TRUCK 2 MOUNT THE GEAR BACKWARDS YOU MUST SWAP THE WHEELS DRIVER SIDE INSULATED WHEEL SHOULD ALWAYS BE ON THE ACTUAL DRIVER S OF RAILGEAR SIDE OF THE TRUCK PIN OFFS TO FRONT OF TRUCK TRUCK FRONT PASSENGER SIDE OF TRUCK DRIVER SIDE OF RAILGEAR PASSENGER SIDE DRIVER SIDE OF RAILGEAR TRUCK REAR OF TRUCK PIN OFFS TO FRONT REAR OF TRUCK FRAC MACH 1732 FRAC OTHER r1 16 063 9 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER REV JBG 8 10 2010 M1630110 PART NO DESCRI
59. AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE G INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft Ib 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL WILL SPIN FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 6 REPEAT IF ADJUSTMENT IS NECESSARY J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE K ADJUST INNER WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 L INSTALL TAB WASHER ITEM 7 M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND Wheel Bearing Grease Mystik 1 6 Lo Temp Extreme Grease factory standard preferred for colder climates NOTE DRAWING amp PART NUMBERS ARE APPLICABLE FOR BOTH 1630 AND UNDER CAB REAR BRAKE SADDLES Must be hardened washer P N 820494 2 PC INSULATED 4 amp 12 ABOVE KEEP ALL OTHER EXCEPT HUBCAP PARTS Must have serial when ordering COMPLETE REAR AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS INSULATED
60. BACK SIDE OF BEARING 6 5 D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE q amp G INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 El ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft lb 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL 8 WILL SPIN FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 6 REPEAT IF ADJUSTMENT 15 NECESSARY J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE K ADJUST INNER WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 L INSTALL TAB WASHER ITEM 7 M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND N SELECT THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS O FILL OUTBOARD CAVITY COMPLETELY P RUN A BEAD SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N
61. BOTH PASSENGER amp DRIVER COMMON SENSE PREVAILS RW 1630 FRONT RAILGEAR ASSY SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS FRAC MACH es REF P N 801192 ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET XX 2 ROR DIVERSIFIED METAL FABRICATORS INC 404 875 1512 FOR DETAIL DWG S OF THIS CYLINDER ANGULAR E DRAWN BY APPD BY DATE DRAWING NUMBER REV amp OTHER VARIOUS CYLINDERS SEE SECTION 5 5 SURF FINISH 125 MICRO THREADS 2A AND 2B JBG 1 25 10 M1630104 DESCRIPTION DESCRIPTION 1 818483 1 VALVE PRESSURE PROTECTION BW103976 SPL PR 4 KIT 818437 16 818460 1 AIR BRAKE CHAMBER REAR DRIVER S SIDE 2 818484 1 ANGLE BRKT AIR BRAKE VALVE OPTIONAL 17 81846 1 AR BRAKE CHAMBER REAR PASSENGER S SIDE r 3 818485 1 VALVE TOGGLE 0052037 0 8 18 818491 1 VALVE MOUNT BRKT FRONT AIR BRAKE 4 818486 1 LEGEND PLATE ON OFF FOR TOGGLE AIR VALVE 19 818493 1 VALVE MOUNT BRKT REAR AIR BRAKE 2 5 818488 2 VALVE BRASS BALL 3 8 PBv500P 6 J 20 818421 HEX HEAD 5 16 18 x 1 1 4 6 818498 4 FITTING NIPPLE 215PN 6 21 5 5 16 18 4 5 16 18 NYLON LOCK NUT 818489 2 REGULATOR AIR MIDLAND KN31070 RAIL GEAR AIR BRAKES 22 818424 2 ROUND HEAD MACHINE SCREW 10 24 X 3 4 8 818490 2 VALVE AIR RELAY MIDLAND KN28500 wc
62. CKET HEX HEAD BOLT 4X 10 818289 WASHERS FLAT 1 1 4 5 8 11 GRADE 5 141 818194 1 REAR BRACKET SHIMS PACKAGE EOS ours seu 1 Cra coner em 1 45 2 1 29 PEATE 3 1 HYDRAULIC CYLINDER ASSY DRIVER S SIDE 4 1 HYDRAULIC CYLINDER ASSY PASSENGER S SIDE REAR FRAME BRACKET _15 PIN 0FF ASSY REAR DRIVER S SIDE 1 Dia SEE NOTE 3 L16 PIN OFF ASSY REAR PASSENGER S SIDE 1 Dio SEE NOTE 3 ENSURE ALL SPACERS ARE FIRMLY AGAINST SIDE s DE na ss SHOWN IF MULTIPLE SPACERS ARE USED SPACERS NOTE 1 GRADE 5 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NEED TO BE WELDED TO ONE ANOTHER AT THE REAR amp TACK WELDED ON THE SIDES IF POSSIBLE NOTE 2 IF SHIMMING IS REQ D BRACKET MUST BE EQUAL ON BOTH SIDES SPACERS MIN 1 2 MAX 3 IF OUTSIDE OF THIS RANGE ON FINAL INSTALLATION CONTACT DMF 5 8 11 NYLOCK NUTS amp 5 8 FLAT WASHERS NOT PROV D SEE SECTION 5 4 FOR VARIOUS LINK COMBINATIONS NOTE 3 5 8 11 NC HEX CAP BOLTS NOT PROV D MUST BE GRADE 5 FOR REAR ONLY LENGTH TO BE DETERMINED ONCE BRACKET MOUNTED amp SHIMMED N FOR DETAIL DWG S OF THIS 4 CYLINDER amp OTHER VARIOUS CYLINDERS SEE SECTION 5 4 BRAKES NOT SHOWN SEE SECTION 5 2 OPTIONS REF MANUAL 5 STANDARD 15 SEE SECTION 5 2 FOR VARIOUS PIN OFF OPTIONS 4 APPROPRIATE PART jS FOR ORDERING REPLACEMENT PARTS Q MN
63. D ALREADY BE WELDED IN THEIR PROPER LOCATION L2 P N 108045 AUXILIARY ASSEMBLY P N 108044 AUXILIARY PIN OFF CHAIN P N 108041 1 5 8 ASSEMBLY w CHAIN BEHIND CAB BEHIND CAB PIN OFF P N 818163 P N 818164 DRIVER S SIDE PASSENGERS SIDE FRONT O FRONT SIDE VIEW 1650 50 MANUAL PIN OFFS C Must have serial when ordering parts A 5 26 11 FIXED TYPO AUXILIARY NH A 8 11 10 CHANGED P N 108042 TO 108041 vec P N 818234 P N 818245 DESCRIPTION PASSENGER SIDE DRIVER SIDE UN ESS TITLE REAR REAR RW 1630 ASSORTED PIN OFF ASSEMBLIES DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE uei J DRAWING NUMBER 1 50 SU M1630100 NOTE 1 Note Remote Rear Pin Offs SPECIFY THE CABLE THAT There are two different types of remote pin offs available for both front and rear BEST FITS YOUR APPLICATION Railgear and they can be used in any combination The two different types are Cable operated PN uw Cable operated with air Remote pin offs are not installed at the factory to prevent damage during shipment 818578 818579 818580 Once cables are installed to pins route cables to easily accessible location for operator use preferably as near as possible to the rear Railgear control valves In this location mount two cable handle mounting plates not supplied These plates should have a 3 4 hole to attach the handle end of t
64. DIVERSIFIED METAL FABRICATORS INC 00 1 Parts amp Service Manual RW 1630 amp RW 1630 50 ATLANTA April 2012 SERIAL NUMBER FRONT SERIAL NUMBER REAR NOTE Please refer to the serial numbers when ordering parts or inquiring about warranty items This manual applies to both DMF s RW 1630 Railgear and DMF s higher capacity RW 1630 50 Railgear including all configurations standard behind cab and under cab DMF 665 Pylant Street Atlanta Georgia 30306 Parts 404 607 1684 Parts Fax 404 879 7888 parts dmfatlanta com Service Department 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com DIVERSIFIED METAL FABRICATORS INC RW 1630 Message from DMF Thank you for choosing DMF Railgear We make every effort to provide quality safe and rugged products for the railroad We hope you ll find our gear to be satisfactory in every way We take product support very seriously so if you have any questions please contact us Manuals service bulletins and general information are available on our website listed below Contact Diversified Metal Fabricators 665 Pylant St NE Atlanta GA 30306 404 875 1512 404 875 4835 Fax 404 607 1684 Parts http www dmfatlanta com info dmfatlanta com Ship to 668 Drewry St NE Atlanta GA 30306 2012 DMF Inc All Rights Reserved DIVERSIFIED METAL
65. E DO NOT EXCEED 2000 PSI REAR VALVE DO NOT BOTTOM OUT RELIEFS IF ADJUSTED 800135 HI RAIL VEHICLE COMPLETED BY WITH APPLICATION OF HI RAIL AND FINISHED BODY THIS VEHICLE HAS POUNDS OF AVAILABLE PAYLOAD DATE OF COMPLETION OF HI RAIL EQUIPPED VEHICLE mo yr INSTRUCTIONS 1 REMOVE SAFETY PINS 2 ACTIVATE VALVE A PUSH RAIL POSITION B PULL HIGHWAY POSITION 3 REPLACE SAFETY PINS IN PROPER LOCATION CAUTION THIS MUTIPURPOSE VEHICLE HAS SPECIAL DESIGN AND EQUIPMENT FEATURES FOR OFF ROAD USE IT HANDLES DIFFERENTLY FROM AN ORDINARY PASSENGER CAR IN DRIVING CONDITIONS WHICH MAY OCCUR ON STREETS HIGHWAYS AND OFF ROAD WEIGHT AND LOCATIONS OF AVAILABLE PAYLOAD MAY ALSO AFFECT THE HANDLING OF THIS VEHICLE DRIVE WITH CARE AND WEAR SAFTETY BELTS AT ALL TIMES FOR PRECAUTIONS READ THE VEHICLE OWNER S GUIDE AND HI RAIL 800117 OPERATORS SERVICE AND PARTS MANUAL 800118 LA DESCRIPTION INSTRUCTION amp SAFETY DECALS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER 10 12 98 ST1652 TITLE Purchased Fastener Torque Specification PURPOSE To Establish Production Methods For The Installation Of Commonly Purchased Threaded Fasteners COMMON USAGE Most Areas Of Multiple Part Assembly And Retention PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Most Common Sizes Of SAE J429 Grade 5 And 8 And Of ASTM A574 Alloy Bolts PROCEDURE A Identify The Fastener As Eithe
66. E COMPONENTS OF ITEM 2 RESPECTIVELY REF MANUAL 5 STANDARD 16 SEE SECTION 5 2 FOR VARIOUS PIN OFF OPTIONS amp A PPROPRIATE PART S FOR ORDERING REPLACEMENT PARTS FOR DETAIL DWG S OF THIS 14 CYLINDER amp OTHER VARIOUS CYLINDERS SEE SECTION 5 4 FOR SPECIFIC PART NUMBERS OR MAJOR COMPONENTS SEE SECTION 5 4 Drawing is for illustrative purposes Your parts may not be exactly as pictured Al LA REV DATE OLERANCE UNLESS SPECIFIED COMMON SENSE PREYLS DESCRIPTION RW 1630 REAR RAILGEAR ASSY NON INSULATED MANUAL PIN OFFS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 X XXX 1005 GULAR j er DRAWN BY APPD BY DATE DRAWING NUMBER THREADS _ 2A AND 2B BREAK SHARP EDGES JBG 1 25 10 ays M1630105 TIE PIN ASSEMBLY PIVOT ARM a FRONT COBRA WHEEL amp AXLE assy 1 PASSENGER SIDE OUTER PIVOT ARM e PASSENGER SIDE INNER PIVOT ARM 8 818153 2 SPRING HANGER BRACKET RUBBER MOUNTING PAD 9 2 SPRING HANGER BRACKET ASSEMBLY 10 818160 6 SPRING HANGER BRACKET MOUNTING SPACER 1 11 818158 REF SPRING HANGER BRACKET MOUNTING SPACER BAR 1 2 OPTIONAL 132 eW OS 1 HYDRAULIC CYLINDER ASSEMBLY FRONT DRIVER S SIDE 14 1 HYDRAULIC CYLINDER ASSEMBLY FRONT PASSENGER S SIDE 5 2 CROSS TUBE DETAIL FRONT SEE SECTION 56 16
67. ECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 BEEN RW 1630 REMOTE CABLE PIN OFF ASSY REAR P N LW5 16 LOCKWASHER 5 16 818593 QTY 1 818596 QTY 2 818599 QTY 2 818765 QTY 2 amp LW5 16 QTY 2 RAC kil 1 16 NOTE 2 RETO FIT KIT GENERIC DRAWING DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ES DRAWN BY APPD BY DATE DRAWING NUMBER KLC 10 06 98 d M1630113 INSTALLATION NOTES INSERT AIR CYLINDER THROUGH PLATE AND SCREW INTO P O SLIDE WELDMENT P O ASSEMBLY MUST BE PARALLEL TO LINK AND STUDS SHOULD BE FLUSH WITH au Z WT SSSSSNDL TT 22 24 WMI a Hi ae 1 818124 4 PINASSEMBLY FRONTMOUNTINGB IHM O S 1 FRONT COBRA WHEEL amp AXLE ASSY s 1 PASSENGER SIDE OUTER Pivot ARM 0 02 6 1 PASSENGER SIDE INNER PIVOT ARM C C l 8 818153 2 SPRING HANGER BRACKET RUBBER MOUNTING PD 9 2 SPRING HANGER BRACKET ASSEMBLY 10 818160 6 SPRING HANGER BRACKET MOUNTING SPACER BAR 1 11 818158 REF SPRING HANGER BRACKET MOUNTING SPACER BAR 1 2 OPTIONAL 2 13 1 HYDRAULIC CYLINDER ASSEMBLY FRONT DRIVER S SIDE 14 1 HYDRAULIC CYLINDER ASSEMBLY FRONT PASSENGER S SIDE 15 2 CROSS TUBE DETAIL FRONT SEE SECTION 55 16 818127 4 Nur SLOTTED HEX 1 8 COTTER PIN 3 16 x 2 NUT SLOTTED HEX 1 1 2 6 e siis
68. ELAY MIDLAND KN28500 2 2 9 78728 2 BRAKE CHAMBER 24 COMBO 10 818424 2 ROUND HEAD MACHINE SCREW 10 24 X 3 4 11 818425 4 10 LOCK WASHER LW 10 13 818427 2 10 24 HEX NUT FROM VEHICLE SERVICE BRAKE CONTROL CIRCUIT FROM VEHICLE PARKING BRAKE TO VEHICLE PARKING BRAKE CONTROL CIRCUIT RELAY AT REAR AXLE TEE INTO EXISTING LINE T 1 1 1 I 1 I I I 1 1 I 1 1 1 1 I I I 1 I 1 I I 1 Al j DESCRIPTION TITLE RW 1650 BEHIND CAB AIR BRAKE PLUMBING DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV 10 29 10 M1630132 DIVERSIFIED METAL FABRICATORS INC Inspection and Adjustment Inspect and adjust brake shoes per Figure 5 2 4 D ADJUST GAP WITH CLEVIS amp Testing JAM NUT e Figure 5 2 4 D Brake Inspection and Alignment ADJUST TO 1 REPLACE SHOE IF UNABLE TO ADJUST TO MAX ALLOWED 1 4 RW 1630 1 8 MIN SHOE 716 Operate the vehicle on a test track With the on off toggle valve on and the ball valve s open check that 1 when the vehicle brake pedal is depressed the guide wheel brakes clamp the Rail wheel enough to begin slowing its rotation but not enough to totally lock the Rail Wheel The Rail Wheels should not be allowed to lock up since t
69. ELECT THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS 0 FILL OUTBOARD CAVITY COMPLETELY P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N 800020 ALL HARDWARE KIT FOR RW 1630 WHEEL Does not include silicon for hubcap or wheel greose or beoring race PART NO QIY NOTE IF YOU ORDER MANUAL PIN OFFS WITH YOUR RAILGEAR THEY SHOULD ALREADY BE WELDED IN THEIR PROPER LOCATION L2 P N 108045 AUXILIARY ASSEMBLY P N 108044 AUXILIARY PIN OFF CHAIN P N 108041 1 5 8 ASSEMBLY w CHAIN BEHIND CAB BEHIND CAB PIN OFF P N 818163 P N 818164 DRIVER S SIDE PASSENGERS SIDE FRONT O FRONT SIDE VIEW 1650 50 MANUAL PIN OFFS C Must have serial when ordering parts A 5 26 11 FIXED TYPO AUXILIARY NH A 8 11 10 CHANGED P N 108042 TO 108041 vec P N 818234 P N 818245 DESCRIPTION PASSENGER SIDE DRIVER SIDE UN ESS TITLE REAR REAR RW 1630 ASSORTED PIN OFF ASSEMBLIES DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE uei J DRAWING NUMBER 1 50 SU M1630100 NOTE 1 SPECIFY THE CABLE THAT BEST FITS YOUR APPLICATION REPLACEMENT CABLES Note Remote Front Pin Offs There are two different types of remote pin offs available for both front and rear Railgear and they ca
70. ER SIDE 241319 1 ASSY 3 1 2 TUBE LVALVE RR DRIVER SIDE 11 240229 1 HYD CYL REAR ROD ASSEMBLY LVL 818235 1 GREASE FITTING 1 8 NPT STRAIGHT 241016 1 PARKER LOCKING VALVE 45 DEG FITTING FOR LVL TUBES REAR 2504 06 04 FG AQP FITTING NUT FC2875 06S 16 810313 2 AQP FITTING FERRULE FF9605 065 13 750 REF ROD END PORT ROD END PORT DETAIL A A P N 241303 PASSENGER S SIDE DETAIL P N 241304 DRIVER S SIDE BASE END PORT 1630 REAR EXTRA SHORT CYLINDER A 4 16 12 818235 WAS 240123 12 1 11 241016 was 241013 DATE DESCRIPTION SPECIFIED _ TITLE COMMON SENSE PREVAILS RW 1630 REAR EXTRA SHORT DS PS L VLV CYLINDER ASSEMBLY 3 1 2 BORE x 2 ROD x 9 1 2 STROKE DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV 241303 DS 9 11 09 241304 PS B m vor ITEM PART NO DESCRIPTION 1 240101 1 PISTON 4 172 DMF P N 240125 SEAL KIT 240102 GLAND 4 1 2 a i SEAL KIT INCLUDES ITEM Z s 4 5 6 7 8 amp 9 240104 SEAL PISTON 3120 3875 5 240105 1 SEAL ROD 3750 2000 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE a 240106 1 WIPER 859 271 DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE 240107 31 O RING PISTON 2 214 FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER WITH la 240108 1 O RING GLAND 2 346 FITTIN
71. ES CONNECTED TO 240208 O RING GLAND 2 338 PASE 240209 BACKUP RING GLAND 8 338 IF THE TUBES ARE FACING YOU OR CLOSEST TO YOU THEN 4 240254 WELD 55 3 1 2 TUBE SAE PORT LOCKING VALVE RR LH IT IS A DRIVER SIDE CYLINDER DS PART 240232 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 NPT STRAIGHT IF THE TUBES ARE FACING AWAY FROM Y THEN IS A PASSENGEH DE PS ANA Hor 240258 90 DEGREE ELBOW 4 MJIC x 3 SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123 A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP UNLESS SPECT mz CYLINDER REAR SAE PORT L VLV 3 1 2 BORE x AC oW ue 9 1 2 STROKE LH DRIVER SIDE x on H DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES DRAWN BY APPD BY DATE DRAWING NUMBER ANGULAR SURF FINISH 125 MICRO THREADS 2A AND 2B BJF 10 7 09 240256 PART NO DESCRIPTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240
72. GS 1 IF HANDLE REVERSED FRONT VALVE PLUMBING MUST BE REVERSED sea CORRECTED SECTION REFERENCE DELETED P N S 810311 810312 amp 810313 amp ADDED 240258 910909 REVISED SCHEMATIC LAYOUT AND B O M PER AS BUILT NOW SEE SECTION 4 3 OF MANUAL WHICH SPECIFIES HYDRAULIC SYSTEM REQUIREMENTS LA REVISED BY REMOVING TYPE OF VALVES ENERGY GRESEN DATE DESCRIPTION TOLERANCES LLL x LUBRICATION SPECIFICATIONS EE m TITLE HYDRAULIC OIL NAC Aa VALVE ASSEMBLIES amp HYDRAULIC SCHEMATIC ASTM D6158 HM UNAX RX 46 HYDRAULIC OIL SHELL TELLUS EE 46 OR EQUAL x N OR A fe DIVERSIFIED METAL FABRICATORS INC 404 875 1512 SOME CUSTOMERS OPERATE ON DEXRON ATF DRAWN BY APPD BY DATE DRAWING NUMBER REV KLC 10 07 98 M1630114 D BREAK SHARP EDGES PART NO DESCRIPTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 DMF P N 240225 SEAL KIT SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUB
73. GS POINTED UP AS IF YOU WERE HOLDING THE BASE SEE PP008 FOR CYLINDER o 240109 1 O RING GLAND BACK UP 6 346 END IN YOUR ED 5 ASS Y amp TEST PROCEDURE 10 240110 BARREL ASSEMBLY 4 1 2 DRIVER S SIDE HAND WITH IT POSITIONED AS SUCH LOOKING AT THE ACTUAL ENSEM 7 M 240115 1 BARREL ASSEMBLY 4 1 2 PASSENGER S SIDE FITTING ON THE BASE END 1 245125 1 RoDp ASSEMBLY 2 THE FITTING ITSELF IS POINTING TOWARDS YOU THEN IT IS 818255 1 CREASE FITTING 1 8 A DRIVER SIDE CYLINDER DS PART 240099 241006 FITTING ELBOW 1 4 JIC x 9 16 18 6801 NW 4 6 IF THE FITTING ITSELF IS POINTING AWAY FROM YOU THEN IT IS A PASSENGER SIDE CYLINDER PS PART 240100 Torque 300 ft lbs 6 3 16 11 CLOSED 20 11 16 OPEN A 30 41630 1420 1212 1019 FRONT CYLINDER ROD END ROD END BASE END A 2 17 12 818235 WAS 240123 PORT PORT PORT A 4 21 11 ADDED PRODUCT LINES TO NOTE 9 17 09 COMBINED 240099 240100 INTO ONE DWG amp ADD SEAL KIT DATE DESCRIPTION TOLERANCES TITLE RW 1630 FRONT HYDRAULIC CYLINDER ASSEMBLY 4 1 2 BORE x 2 ROD x 9 11 16 STROKE DETAIL A A DETAIL A A DIVERSIFIED METAL FABRICATORS INC 404 875 1512 le x Ie es P N 240100 P N 240099 D es t 015 DATE DRAWING NUMBER PASSENGER S SIDE DRIVER S SIDE SURF tH 129 lt gt 240099 DS THREADS 2A AND 2d 11 10 92 S 240100 PS TITLE Cylinder Assembly PURPOSE To Establi
74. IFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 3 Front Railgear DMF s Heavy Duty Front Railgear is available in 3 different variations The standard front Railgear uses a 1630 axle see section 1 3 1 the Behind Cab variation uses an extra heavy duty 1650 axle and wheels see section 1 3 2 and the Under Cab variation uses the 1630 axle see section 1 3 3 1 3 1 Standard Front Railgear Components Figure 1 3 1 A shows the individual parts of the installed front Railgear These item descriptions will be used throughout this installation manual DMF Railgear assemblies are also referred to as guide wheels Rail wheels or hi rail gear Front Railgear attached to front vehicle springs and front bumper with 16 guide wheels GVWR Range 33 000 Ibs and above Approx Installed Weight Front 1385 Ibs Capacity 40 000 pounds per Railgear axle 20 MPH For detailed drawings see Section 5 0 and for installation instructions see Section 4 0 TRUCK FRAME FRONT TRUCK SPRING Item Description SPRING BRACKET SPACERS if required SPACER Top required RUBBER SPACER REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM FRONT MOUNTING PIN CROSS TUBE FRONT EXTENSION if required COBRA BRAKES if equipped Figure 1 3 1 A Front Railgear Components FRONT TRUCK AXLE awn oP ANOUAWN 1 3 2 Behind Cab Front Railgear C
75. IL INCLUDES 818576 CABLE ASSY QTY 2 818759 3 4 PIN QTY 2 amp 818767 WASHER QTY 2 818587 REM AIR P O FITTING 818593 REM P O AIR CTRL TI TRUCK SUPPLY SS P N 818785 PIN OFF HOUSING WELDMENT WS Truck ARM 1 4 FENDER FLAT WASHER gt P N 818599 5 16 24 JAM HEX NUT P N 818596 5 8 18 HEX NUT P N 818758 PIN P N 818755 AIR CYLINDER P N 818755 AIR CYLINDER DRIVER SIDE 2 7 8 3 47 w 5 16 24 ZA m MOUNT INSIDE FOR BRAZIL P N 818528 TEE B18591 1 4 TUBE KIT P N 818774 FRONT REMOTE AIR KIT ASSY LESS PIN OFFS INCLUDES 800136 DECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 818593 QTY 1 818596 QTY 2 818599 QTY 2 818755 QTY 2 818758 QTY 2 amp FW1 4 QTY 2 P N 818758 PIN OFF PIN 2 7 8 x 3 470 w 5 16 24 PASSENGER SIDE MOUNT INSIDE FOR BRAZIL SLERANCI UNLESS SPECIPED REVISED PER NEW BRAZIL MANUAL amp KIT 5 DESCRIPTION RW 1630 REMOTE CABLE PIN OFF ASSY FRONT NOTE 42 RETO FIT KIT GENERIC DRAWING 1 2 CROSS TUBE P N 810349 1 00 CROSS TUBE P N 810261 3 00 CROSS TUBE P N 810154 5 00 HIGH 3 PC CROSS TUBE P N 810107 en dl Lo i E 1 1 4 CROSS TUBE P N 810258 5 00 ge 4 00 CROSS TUBE P N 810267 6 00 HIGH 3 PC CROSS TUBE P N 810328 VOLVO CROSS TUBE P N 809999 2 00 CROSS TUBE P N 81
76. IVERSIFIED METAL FABRICATORS INC RW 1630 Air Brake Plumbing Installation An air toggle valve on a plate labeled brakes on off is to be located on the vehicle instrument panel This valve disconnects the guide wheel braking system from the vehicle airbrake system by interrupting the CONTROL line air pressure to the guide wheel system only On the Front Valve Plate Assembly and Rear Frame Bracket an airbrake relay valve will be located The CONTROL line to this relay valve comes from the toggle valve described above The SUPPLY line to this relay comes from the Pressure Protection Valve which is plumbed onto the air reservoir There is a ball valve and an adjustable pressure regulator in the SUPPLY line before the relay valve The ball valve will disconnect the guide wheel braking system from the vehicle airbrake system regardless of the position of the toggle valve by interrupting the SUPPLY line air pressure to the guide wheel system only The adjustable pressure regulator allows the braking effort on each axle to be set so that the Rail wheels do not lock up and slide The guide wheel brake chambers are connected to the DELIVERY ports on the guide wheel air brakes relay valve Install air lines and valves per the drawing on next page Make certain that the Front Air Brake Valve indicates that it has been preset to 75 psi and the Rear Air Brake Valve is labeled 30 psi The brake valves are already preset at the factory front at 75 psi re
77. K WASHER FRAME MOUNTING 5 8 COTTER PIN 3 16 x 2 PLATE FRAME BACKING COTTER PIN 1 4 x 2 1 2 FRAME BOX ASSEMBLY DRIVER S SIDE AIR REMOTE PIN OFF ASSEMBLY SEE PAGE 16 FRAME BOX ASSEMBLY PASSENGER S SIDE UNDER CAB AXLE ASSEMBLY ONLY NON INSULATED WITH BRAKES 110510 INSULATED WITH BRAKES 110513 UNDER CAB AXLE TUBES ONLY FRONT TUBES W BRAKE SADDLES 818114 A A DATE DESCRIPTION TITLE FRAC MACH RW 1630 UNDER CAB FRONT RAILGEAR ASSEMBLY FRAC OTHER 1 16 x SEE DRAWING M1 6301 02 amp M1 6301 03 IN s DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES 4 s ANGULAR e DATE DRAWING NUMBER SECTON 5 FOR AXLE amp WHEEL ASSEMBLY PARTS ido 10 09 01 UC110005 12 108252 4 HEX HEAD BOLT HHCS 17 8 x 8 G8 108015 2 BEHIND CAB FRAME BOX ASSEMBLY O 13 10825 4 SLOTTED HEX NUT SLHN 1 8 2 108056 4 UPPER CYLINDER PN DETAL 14 108258 4 COTTER PN 3 16x 2 88 3 108060 8 BANJO PIN 1 47 3 REID ROD END FORGED 15 108200 1 Rw 1650 BEHIND NON INSULATED AXLE ASSEMBLY 108062 8 HEX HEAD BOLT HHCS 5 16 18 x 1 10823 1 BC FRONT AXLE TUBE WELDMENT ASSEMBLY 5 108064 8 LOCK WASHER 5 16 18 82001 1 Rw 1650 AXLE HD 4 X 64 AXLE ONLY 6 108074 4 LOWER CYLINDER PIN DETAIL 16 108262 12 MOUNTING BOLTS 5 8 11 x 2 1 2 G
78. LS NON INSULATED WITH BRAKES 1650 amp BEHIND CAB 800213 NON INSULATED NO BRAKES 1650 amp BEHIND CAB 800214 INSULATED NO BRAKES 1650 amp BEHIND CAB 800216 INSULATED WITH BRAKES 1650 amp BEHIND CAB 800227 INSULATED NO BRAKES 1650 amp BEHIND CAB 800215 2 PC WHEEL NO BRAKES 1650 amp BEHIND CAB 800218 2 PC WHEEL WITH BRAKES 1650 amp BEHIND CAB 8002614 1650 amp BEHIND CAB AXLE TUBES 1650 amp BEHIND CAB BEARING RACE AXLE TUBE WITH BRAKES 818203 TIMKEN 6420 BEARING RACE AXLE TUBE NO BRAKES 818210 800125 1650 amp BEHIND CAB WHEELS NON INSULATED 1650 WHEEL w RACES 800015 INSULATED 1650 WHEEL w RACES 800016 INSULATED 2 PIECE 1650 WHEEL w RACES 820496 NOTE SPECIAL PROFILE WHEELS PLEASE CALL Never Re Use Previously Bent Tabs Torque to 120 ft Ibs 5 8 11 C prevailing Torque Nut Must replacebolts nuts at same time P N 4820496 2 PC INSULATED 1650 WHEEL W RACES REPLACES ITEMS 4 amp 5 ABOVE KEEP ALL OTHER PARTS Decal 800300 apply to hubcap cover when using 2 pc wheel 1 PIN 800300 DECAL 2 PC WHL INSPECTION P N 800301 KIT 2 WHL TORQUE INDICATORS 1650 amp BEHIND CAB REAR AXLE DWERSIFED METAL FABRICATORS INC 404 875 1512 ave PART NO QIY NOTE IF YOU ORDER MANUAL PIN OFFS WITH YOUR RAILGEAR THEY SHOUL
79. NAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE e MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET LONG ARMS VARY DEPENDING ON TRUCK MODEL SEE SECTION 5 5 FOR VARIOUS LONG ARM OPTION amp DETAIL DRAWINGS FRONT CROSS TUBE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS TO TRUCK FRAME OR FRAME EXTENSIONS ALL THE WAY AROUND IF SHIMS REQUIRED FULLY WELD ALL SHIMS IN ALL LOCATIONS IN PLACE ONCE ALIGNMENT IS RW ACHIEVED IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED AT LOCATION SHOULD TOPVIEW ab NOTE 3 BE WELDED TO ONE ANOTHER A NOTE 3 N ONCE SPRING BRACKET IS FINALLY SET WHERE CLEARANCE ALLOWS LEAVE 1 THREADED ROD EXPOSED ABOVE NUT 2 THREADS MIN SEE ABOVE ILLUSTRATION ITEM 5 5 6 25 amp 26 ARE COMPONENTS OF ITEM 4 RESPECTIVELY DESCRIPTION MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE TITLE UNLESS SPECIFIED OF THE OUTER PIVOT ARM FOR
80. NECTS TO THE RED LED INSTALLATION NOTE INSTALL LED S AND PIN OFF AIR VALVE IN LEGEND PLATE ON OUTSIDE OF FRAME WELDING TO RAILGEAR FRAME APPLY 2 1 2 PASSES ON EACH VERTICAL EDGE OF PIN OFF TUBE DO NOT WELD ACROSS TOP amp BOTTOM OF TUBE 6 08 10 ADDED VIEW OF LEGEND PLATE 818754 11 20 01 ITEM 1 WAS P N 818746 amp DELETED ITEM 4 P N 818749 DATE DESCRIPTION TOLERANCES TITLE UNLESS SPECIFIED COMMON SENSE PREVAILS FRAC MACH RW 1630UC REMOTE AIR PIN OFF ASSEMBLY FRAC X XX XXX OR XXXX OTHER DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES 4 s q ANGULAR DRAWN BY APPD BY DATE DRAWING NUMBER SURF FINISH THREADS 10 22 01 818745 reno 0 020 z as DIVERSIFIED METAL FABRICATORS INC RW 1630 4 10 Behind Cab Front Unit Installation Detailed Installation Drawings are available in Section 5 1 NOTE Read through the Section 4 10 1 before dismantling any equipment and starting installation Factors that control installation of the behind cab unit is the location of fuel tanks relative to the rear of cab and available open frame space for proper assembly For any questions please contact DMF for assistance 4 10 1 Behind Cab General Information Ideally 36 of open frame behind the cab is required for installation including unobstructed upward movement of the brake chambers to the highway position The leading edge of the frame mounting
81. OTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL 8 WILL SPIN FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 6 REPEAT IF ADJUSTMENT IS NECESSARY J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE K ADJUST INNER WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 L INSTALL TAB WASHER ITEM 7 M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND N SELECT O FILL OUTBOARD CAVITY COMPLETELY P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS P N 800020 ALL HARDWARE KIT FOR RW 1630 WHEEL Does not include silicon for hubcap or wheel grease or bearing race P N 820494 2 PC INSULATED 1630 WHEEL W RACES REPLACES ITEMS 1 KEEP ALL OTHER PARTS EXCEPT HUBCAP PARTS Must have serial when ordering COMPLETE FRONT AXLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS PIVOT ARMS 1630 ONLY NON INSULATED WITH BRAKES 1630 800060 NON INSULATED NO BRAKES 1630 800022 INSULATED NO BRAKES 1630 800026 INSULATED WITH BRAKES 1630 800061 2 WHEEL INSULATED WITH BRAKES 1630 800075 A FRONT AXLE TUBES 1630 ONLY FRONT TUBE W OUT BRAKE SADDLES 818113 FRONT TUBE W BRAKE SADDLES 818114 NOTE PART 5 ARE FOR ONE SIDE IF
82. OU THEN IT IS A DRIVER SIDE CYLINDER DS PART 240232 IF THE TUBES ARE FACING AWAY FROM YOU THEN IT IS PASSENGER SIDE CYLINDER PS PART 240231 SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE o o o s o m o x Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123 A 12 1 11 241016 WAS 241013 REV DATE DESCRIPTION BY APP TOLERANCES TITLE BEEN CYLINDER REAR SAE PORT L VLV 3 1 2 BORE x OTHER re 9 1 2 STROKE RH PASSENGER SIDE x on DIVERSIFIED METAL FABRICATORS INC 404 875 1512 GUAE ie DRAWN BY APPD BY DATE DRAWING NUMBER SURF FINISH 125 MICRO THREADS 2A AND 28 BJF 10 7 09 240257 BASE END PORT DMF P N 240225 SEAL KIT SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO BASE OF CYLINDER IF THE TUBES ARE FACING YOU OR CLOSEST TO YOU THEN IT IS A DRIVER SIDE CYLINDER DS PART 24130
83. One flat on a hex is equal to 1 6th of a full turn Tolerance on tightening is plus or minus 1 4 flat 1 24th of full turn SAE JIC 37 Flare Fittings Swivel Nut Tube or Hose Thread Connection Connection Size F F F T F F F T 7 16 20 9 16 18 3 4 16 1 1 16 12 1 5 16 12 1 5 8 12 1 7 8 12 DESCRIPTION TLE PRODUCTION PROCEEDURE 005 JIC FITTING INSTALLATION d zr SURF FINISH 125 MICRO THREADS D 28 BREAK SHARP EDGES PART NO DESCRIPTION Lei T T E TITLE SAE O Ring Fitting Installation PURPOSE To Establish Production Methods For The Installation Of O Ring Medium And High Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 4000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With O Ring Seals And SAE Straight Threads PROCEDURE A Inspect to ensure that both mating parts are free of burrs nicks scratches or any foreign particles B Lubricate O Ring with light coat of system fluid or compatible oil C For adjustable fittings back off lock nut as far as possible Make sure back up washer is not loose and is pushed up to nut D Screw fitting into port until finger tight Back up washer adjustable or hex face non adj should contact port face Light wrenching may be necessary E To align an adjustable fitting unscrew by desired amount but not more than one full turn Use wrench to hold in po
84. PIN 5 16 7 7191 818289 s washers AT i 1 eee 1 FEAR BRACKET SHINS 1 HYDRAULIC CYUNDER ASSY DRVERS SE 4 1 HYDRAULC CYUNDER ASSY PASSENGER S PIN 0FF ASSY REAR DRNER S SIDE Dio SEE NOTE 8 as PIN OFF ASSY REAR PASSENGER S SIDE 17 SEE NOTE 48 2 WELD CENTER TOP amp BOTTOM HEX HEAD BOLT 4X 5 8 11 GRADE 5 ENSURE NUTS amp BOLTS SECURELY FASTENED TO BOLT SPEC 154 LBF FT MOUNTING PLATE NOTE 1 GRADE 5 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE ENSURE SPACERS ARE PRESSED FULLY AGAINST SIDE BRACKET OR SHIMS amp ALIGNED WITH THE REAR BRACKET WELD AS INDICATED IN DETAIL ABOVE IF MULTIPLE SPACERS ARE USED ENSURE THAT THEY ARE WELDED TO ONE ANOTHER WELD AS INDICATED IN DETAIL ABOVE e ENSURE BOLTS amp NUTS ARE TIGHTENED TO TORQUE SPECS 154 LBF FT e WELD 4 HOLE MOUNTING PLATE TO REAR BRACKET SIDE PLATE NOTE 3 SEE SECTION 5 4 FOR VARIOUS LINK COMBINATIONS ITEM 5 15 amp 16 AR
85. POINTING TOWARDS YOU THEN IT IS 818255 1 CREASE FITTING 1 8 A DRIVER SIDE CYLINDER DS PART 240099 241006 FITTING ELBOW 1 4 JIC x 9 16 18 6801 NW 4 6 IF THE FITTING ITSELF IS POINTING AWAY FROM YOU THEN IT IS A PASSENGER SIDE CYLINDER PS PART 240100 Torque 300 ft lbs 6 3 16 11 CLOSED 20 11 16 OPEN A 30 41630 1420 1212 1019 FRONT CYLINDER ROD END ROD END BASE END A 2 17 12 818235 WAS 240123 PORT PORT PORT A 4 21 11 ADDED PRODUCT LINES TO NOTE 9 17 09 COMBINED 240099 240100 INTO ONE DWG amp ADD SEAL KIT DATE DESCRIPTION TOLERANCES TITLE RW 1630 FRONT HYDRAULIC CYLINDER ASSEMBLY 4 1 2 BORE x 2 ROD x 9 11 16 STROKE DETAIL A A DETAIL A A DIVERSIFIED METAL FABRICATORS INC 404 875 1512 le x Ie es P N 240100 P N 240099 D es t 015 DATE DRAWING NUMBER PASSENGER S SIDE DRIVER S SIDE SURF tH 129 lt gt 240099 DS THREADS 2A AND 2d 11 10 92 S 240100 PS P N 808119 REPLACED BY P N 808151 808120 PASSENGER SIDE INNER OBSOLETE 808121 DRIVER SIDE INNER OBSOLETE REPLACED BY P N s 808152 amp 153 EXTENDED LONG ARM 808140 DRIVER SIDE OUTER 808141 PASSENGER SIDE OUTER 808142 DRIVER SIDE INNER 808143 PASSENGER SIDE INNER 808144 SET SHORT EXTENDED LONG ARM 808160 INNER 808164 DRIVER SIDE OUTER 808165 PASSENGER SIDE OUTER USED WITH PIVOT ARMS 810066 amp 810067 LONG ARM KENWORTH T 800
86. PORT L VLV 3 1 2 BORE x OTHER re 9 1 2 STROKE RH PASSENGER SIDE x on DIVERSIFIED METAL FABRICATORS INC 404 875 1512 GUAE ie DRAWN BY APPD BY DATE DRAWING NUMBER SURF FINISH 125 MICRO THREADS 2A AND 28 BJF 10 7 09 240257 BASE END PORT DMF P N 240225 SEAL KIT SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR OR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO BASE OF CYLINDER IF THE TUBES ARE FACING YOU OR CLOSEST TO YOU THEN IT IS A DRIVER SIDE CYLINDER DS PART 241303 Torque 300 ft Ibs THE TUBES ARE FACING AWAY FROM YOU THEN IT IS PASSENGER SIDE CYLINDER PS PART 241304 SEE PPOO08 FOR CYLINDER ASS Y amp TEST PROCEDURE 1 240246 1 HYD CYL PISTON 5 7 2 240202 1 GLAND 3 1 722 3 240103 1 Nur NYLOCK 1 14 5 240105 1 SEAL ROD 3750 2000 6 240106 1 WIPER ROD 59 7 7 4 7 240107 1 O RING PISTON 2 214 8 240208 1 O RING GLAND 2 338 9 240209 1 O RING GLAND BACK UP 8 338 10 241318 1 or ASSY 3 1 2 TUBE LVALVE RR PASSENG
87. PTION 240246 HYDRAULIC CYLINDER PISTON LVLV 3 1 2 240202 HYDRAULIC CYLINDER GLAND 3 1 2 240103 NYLOCK NUT 1 14 240204 SEAL PISTON 3120 2875 240105 SEAL ROD 3750 2000 240106 WIPER ROD 959 21 240107 O RING PISTON 2 214 DMF P N 240225 SEAL KIT SEAL KIT INCLUDES ITEM s 4 5 6 7 8 amp 9 TO DETERMINE DRIVER SIDE VS PASSENGER SIDE DUE TO WEIGHT OF CYLINDERS PLACE CYLINDER ON THE FLOOR TABLE FIRST THEN POSITION THE CYLINDER AS IF YOU WERE HOLDING THE BASE END IN YOUR LEFT HAND AND THE ROD END IN YOUR RIGHT HAND WITH IT POSITIONED AS SUCH LOOKING AT THE 3 FITTINGS TUBES CONNECTED TO 240208 O RING GLAND 2 338 PASE 240209 BACKUP RING GLAND 8 338 IF THE TUBES ARE FACING YOU OR CLOSEST TO YOU THEN 4 240254 WELD 55 3 1 2 TUBE SAE PORT LOCKING VALVE RR LH IT IS A DRIVER SIDE CYLINDER DS PART 240232 240229 HYDRAULIC CYLINDER REAR ROD WELDMENT LOCKING VALVE 818235 GREASE FITTING 1 8 NPT STRAIGHT IF THE TUBES ARE FACING AWAY FROM Y THEN IS A PASSENGEH DE PS ANA Hor 240258 90 DEGREE ELBOW 4 MJIC x 3 SAE PORT 6801 04 03 241016 PARKER LOCKING VALVE SEE PP008 FOR CYLINDER ASS Y amp TEST PROCEDURE Torque 300 ft lbs 21 3 8 OPEN 11 7 8 CLOSED 2 17 12 818235 WAS 240123
88. RE KIT FOR RW 1630 WHEEL see drawing M1630103 in Section 5 3 O co 1 O On 5 8 11 x 4 Grade 8 Bolts see Section 3 2 for detail Must replace bolts nuts at same time amp care for 2 pc wheels MUST BE HARDENED WASHERS TORQUE TO 120 FT LBS 5 8 11 C prevailing Torque Nut Must replace bolls nuls at same time IF A LOCK NUT BECOMES LOOSE RETIGHTEN TO TORQUE SPEC amp USE RED TORQUE INDICATOR TO MARK THAT PARTICULAR NUT UNTIL NEXT INSPECTION In addition to following the inspection amp maintenance procedures as defined in Section 3 1 Two Piece Wheels require the following specific inspections As previously specified in Section 3 1 1 check the bolt torque indicators the tabs around each bolt daily to ensure that they have not moved If torque indicators are missing or damaged please contact DMF for replacements If torque indicators have moved you must follow this procedure to remedy the situation 1 The ariver would remove the green torque indicator retorque the loose nut see torque specifications below and then replace with a red torque indicator DMF provides one red torque indicator per wheel This identifies the loose nut to the maintenance shopat a simple glance and they will know that the
89. TIL FLUSH WITH WHEEL HUB E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE G INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft Ib Wheel Bearing Grease Mystik JT 6 Lo Temp Extreme Grease factory stondord preferred for colder climotes NOTE ALL PARTS ARE NOT THE SAME BETWEEN 1630 FRONT amp UNDER FRONT SEE DRAWING UC110005 FOR SPECIFIC UNDER CAB PARTS IN SECTION 5 1 Possenger Side 2 ROTATE WHEEL ONE FULL TURN IN BOTH DIRECTIONS TO SEAT BEARING RETURN TO STEP 1 IF BEARING LOOSENS 3 BACK OFF NUT ITEM 5 APPROXIMATELY 1 8 TO 1 4 OF A TURN THIS WILL PRODUCE 0 005 TO 0 010in OF ENDPLAY 4 WITH ONE HAND FIRMLY GRAB WHEEL amp ROTATE 5 CHECK WHEEL ADJUSTMENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS A PROPERLY ADJUSTED WHEEL WILL FREE FOR AT LEAST 1 2 A TURN IF ROTATED HEAVILY BY HAND b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT 6 REPEAT IF ADJUSTMENT IS NECESSARY J INSTALL AXLE LOCK WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN AXLE K ADJUST INNER WHEEL NUT ITEM 5 TO LINE UP PIN WITH NEAREST HOLE IN AXLE LOCK WASHER ITEM 6 L INSTALL TAB WASHER ITEM 7 M INSTALL OUTER WHEEL NUT ITEM 8 AND TIGHTEN HEAVILY BY HAND P N 4820494 2 PC INSULATED PARTS Must have serial when ordering COMPLETE FRONT A
90. TION SPECIFICATIONS WHEEL BEARING GREASE GREASE FITTINGS 1 4 FRONT CYLINDER ROD CROSS TUBES 2 4 PIVOT ARM CROSS TUBES UPPER amp LOWER 3 2 REA BRACKET UPPER PIN CROSS TUBES L Aj 2 REA AXLE LOWER PIN SADDLE BLOCK s E 8 REA SCISSORS LINK MECHANISM ls F 2 REA CYLINDER ROD CROSS TUBES RW 1630 50 FRONT MOUNT RW 1630 UNDER CAB RW 1650 BEHIND CAB Cr ib TC JA MYSTIK JT 6 LO TEMP EXTREME GREASE FACTORY STANDARD PREFERRED FOR COLDER CLIMATES MZ NIU 1 4 UPPER CYLINDER ROD CROSS TUBES Cid 2 4 LOWER CYLINDER ROD CROSS TUBES Cid 3 c 2 REAR BRACKET UPPER PIN CROSS TUBES i a p 2 REAR AXLE LOWER PIN SADDLE BLOCK i 5 E 8 REAR SCISSORS LINK MECHANISM e F 2 FEAR CYLINDER ROD CROSS TUBES Ci 7 c s sweex RW 1630 50 FRONT MOUNT m Ter PPTHI RS r 7 l JL RW 1630 UNDER CAB Il Ig 3e1 ln t X Z i g E 5 DESCRIPTION RW 1630 50 GREASE POINT LOCATIONS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER 10 14 98 dy M1630126 DIVERSIFIED METAL FABRICATORS INC RW 1630 4 0 RAILGEAR INSTALLATION Detailed drawings of Railgear Installation can be found in section 5 0 Technical Details 4
91. TO TRUCK FRAME k NOTE 2 AT FINAL INSTALLATION LONG ARMS VARY DEPENDING ON TRUCK AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED MODEL SEE SECTION 5 5 FOR VARIOUS 23 C FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD USED LONG ARM OPTION amp DETAIL DRAWINGS REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE e b i MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET FRONT CROSS TUBE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS TO TRUCK FRAME OR FRAME EXTENSIONS ALL THE WAY AROUND IF SHIMS REQUIRED FULLY WELD ALL SHIMS IN ALL LOCATIONS IN PLACE ONCE ALIGNMENT IS e ACHIEVED IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED LOCATION SHOULD M TOPVIEW NOTE 3 BE WELDED TO ONE ANOTHER TE a ONCE SPRING BRACKET IS FINALLY SET WHERE CLEARANCE ALLOWS LEAVE 1 THREADED ROD EXPOSED ABOVE NUT 2 THREADS MIN SEE ABOVE ILLUSTRATION ITEM S 5 6 25 amp 26 ARE COMPONENTS OF ITEM 4 RESPECTIVELY 41712 UPDATED AS PER 1630 MANUAL CHANGES L DATE DESCRIPTION MUST BE WELDED IN RAIL
92. X 46 HYDRAULIC OIL SHELL TELLUS EE 46 OR EQUAL OR SOME CUSTOMERS OPERATE DEXRON ATF DESCRIPTION FRAG MACH EIRA VALVE ASSEMBLIES amp HYDRAULIC SCHEMATIC FRAC OTHER x T Sox OR 10006 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES E ANGULAR DRAWN BY APPD BY DATE DRAWING NUMBER 517 SURF FINISH 125 MICRO KLC 10 07 98 M1630114 ITEM NO PART NUMBER DESCRIPTION 1 1630 REAR AXLE WELDMENT TUBE WIDE W BRAKES 1 2 RW 1630 SEAL STANDARD CR 39934 3 4 1630 WHL ASSY NON INS W RACES 5 RW 1630 NUT INNER WHEEL EUCLID E 540 6 RW 1630 WASHER AXLE LOCK EUCLID E 573 7 RW 1630 WASHER AXLE TAB EUCLID 2237 8 RW 1630 NUT OUTER WHEEL EUCLID E 572 9 RW 1630 HUBCAP DETAIL 7 DIA 10 800109 8 5 16 LOCK WASHER LW5 16 11 80008 8 HEX HD SCREW 5 16 18 x 3 4 LONG 12 BEARING RACE TIMKEN 563 COMPONENT OF P N 820220 13 818101 RW 1630 AXLE STANDARD 3 1 4 X 61 29 32 5 8 11 x 4 Grade 8 Bolts Must replace bolts nuts at same time WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB E PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGS AND
93. XLE ASSEMBLY OPTIONS AXLE AXLE TUBE WHEELS PIVOT ARMS 1630 ONLY NON INSULATED WITH BRAKES 1630 800060 NON INSULATED NO BRAKES 1630 800022 INSULATED NO BRAKES 1630 800026 INSULATED WITH BRAKES 1630 800061 2 PC WHEEL INSULATED WITH BRAKES 1630 800075 1630 amp UNDER CAB BEARING RACE TIMKEN 567 RACE BEARING 800100 FRONT AXLE TUBES 1630 ONLY FRONT TUBE W OUT BRAKE SADDLES 818113 FRONT TUBE W BRAKE SADDLES 818114 NOTE PART fS ARE FOR ONE SIDE IF YOU NEED THE WHOLE FRONT AXLE THEN YOU WOULD ORDER QTY 2 OF 818114 DOES NOT INCLUDE PIVOT ARMS 1630 amp UNDER CAB WHEELS NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 INSULATED 2 PIECE 1630 WHEEL w RACES 820494 NOTE SPECIAL PROFILE WHEELS PLEASE CALL UNDER CAB AXLE ASSEMBLY ONLY NON INSULATED WITH BRAKES 110510 INSULATED WITH BRAKES 110515 UNDER CAB AXLE TUBES ONLY FRONT TUBES W BRAKE SADDLES 818114 ALSO REFER TO SECTION 5 3 FOR WHEEL ASSEMBLY PROCEDURES AND BEARING ADJUSTMENT PROCEDURES Torque to 120 fbs gt _ 5 8 11 Type C prevailing Torque Nut ai replace bolts nuts at same time 2 pc wheel uses 1650 hubcap Decal 800300 apply to hubcap cover when using 2 pc wheel P N 4800300 DECAL 2 PC WHL INSPECTION P N 4800301 KIT 2 WHL TORQUE INDICATORS 1630 WHEEL W RACES REPLACES ITEMS 1 KEEP ALL OTHER PARTS EXCEPT HUBCAP N S
94. YOU NEED THE WHOLE FRONT AXLE THEN YOU WOULD ORDER QTY 2 OF 818114 DOES NOT INCLUDE PIVOT ARMS 1630 amp UNDER CAB BEARING RACE TIMKEN 567 RACE BEARING 800100 1630 amp UNDER CAB WHEELS NON INSULATED 1630 WHEEL w RACES 800050 INSULATED 1630 WHEEL w RACES 800052 INSULATED 2 PIECE 1630 WHEEL w RACES 820494 NOTE SPECIAL PROFILE WHEELS PLEASE CALL UNDER CAB AXLE ASSEMBLY ONLY NON INSULATED WITH BRAKES 110510 10513 UNDER AXLE TUBES ONLY FRONT TUBES W BRAKE SADDLES 818114 ALSO REFER TO SECTION 5 3 FOR WHEEL ASSEMBLY PROCEDURES AND BEARING ADJUSTMENT PROCEDURES INSULATED WITH BRAKES 1 Torque to 120 fi bs i 5 8 11 Type C prevailing Tania Nut Must replace bolts nuts at same time 2 pc wheel uses 1650 hubcap Decal 800300 apply to hubcap cover 69 when using 2 pc wheel 9 on P N 4800300 DECAL 2 PC WHL INSPECTION P N 4800301 KIT 2 WHL TORQUE INDICATORS THREE TABS THAT MOST NEARLY LINE UP WITH FLATS ON OUTER WHEEL NUT ITEM 8 AND BEND THEM UP TO SECURE NUTS CORRECTED PART WAS 800072 DESCRIPTION TITLE RW 1630 FRONT WHEEL amp AXLE ASSY EXPLODED am METAL FABRICATORS INC 404 875 1512 PART NO DESCRIPTION 1 NOTE 1 REF REMOTE PIN OFF CABLE MORSE NOTE 1 Note Remote Front Pin Offs SPECIFY THE CABLE THAT There are two different types of remote pin offs available for both front and rear Railgear and
95. acking up vehicle e Use personal protective equipment and clothing 4 1 2 Installation Order This manual presents the installation information in the order that we find to work best Your shop tools personnel or other factors may dictate a different order This is acceptable as long as the Rail Test Road Test and Final Inspection are performed at the end 4 1 3 Installation Sheets Refer to installation drawings located in Section 5 1 Note that there may be additional drawing s specific to your chassis Study these drawings before proceeding through the general instructions 4 1 4 Required Tools amp Materials Aside from general shop tools and safety equipment the following tools will be required e Arc or Welder Surge Protector Protects ECM from damage during welding Cutting Torch Hand Grinder Frame Drill Air Saw Angle Finder Test Rail See Section 4 2 3 Hydraulic Oil ASTM D6158 HM Unax RX 46 Hydraulic Oil Shell Tellus EE 46 or equal or some customers operate on DEXRON III ATF Fluid e Wheel Bearing Grease Grease Fittings Mystik JT 6 Lo Temp Extreme Grease Factory Standard preferred for colder climates 2010 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC Additionally the following tools are recommended e Transmission Jack Motorcycle Lift Pallet Jack or Forklift e Overhead Crane e Work Lights e Wheel Dolly 4 1 5 Welding Infor
96. ain an 11 Rail wheel G C in Highway mode This can be reduced for fitting under lower tanks but you must contact DMF Another option would be to reinstall the tanks higher during re assembly Is there room to move the tanks higher 4 Do you have squared or cylindrical tanks This affects Rail wheel clearance between the bottom corner of the tank as it is deployed into the rail position a For cylindrical tanks nominally 26 dia spaced 2 from frame Mount the back edge of the frame mounting bracket behind and no closer than 3 from back edge of 13 1 4 G C tank 1 1 2 14 5 8 15 3 16 16 Table 4 6 1 A Cylindrical Tank Spacing b For squared step tanks mount the back edge of the frame mounting bracket behind and no closer than 5 from the back edge of 13 1 4 G C tank 2 7 8 14 1 5 8 15 34 16 Table 4 6 1 B Squared Tank Spacing c The Railgear may be located further rearward than allowed above but you must contact DMF 5 The rail axle requires 24 of ground clearance to stow under the truck drive shaft The rail axle will stow 10 1 2 behind the back edge of the mounting bracket 6 Mark the location of the back of the frame mounting bracket on both sides as described above Measure forward from these marks 31 1 4 bracket length and mark frames again MOTOR TRANSMISSION PTO ARRANGEMENT The mounting shelf of each frame mounting bracket is 9 wide The inboa
97. al at our website http www dmfatlanta com 1 1 1 Operation Once you have read this entire manual there are some key sections that you may want to mark for convenient future reference including Section 1 0 General 2 0 Operations and 3 0 Routine Maintenance and Inspection Section 2 0 will give you very important guidelines on operating your Railgear equipped vehicle both on the highway and on rail Section 3 0 will cover your daily routine maintenance check that should be performed every time before you operate your vehicle It will also go over semiannual and annual routine maintenance items that should be performed and it contains a drawing with all the grease point locations on your Railgear 1 1 2 Installation Once you have read this entire manual there are some key sections that you may want to mark for convenient future reference including Section 1 0 General Section 4 0 Installation and 5 0 Technical Details Section 4 0 will give you written instructions and drawings In Section 5 0 Technical Details there are additional detailed drawings grouped according to their major systems and components For your convenience we have included a separate packet containing several duplicate Installation Drawings in the kit that accompanies your set of Railgear 1 1 3 Routine Maintenance Once you have read this entire manual there are some key sections that you may want to mark for convenient future reference including Section 1 0 Ge
98. al law to also include ABS The system is designed to prevent wheel lock up during braking The ABS consists of wheel speed sensors an ECU electronic control unit and all wiring and airlines that link the ABS components to the brakes and the truck s electrical system During braking the sensors will detect if one or more of the wheels are locking and automatically engage the ABS The ECU 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 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 1 5 2 Rail Operation of Trucks with ABS When the Railgear is in the rail position the front truck tires are lifted off the ground This may produce an ABS fault and cau
99. als e Label the vehicle according to the diagram on the back of the decal sheet See decal drawings in section 5 1 2012 DMF Inc All Rights Reserved 04_00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 15 Installation Review Checklist The following checklist is intended to assist the installer in re checking and verifying aspects of the installation that are often overlooked or forgotten OOO D OOO Check tire pressures 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 Railgear height as required Re check alignment of the Rear Railgear to the rear axle Weld the Mounting Plate to the Rear Frame Bracket with two 2 welds at the top center and bottom center Welding the plates must be done DO NOT forget to do it Double check all welds and fasteners and mounting cotter pins Tie strap all hydraulic hoses air hoses and electrical wires away from exhausts and moving parts Ensure that all hydraulic and air hoses have sufficient radius at bends Top off the hydraulic oil in the tank Verify grease installed at all grease fittings see section 3 5 2 Touch up the black acrylic enamel paint on the Front and Rear Railgear Raise the Railgear highway position and install all of the pin offs Apply the D
100. and female threads are free of nicks burrs dirt etc B Apply sealant lubricant to male pipe threads Use only Permatex 14D Thread Sealant With Teflon paste or Engineering approved equal The first few threads must be left uncovered to avoid system contamination C Screw fitting into female pipe port to the finger tight position D Wrench tighten the fitting to the appropriate Turns From Finger Tight T F F T shown in chart below Make sure that tube end of shaped fitting is aligned to receive in coming tube or hose assembly STEEL PIPE THREAD FITTINGS Size Size NPT T F F T 1 8 27 1 8 27 1 4 18 3 8 18 1 2 14 3 4 14 3 4 14 1 11 1 2 1 1 4 11 1 2 1 1 2 11 1 2 COMMENTS Teflon Tape May Be Used In Certain Situations With Engineerin A p y in Situati i gi ing Approval A Pipe Fitting Is Limited To One Or Two Re Uses DESCRIPTION TITLE PRODUCTION PROCEDURE 004 PIPE FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC RW 1630 This page intentionally left blank 2012 DMF Inc All Rights Reserved 05 03 Hydrualic System doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 4 1 Before Ordering Parts Rear Railgear Required Information for Ordering Parts You must have the Railgear serial number when ordering parts This uniquely identifies your Railgear as it was built to your specifications and also allows DMF to help you maintain a history of your Railgear If you are placing a parts
101. angers are properly installed before attempting to install front spring bracket Ensure that the safety pin off pins are in the highway position Then place a floor jack under the center of the Railgear axle Using the jack raise the Railgear up toward the truck s leaf springs paying close attention to clearances to prevent damaging chassis components Raise the axle until a 10 minimum 8 ground clearance is achieved at the rail wheel flange NOTE If the required ground clearance cannot be achieved the front truck axle may have to be blocked down to provide additional clearance Have this work performed by a professional axle shop that can ensure these changes will not produce unsafe steering geometry or other problems for the vehicle After achieving proper ground clearance swing the front spring bracket into position normal to the front leaf springs and insert the upper pin Weld spacers onto the front spring bracket above or below the leaf springs as shown in figure 4 7 2 A This will restrict the amount of vertical travel while still allowing fore and aft travel as the suspension flexes Ensure that the safety pin off pins are removed and actuate the Railgear through its full range of motion to check that there is proper clearance Since the front mounting bracket is no longer pinned to a fixed point on the truck frame a permanent attachment is to be made at the truck axle see figure 4 7 2 A The width of the flat bar de
102. apacity 40 000 pounds per Railgear axle 20 MPH RW 1650 GVWR Range 33 000 Ibs and above for heavy load applications Approx Installed Weight Rear 1385 Ibs Capacity 70 000 pounds per Railgear axle 20 MPH Figure 1 4 1 A shows the individual parts of the installed rear Railgear with the rail wheels in the rail position These item descriptions will be used throughout this installation manual TRUCK FRAME TRUCK TIRES E 49 m ITEM DESCRIPTION ITEM DESCRIPTION REAR FRAME MOUNTING BRACKET FLAT PLATE H REAR AXLE B 4 HOLE MOUNTING PLATE INSIDE BRACKET REAR RAIL WHEEL SPACER S IF REQUIRED J REAR UPPER MOUNTING PINS D REAR HYDRAULIC VALVE ASSEMBLY K REAR LOWER MOUNTING PINS E REAR UPPER LINKS 4 L REAR CYLINDER PINS F REAR LOWER LINKS 4 M REAR BRACKET SHIM S PLATE G REAR LIFT CYLINDERS 2 N SIDE PLATE Figure 1 4 1 A Rear Railgear Components For detailed drawings see Section 5 0 and for installation instructions see Section 4 0 2012 DMF Inc All Rights Reserved 01 00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 5 Anti Lock Brake System ABS 1 5 1 Trucks Equipped with ABS All medium and heavy duty trucks manufactured after March 1 1998 and equipped with air brakes are required by feder
103. ar at 30 psi Cobra Air Brake System Plumbing Overview See additional detailed drawing on next page 2012 DMF Inc All Rights Reserved 05 02 Options doc DESCRIPTION DESCRIPTION 1 818483 1 VALVE PRESSURE PROTECTION BW103976 SPL PR 4 KIT 818437 16 818460 1 AIR BRAKE CHAMBER REAR DRIVER S SIDE 2 818484 1 ANGLE BRKT AIR BRAKE VALVE OPTIONAL 17 81846 1 AR BRAKE CHAMBER REAR PASSENGER S SIDE r 3 818485 1 VALVE TOGGLE 0052037 0 8 18 818491 1 VALVE MOUNT BRKT FRONT AIR BRAKE 4 818486 1 LEGEND PLATE ON OFF FOR TOGGLE AIR VALVE 19 818493 1 VALVE MOUNT BRKT REAR AIR BRAKE 2 5 818488 2 VALVE BRASS BALL 3 8 PBv500P 6 J 20 818421 HEX HEAD 5 16 18 x 1 1 4 6 818498 4 FITTING NIPPLE 215PN 6 21 5 5 16 18 4 5 16 18 NYLON LOCK NUT 818489 2 REGULATOR AIR MIDLAND KN31070 RAIL GEAR AIR BRAKES 22 818424 2 ROUND HEAD MACHINE SCREW 10 24 X 3 4 8 818490 2 VALVE AIR RELAY MIDLAND KN28500 wc 818425 4 10 LOCK WASHER LW 10 9 818492 1 HOSE AIR LINE FRONT LH w SPRING GUARD HO6906 x 62 24 Fw 10 2 8 FLAT WASHER 10 818494 1 HOSE AIR LINE FRONT RH w SPRING GUARD 06906 x 75 25 818427 2 10 24 HEX NUT 11 818496 2 HOSE AIR LINE REAR HO6906 x 59 n 26 510 24 1 2 RD HEAD MACHINE
104. ar axle if tandem weigh both 2 With front and rear Railgear in the rail position add or remove shims until rear Railgear axle weight is distributed equally between rear truck axle amp Railgear If truck has tandem axle the weight should be equally distributed over all 3 axles tandem amp railgear axle 1 3 1 3 1 3 3 Once weight is equally distributed then raise Railgear to the highway position 4 Re tighten the rear mounting bracket bolts to 154 ft lb torque and re weld the mounting plates and shims to the bracket per rear install detail in section 5 1 If have multiple spacers remember to weld spacers to one another INSPECTOR DATE SPECIFICATION SPECIFICATION Pe FRONT GUIDE WHEELS A mr TOLERANCES FRONT TIRES UNLESS SPECIFIED COMMON SENSE PREVAILS DRILL SIZES ANGULAR SURF FINISH THREADS 81 125 MICRO 2A AND 2B INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE Note Install shims on both pivot arms per side of truck not just outboard Frame Set OK Frame Too High Frame Too Low UPDATED AS PER 1630 MANUAL CHANGES pl UPDATED AS PER 1630 MANUAL CHANGES uc DESCRIPTION TITLE ALIGNMENT PROCEDURE amp TEAR SHEET amp TRACTION ADJUSTMENT PROCEDURES DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV 12 20 91 MP M1630115 B INSPECTION AND MAINTENANCE OF D M F GUIDE WHEEL SYSTEM DAILY Visually
105. assumed to be within specifications and should only be addressed if after alignment of the railgear excessive flanging occurs 1 Frame should be square to within 1 8 maximum on the diagonal 2 Rear drive axle should be square to frame within 1 1 6 maximum on the diagonal to achieve 0 thrust angle this should be checked by a qualified alignment shop B The following procedure applies to shop or field inspection 1 Check air pressure in all tires tires should be inflated to the minimum rating of the wheel or tire 2 Place vehicle on straight and level track or 3 channel to simulate rail Lower the railgear to the rail so that front to rear and diagonal measurements can be made Note these measurements can be made from any convenient locations as long as it stays consistent from side to side 3 If diagonal measurement is out of tolerance adjustment of the front railgear must be made The procedure for this is as follows for D 1 amp D 2 only Place shim material between the stop block on the pivot arm see dwg below amp where it comes into contact with the long arm The location for the shim is most accessible from behind the front Railgear axle example shim on left side it will push left axle forward Once proper shimming has been obtained weld the shim into place on the pivot arm Max allowable 1 4 Contact DMF if outside the maximum range RAIL WHEEL LOAD ADJUSTMENT PROCEDURE Tire traction varies w ev
106. brackets should be as close to the rear of the cab as practical Establish a forward point and mark the truck frame both sides Measure from these marks 29 5 8 bracket length and mark the frame again both sides This is the clear space required to mount the frame brackets if the brakes are located behind the axle In some cases step side fuel tanks on either side of the cab may need to be moved forward to achieve the desired space near the rear of the cab It may also be necessary to re locate tool boxes hydraulic tanks air tanks etc rearward 28 3 4 is the minimum vertical ground clearance at the rail width needed for the brake chambers in the highway position The guide wheels are reversible at installation If the wheels are insulated it is noted that DMF installs the insulation on the driver s side wheel which in this case locates the brakes to the rear of the axle Keep in mind that even though this feature allows positioning of the brakes to the front or rear of the unit as space permits an insulated wheel reverses to the passenger side of the truck if the brakes are in front of the axle NOTE The rear position is desirable from the standpoint of protecting the brake assembly from obstructions in the forward travel mode The behind cab unit is designed to fit a truck frame with as little as 29 ground clearance Since the Railgear is raised vertically to the highway position well below the 29 horizontal plane it is unlikel
107. ck while allowing access for a frame drill and platform Proceed to drill a minimum of six 5 8 diameter holes in a balanced pattern through each bracket assembly and frame member and cross member gusset where applicable Attach each frame bracket assembly to the truck with 5 8 11 Grade 8 bolts and 5 8 11 Type C lock nuts The lower axle assembly complete with wheels and brakes is the remaining mechanical portion of the unit to be installed Position the 4 elastomer springs in their lower seats With the 4 lower axle straps removed raise the assembly up to the upper spring seats Install the 4 threaded rods through the springs and secure with slotted nuts and cotter pins top and bottom Next install the 4 axle straps and secure with the sixteen 5 8 11 bolts and lock washers 4 10 4 Completion Provided the frame brackets of the behind cab unit are properly centered on the truck no further adjustment to gauge is required Welding is not necessary Finish installing the rear guide wheel unit other applicable options hydraulic system pneumatic connections etc as detailed in Section 4 and Section 5 2 Railgear Options Continue on to Section 4 11 for Overall Alignment Procedure 4 11 Overall Alignment Procedure 4 11 1 Overall Alignment Procedure and Final Weight Adjustment See drawing M1630115 Alignment Procedure and Traction Adjustment in Section 5 1 for alignment and weight drawing Once you have completed the alignment procedu
108. designated by us any part or parts there of which shall within 30 DAYS of the date of failure or notice of defect be returned and which upon examination shall appear to DMF s satisfaction to have been defective Such repair or replacement does not include the cost of installing the new part or any other expenses incident thereto however the outbound direct ground freight on the part will be prepaid to locations within the continental United States and Canada DMF shall not be liable for other loss damage or expense directly or indirectly arising from the use of its products Ordinary wear and tear abuse misuse neglect or alteration is not covered by this warranty DMF assumes no liability for expenses or repairs made outside its factory except by written consent Warranty is null and void if instructions and operating procedures specifically referring to warranty coverage are not followed Equipment or parts not manufactured by this company but which are furnished in connection with DMF products are covered directly and solely by the warranty of the manufacturer supplying them This warranty is in lieu of other warranties expressed or implied including any implied warranties of merchantability or fitness for a particular purpose and any liability for special or consequential damages All warranty claims must reference a serial number Returns must reference a RA number DMF 665 Pylant Street Atlanta Georgia 30306 Parts
109. dure The rear Railgear is usually installed with the Safety Pin Offs manual cable or air operated facing towards the rear of the truck However truck work body may dictate locating the Safety Pin Offs on the front side If the Rear Pin Offs must be located toward the front and the Railgear is supplied with insulated Rail Wheels make sure to swap the left and right Rail Wheels see Illustration in Section 5 4 2 The insulated Rail Wheels should always be on the driver s side of the Railgear It is important that the truck tire pressure especially the rear tires be checked and brought to the tire manufacturer s intended pressure for a given load Reference your tire manufacturer s load rating and inflation chart Inflating tires to their max side wall pressure may result in drastically reduced contact with the rail if under loaded If the rear truck frame does not extend the minimum of 21 1 4 for single axle or 17 1 4 for tandem axle trucks it should be properly lengthened to provide the necessary mounting clearance for the Railgear 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 2 Diagram of Key Components Figure 4 4 2 A shows the individual parts of the installed rear Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual TRUCK FRAME
110. e ONCE SPRING BRACKET IS FINALLY SET WHERE CLEARANCE ALLOWS LEAVE 1 THREADED ROD EXPOSED ABOVE NUT 2 THREADS MIN SEE ABOVE ILLUSTRATION ITEM 4 5 5 6 25 amp 26 ARE COMPONENTS OF ITEM 4 RESPECTIVELY UPDATED AS PER 1630 MANUAL CHANGES J L DATE DESCRIPTION TITLE U RW 1630 FRONT RAILGEAR ASSY FRAC MACH 1 32 FRAC MACH E 132 REF P N 801192 X d E DIVERSIFIED METAL FABRICATORS INC 404 875 1512 id Ee DRAWN BY APPD BY DATE DRAWING NUMBER REV 125 MICRO z 8 JBG 1 25 10 Ty M1630104 A ITEM NO PART NUMBER DESCRIPTION 1 WHEEL WHEL 727 1630 WHEEL ASSY NON INSULATED w RACES 2 1800100 4 RW 1630 BEARING CONE TIMKEN 567 800102 2 RW 1630 SEAL STANDARD CR 39934 4 800104 RW 1630 WASHER AXLE TAB EUCLID E 2237 5 800105 RW 1630 NUT INNER WHEEL EUCLID E 540 6 800106 RW 1630 NUT OUTER WHEEL EUCLID E 572 7 800107 RW 1630 WASHER ANE LOCK EUCLID E 573 81800108 8 HHCS 5 16 18 x 35 4 09 800109 me 818101 1 RW 1630 AE STANDARD 3 1 4 x 61 29 32 818104 2 7 DA RW NNER DRIVER AD ET ARM OUTER DRIVER SIDE PIVOT ARM A INNER POT ARM INNER PASSENGER SIDE PIVOT ARM QUTER PASSENGER SIDE PIVOT ARM OUTER PIVOT ARM 1 ce e pe RW 1630 AXLE TUBE ASSY FRONT w BRAKE SADDLES Must have serial when ordering parts INNER PIVOT ARM 1 OUTER PIVOT ARM 1
111. e Railgear typically drops straight down but it can also articulate from side to side to allow alignment of the vehicle with the rail A clear space of 19 inches must extend outward from each side of the frame in this area to allow for proper articulation see Figure 4 4 4 A is important that nothing encroach upon this space e g outriggers lift gates and body tie down bolts SINGLE AXLE TRUCK TANDEM AXLE TRUCK TRUCK FRAME REAR FRAME BRACKET Figure 4 4 4 A Location and Clearance of Railgear 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 5 Shimming and Temporarily Spacing Rear Bracket Once Railgear is correctly located on rear frame as above if more than a 1 16 gap exists between the rear Railgear bracket side plate and the side of the truck frame install equal amount of shims on each side to fill the gap thus keeping the Railgear bracket centered Note that DMF provides shims of different thicknesses and it is important that the same amount of shim measurement is achieved on both sides With the rear bracket correctly located against bottom of frame rail and centered there are two differing methods of setting a preliminary weight setting 1 The first method is to measure from top of rear bracket plate to floor and adjust bracket with temporary spacers as shown in Table 4 4 5 A This should provid
112. e a good starting point for final weight setting 26 27 28 29 30 31 32 33 Xtra Short Links 0 1 2 3 Short Links 0 1 2 3 Long Links 0 i 2 cH Table 4 4 5 A Shimming Chart 2 The second method is to insert the minimum 1 2 or maximum 3 of spacers and then during the final weight setting add or remove spacers as appropriate until optimal weight setting is achieved Once spacers are positioned temporarily clamp chain or otherwise secure rear Railgear to truck frame Keep in mind that spacers and rear bracket may have to be adjusted for final weight setting and squaring aligning with the truck axle 4 4 6 Square Rear Railgear with Truck Axle The Rear Railgear needs to be made absolutely square with the rear truck axle Four measurements shown in Figure 4 4 7 A need to be taken to ensure this requirement 1 The distance from the truck axle to the Rear Railgear Axle at each end In Figure 4 4 7 A distance A must be equal to B within 1 8 This is an important alignment check 2 The diagonal from the truck axle to the opposite Rear Rail Wheel In Figure 4 4 7 A distance C must be equal to D within 1 4 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 7 Squaring up Rear Railgear to Truck Frame REAR TRUCK AXLE ALIGNMENT CHECK within 1 8 BU
113. ear Railgear to be moved both vertically and horizontally This mechanism provides the side shift action which has made DMF gear so well known in the industry It gives operators a greater margin for aligning the vehicle to the track which speeds and simplifies the process of getting the vehicle on rail DMF RW 1630 Railgear is designed for vehicles with GVWR s 33 000 Ibs and above For greater capacity you can upgrade to our RW 1650 rear gear It can boost your Railgear weight capacity by supplying a larger axle bigger bearings and special hardened rail wheels The front Railgear and all other components remain the same as standard RW 1630 In addition to the high capacity axle upgrade available with our RW 1650 Railgear we also offer additional options for extreme conditions or tight curvature situations See Sections 1 3 and 1 4 for specific configuration information For purposes of this manual we will refer to RW 1630 when discussing either RW 1630 or RW1630 50 and we will explicitly call out any differences when appropriate Materials structural members and brackets are constructed of carbon steel The 16 guide wheels for DMF RW 1630 Railgear are machined from hardened steel castings and are fitted to high strength alloy steel axles with heavy duty tapered roller bearings Installation Both DMF front and rear guide wheel units bolt to the truck frame using only hand tools found in any shop They are designed to minimize the a
114. ecal Kit Check Front Alignment o Front Mounting Pin height 25 1 2 o Rear Mounting Pin height 12 3 4 Check Rear Alignment o Tire to Rail Wheel center Single Axle 15 1 4 Tandem Axle 11 1 4 o Minimum Truck Frame extension Single Axle 21 1 4 Tandem Axle 17 1 5 Check overall measurements o Rear Truck Axle to Rear Railgear Axle straight A1 A2 within 1 8 o Rear Truck Axle to Rear Railgear Axle diagonal B1 B2 within 1 4 o Front Railgear to Rear Railgear straight C1 C2 within 1 8 o Front Railgear to Rear Railgear diagonal D1 D2 within 1 4 Raise and lower Railgear and verify pin off at highway and rail positions Verify that all bodywork is replaced and secure In a parking lot or open area verify that the truck tires and rims do not contact the Railgear in any bump droop or steering position Check for any rattles and vibration 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 0 TECHNICAL DETAILS 5 1 Installation Drawings 5 1 1 M1630105 Rear Installation Detail Drawing 5 1 2 M1630104 Front Installation Detail Drawing 5 1 3 UC110005 RW 1630 Under Cab Front Railgear Assembly 5 1 4 BC108005A RW 1630 Behind Cab Front Railgear Assembly 5 1 5 M1630115 Alignment Procedure and Traction Adjustment 5 1 6 ST1652 Instruction and Safety Decals 5 1 7 0 06 Purchased Fastener Torque Specifications 5 2 1 Doc Rai
115. ent 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 4 8 2 Final Steps If the Spring Bracket location had to be adjusted make sure that the hex nuts two per stud on both Spring Brackets have been tightened down Then with a torch cut the excess stud length on the Spring Brackets If these studs are not trimmed down they may pose a clearance problem with other parts on the truck see CLEARANCE NOTE and Figure 4 6 7 A NOTE Remount the truck front bumper or use 8 standard channel welded onto the ends of the Frame Extensions 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 9 Under Cab Front Unit Installation Detailed Installation Drawings are available in Section 5 1 NOTE Two factors control the installation of the Under cab front unit A Fuel Tanks and B Motor Transmission PTO Arrangement Read Section 4 9 1 before dismantling any equipment 4 9 1 Under Cab General Information FUEL TANKS 1 Are cab steps part of the tank or tank brackets You can either leave tanks in location or relocate tanks and add new Under Cab steps 2 Can tanks be relocated Do you have room down the frame 3 What is the Ground Clearance under tanks You need a minimum of 13 1 4 under tank and or tank brackets to maint
116. ers added removed as necessary NOTE Only use Grade 5 bolts on rear Railgear 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 4 9 Mounting Plate Installation TRUCK FRAME 2 WELD CENTER TOP amp BOTTOM HEX HEAD BOLT 4X 5 8 11 GRADE 5 ENSURE NUTS amp BOLTS SECURELY FASTENED TO BOLT SPEC 154 LBF FT 4 HOLE MOUNTING PLATE REAR FRAME BRACKET SPACER S Figure 4 4 9 A Mounting Plate Installation 4 4 10 Welding of Spacer TRUCK FRAME L SPACER REAR SIDE TACK WELD REAR FRAME BRACKET ENSURE ALL SPACERS ARE FIRMLY AGAINST SIDE BRACKET amp ALIGNED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO MOUNTING BRACKET AS SHOWN IF MULTIPLE SPACERS ARE USED SPACERS NEED TO BE WELDED TO ONE ANOTHER AT THE REAR amp TACK WELDED ON THE SIDES IF POSSIBLE Figure 4 4 10 A Welding of Spacer 4 4 11 Final Rear Railgear Alignment and Weight Settings Rear Railgear alignment and weight settings can only be performed after front Railgear is installed The procedures for these final steps can be found in Section 4 11 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 5 Varying Front Railgear Configurations Due to the numerous variations between chassis DMF has designed several differe
117. ery truck based on several factors such as weight amp tire design It can also vary on the same truck as equipment is added or deleted Thus we recommend performing the traction adjustments after all equipment is installed or removed Since every truck differs there is no exact procedure However we have found the following two methods to be a good guide The true test is how the vehicle performs on rail METHOD 1 Note Method 1 is a visual procedure of the tire capping on rail 1 Grind off the welds on the 2 four hole mounting plates at the rear mounting bracket 2 Loosen the 8 rear bracket mounting bolts 3 Lower the railgear supporting the railgear with a floor jack or with the unit itself 4 Remove or add spacer shim material located between the bottom of the truck frame and the shelf on the rear mounting bracket Add shim to decrease traction and remove shim to increase traction ref side dwg for illustration of proper tire capping 5 Raise Railgear once again to contact the bottom of the truck frame 6 Re tighten the rear mounting bracket bolts to 154 ft lb torque and re weld the mounting plates and shims to the bracket per rear install detail in section 5 1 If multiple spacers are used remember to weld spacers to one another METHOD 2 Note Method 2 distributes the vehicles rear axle s weight s equally over all rear axles including the Railgear 1 If truck scales are available weigh the vehicle s re
118. esive backed hook is placed on the steering wheel column and a second piece placed on the top flat of the steering wheel hub The 4 wide piece of loop fabric can then be applied to bridge the gap between column and wheel preventing the front tires from accidentally being turned while on the rail However in the event of an emergency the steering wheel can be forcibly turned and the Velcro fasteners will separate allowing the driver to steer the vehicle 1 Clean the areas where the self adhesive 2 wide hook strips will be applied on the steering column and wheel with rubbing alcohol and a clean cloth 2 Allow the column and wheel to dry 3 Remove the adhesive backing from the hook strips and apply them to the top of the steering wheel hub and the column as close to the wheel column gap as possible NOTE Trim the strips to fit around obstructions such as hazard light switches 4 Allow the adhesive to cure for 24 hours prior to attaching the 4 loop fabric 5 When putting the truck on the rail position the 4 loop fabric to bridge the gap between the hooks on both the column and wheel as shown below and press firmly 6 To remove the lock simply pull on the D ring and store the piece of Velcro fabric 2012 DMF Inc All Rights Reserved 05 02 Options doc ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION mer 1 PUMP XSTING 5t07 gpm 2000 nni amine tes
119. f the installed front Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual TO MAINTAIN GROUND CLEARANCE ADD PIPE OVER PIN amp FLAT BAR TO SPACE GAP OVER SPRING N 3 8 FRONT TRUCK SPRING SECURE SPRING HANGER TO AXLE BY ADDING A 3 4 THICK FLAT BAR AS SHOWN DRILL HOLES TO MATCH EXISTING U BOLT ON TRUCK FRONT TRUCK AXLE em Description REAR SPRING BRACKET SPACERS if Required SPACER Top Required RUBBER SPACER Required REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM FRONT MOUNTING PIN FRONT SPRING BRACKET amp PIN e oh idessonsova Figure 4 7 2 A Diagram of Key Components Front Mounting Dimensions 4 7 3 Mount Front Railgear Mounting Rear Spring Bracket 1 Remove the truck s front bumper 2 Slide the front Railgear under the truck frame positioning the spring bracket hangers as close as possible to the front truck axle Make sure at least half of the spacer is seated on the leaf spring closest to the front truck axle If the spacer is not at least half seated move spring bracket hanger forward to next leaf spring 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 Once positioned place a floor jack under the outboard and inboard long arm close to the spring hanger on the driver s side Using
120. flat spot on the wheel due to the sliding action on the rail 2 The brakes properly release when the brake pedal is released If brakes do not function properly contact a Service Representative at DMF 3 1 3 Bi annually Perform standard daily and weekly inspection points as listed above and then check the following e Remove the hubcaps from the Rail wheels and inspect for deterioration 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 Rail test for proper traction and adjust as appropriate see Section 5 1 5 Rail test for proper braking and adjust as appropriate see Section 5 2 4 e Check Railgear alignment see Section 5 1 5 3 1 4 Annual Maintenance or as required In addition to the items listed in 3 1 1 Daily Maintenance 3 1 2 Weekly Maintenance and 3 1 3 Bi annual Maintenance perform the following e Disassemble inspect repack and reassemble Rail Wheel Bearings as shown in Section 5 5 4 10 5 5 8 5 5 9 3 2 Lubrication Specification Hydraulic Oil e ASTM D6158 HM Unax RX 46 Hydraulic Oil Shell Tellus EE 46 or equal OR e Some customers operate Dexron ATF Wheel Bearing Grease Grease Fittings e Mystik JT 6 Lo Te
121. g per Figure 4 2 4 A Drive the truck into the work area pulling forward and back several times to align the axles and up onto the Rear Installation Rails The rear inside tires should be on the rails with the rear outside tires off the floor The Front Installation Rails are not needed at this point NOTE Before proceeding be certain that the front truck tires are chocked amp the parking brake is set 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 2 4 Installation Rails c P Mm d 3 Square Tubing za x d j E P x T p a 7 Ps 7 d p d P di w PME Ages m 2i I P d s gc 1 2 d N a p TC m a 2 EM E hos OL P d x I 5 r Bene Front Installation Rails 4 n p d A 5 DE d Rear Installation Rails 10 Et d s P 0 P d Cap ends of rails L 7 we 2 on 45 24 SL 9 is s x d i Figure 4 2 4 A Installation Rails NOTE Inside to Inside measurement of 56 1 2 is the standard gage for the United States If your equipment is to be operated on any other gauge adjust measurements according 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 3 Hydraulic System For Hydraulic System drawings maintenance and repai
122. gure 4 6 3 A for an illustration Check that the Frame Extension tubes are level front to rear and side to side with the frame THREADS BEGIN PAST JOINT Figure 4 6 3 A Bolted Joint Cross Section DMF front frame extensions are designed to support the Railgear only It is the installer s responsibility to properly engineer brackets for rail racks boom rests and etc In normal applications mount the Front Valve Plate Assembly between the Frame Extensions with the Front Valve on the underside and the handle facing forward and weld in place If this is not possible mount Valve Assembly in the most appropriate and easily accessible location 4 6 4 Bridge Kit Information In some instances the frame rails are wider than normal to clear vehicle components such as the radiator When this occurs the frame rail is too wide and the cross tube falls in between the frame rails and a bridge kit is needed There are two different types of bridge kits below frame rails Figure 4 6 4 A and between frame rails Figure 4 6 4 B If the correct front mounting pin height can be achieved with a heavy walled square tube below the frame rail as shown in Figure 4 6 4 A that is recommended However if the correct front mounting pin height cannot be achieved because the below frame rail bridge will cause the front mounting pin to be too low it is recommended to use a between the frame rail bridge with gussets Figure 4 6 4 B 2012 DMF Inc All R
123. hat will cause a flat spot on the wheel due to the sliding action on the rail 2 the brakes properly release when the brake pedal is released If brakes do not function properly contact a Service Representative at DMF 2012 DMF Inc All Rights Reserved 05 02 Options doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 2 6 Options Two Piece Wheels DMF offers a two piece insulated wheel option for extreme applications such as material handlers If your material handler will be insulated then DMF requires the use of our two piece wheel DMF s two piece wheels require additional maintenance over and above our standard wheels so we only recommend them for use in heavy duty applications The additional maintenance procedures center around proper monitoring of the torque of the 8 bolts holding the tread and hub together To assist in monitoring the torque of these bolts DMF has provided Loose Wheel Nut Indicators also referred to as torque indicators on all 8 bolts See the following checklist for additional maintenance procedures Additional Checklist for Two Piece Wheels In addition to following the inspection and maintenance procedures as defined in Section 3 1 Two Piece Wheels require the following specific inspections As previously specified in Section 3 1 1 check the bolt torque indicators the tabs around each bolt daily to ensure that they have not moved If torque indicators are missing or damaged please c
124. he cable to Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex end cap Replace the T handle on the cable Xx L 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK WASHER SEAL 5 8 C HEX END CAP NOTE 43 818587 REM AIR P O FITTING P N 818589 CONVERTS REMOTE CABLE PIN OFFS 818593 REM P O AR CTRL VALVE TO REMOTE AIR OPERATED PIN OFF ASSEMBLY MSs Tr S Truck Y 2222227 P N 818596 5 8 18 JAM NUT P N 818765 AIR CYLINDER 7 N P m Z I 7 bus HEX NUT 4 PLCS 1 2 LOCKWASHER 2 PLCS KIT P N 818613 AIR REMOTE KIT ASSY LESS PIN OFFS P N 818595 MOUNTING PLATE PATIENT TOME INCLUDES 800136 DECAL 818528 QTY 2 818587 QTY 7 818591 QTY 1 P N LWS716 10OCRWASteR 8 16 818593 QTY 1 818596 QTY 2 818599 QTY 2 818765 QTY 2 amp LW5 16 QTY 2 1 2 13 HEX NUT 7 16 WASHER 7 16 FLAT WASHER 7 16 C HEX JAM NUT 818591 1 4 TUBE DESCRIPTION 1 wor 1 REF REMOTE PIN OFF CABLE MORSE 2 818563 REMOTE PIN OFF MOUNTING PLATE 3 818550 REMOTE ASSY for_w LONG LINKS 7 3 4 C to C 818551 REMOTE PIN OFF ASSY for w SHORT LINKS 5 3 4 C to C 5 818571 REMOTE PIN OFF T HANDLE MORSE 1 2 13 x 5 1 2 HEX HEAD BOLT 1 4 20 HEX NUT SEAL UPPER REAR LINK 7 16 INTERNAL LOCK WASHER 7
125. he front brake assemblies with the arm weldments In the rail position the brakes should be located behind the guidewheels and about 15 degrees up from horizontal In the highway position the brake assemblies should be located above the stowed guidewheel and rotated forward by about fifteen degrees 4 9 5 Welding Once the brake and axle positions have been determined you must weld the axle tubes to the lower arm weldments This may be done on the inboard sides of the lower arms Follow the established procedure for welding the axle tubes to the pivot arms found in the standard installation instructions 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 9 6 Remote Air Pin Off Installation The positions for the upper and lower pin offs are located on the inside of each upper arm assembly Due to inaccessibility operation of the pin offs is achieved from a remote location preferably on or near the driver s side of the truck frame The DMF furnished remote pin off assemblies are air operated and include lock pin housings air control valve cylinders and pre set proximity sensors with LED position indicators A legend plate DMF 818754 is also furnished to locate and install the air control valve and LEDs This plate when installed with the LEDs indicates engagement or dis engagement of the lock pins Please refer to the enclosed drawing 818745 for installation instr
126. ights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 25 1 2 12 3 44 REAR MOUNTING PIN FRONT MOUNTING PIN Figure 4 6 4 A Below Frame Rail Bridge Kit 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 FRAME RAIL BRIDGE GUSSET BRIDGE TUBE zi 66 Ji N N 5 24244 L TEL jpeg 25 1 25 FRONT MOUNTING PIN 12 3 4 REAR MOUNTING PIN Figure 4 6 4 B Between Frame Rail Bridge Kit 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 6 5 Front Mounting Dimensions Front Mounting Pin Frame Extension m cud x Z i Spacer Top O O Truck Rubber Spacer Must be directly on top of leaf springs Spacer Distance 4 Max Spring Bracket 25 1 2 Spring Bracket Heigh F Rear Mounting f Pin B 12 3 4 Figure 4 6 5 A Front Mounting Dimensions NOTE If the vehicle has been supplied with an integral extended front frame the Frame Extension will not be required The cross tubes can be brought up to the extended frame as shown in Figure 4 6 5 A Follow all instructions for finding the Front Mounting Pin height with the Frame Extensions Solid or load bearing Spacers may be required bet
127. ilicon for hubcap or wheel grease or bearing race P N 4800301 KIT 2 WHL TORQUE INDICATORS 1630 amp UNDER CAB REAR AXL L _ CORRECTED PART 4 WAS 800259 NH RV par DESCRIPTION Br APP TITLE RW 1 WH AXLE ASSY EXP RW 1630 630 WHEEL amp AXLE ASSY EXPLODED DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER JBG 1 25 10 M1630103 Wheel Bearing Grease Mystik 6 Lo Temp Extreme Grease ae 1650 REAR AXLE WELDMENT TUBE WIDE W BRAKES factory standard preferred for colder climates 800127 RW 1650 SEAL STANDARD 49928 3 80126 4 m RW 1650 BEARING CONE TIMKEN 6466 NOTE DRAWING amp PART NUMBERS ARE APPLICABLE FOR 800125 RW 1650 RACE BEARING TIMKEN 6420 BOTH 1650 AND BEHIND CAB REAR FOR BEHIND CAB FRONT 6 82001 1 RW 1650 AXLE HD 4 X 64 800131 FEIER Wap IE TIE ICI SEA AXLE PARTS SEE DRAWING BC108005A IN SECTION 5 1 8 800150 RW 1650 NUT AXLE EUCLID 2465 9 820441 RW 1650 HUBCAP DETAIL 7 75 DIA 800109 8 5 16 LOCK WASHER LW5 16 800108 8 HEX HD SCREW 5 16 18 x 3 4 LONG BRAKE SADDLES 5 8 11 x 4 Grade 8 Bolts Must replace bolts nuts at same time WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE ON INBOARD SIDE OF BEARING COVERING
128. im De 0 FILL OUTBOARD CAVITY COMPLETELY mE P RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE OUTBOARD FACE OF HUB Q INSTALL HUBCAP WITH PROVIDED SCREWS CAN AA P N 800020 ALL HARDWARE KIT FOR RW 1630 amp UNDER CAB WHEEL Does not include silicon for hubcop or wheel grease or bearing race e 2 807 2 R BEAR 5 800125 2 6 820401 1 MEM PART NUMBER DESCRIPTI i _ 1 1650 REAR DMENT TUB 0 SEAL STA RW 1650 WASHER AX Wheel Bearing Grease Mystik JT 6 Lo Temp Extreme Grease factory standard preferred for colder climates NOTE DRAWING amp PART NUMBERS ARE APPLICABLE FOR BOTH 1650 AND BEHIND CAB REAR FOR BEHIND CAB FRONT AXLE PARTS SEE DRAWING BC108005A IN SECTION 5 1 8 800150 RW 1650 NUT AX 9 820441 2 R BCAP 10 800109 8 11 800108 8 WHEEL ASSEMBLY PROCEDURE A PACK ALL BEARINGS COMPLETELY ENSURING COMPLETE COVERAGE INSIDE AND OUT B INSERT BEARING IN INBOARD SIDE OF WHEEL FLANGE SIDE C PACK GREASE D INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB E PLACE WHEEL F FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE G INSERT BEARING OUTBOARD SIDE OF WHEEL H INSTALL INNER WHEEL NUT ITEM 5 l ADJUST BEARING 1 TIGHTEN WHEEL HEAVILY BY HAND 25 to 50 ft lb 5 8 11 x 4 Grade 8 Bolts Must replace bolts nuts at same time ON INBOARD SIDE OF BEARING COVERING BACK SIDE OF BEARING
129. inor derailment the cause of the derailment should be determined and corrective steps taken The vehicle should be inspected to determine if repairs or adjustments are required This inspection should include but should not be limited to the following Visually inspect Railgear for hydraulic leaks Ensure all lines and hoses are still secured and out of the way of any moving parts Ensure all hydraulic hose connections and fittings are securely in place and not broken Verify that all threaded fasteners are secure and that cotter pins are not broken Visually inspect wheels to ensure that tread and flange are not severely damaged Spin all 4 Rail wheels noting any bearing noise resistance and end play Any items noted should be repaired using Section 4 0 and 5 0 to ensure they are repaired to initial install standards In case of a major derailment a complete inspection should be performed including but not limited to the following Perform all inspection items as listed above in the Minor Derailment section Inspect all long arms pivot arms and links to ensure they are not bent cracked or broken Inspect and test rail brake system see Section 5 2 4 Ensure spring brackets are securely fastened and are not bent cracked or broken Ensure all welds are intact and show no signs of cracking or breaking Ensure all mounting hardware and brackets are securely fastened and are not bent cracked or damaged in any way A full alignment shou
130. inspect rail gear for hydraulic leaks loose fasteners and excessive wear Spin all four wheels noting any bearing noise or resistance Check level of hydraulic oil Compare left and right wheels for wear particularly diagonal flanges WEEKLY Grease all fittings on rail Six 6 on front assembly Fourteen 14 on rear assembly Inspect the bearing grease every 2 000 miles or 6 months whichever comes first Inspect bearings and grease cavity by removing hubcaps Unless bearing problem is suspected the bearings do not need to be removed or repacked If repacking is required the grease cavity should be only 80 filled with suitable grease Replace hubcaps using a bead of Form A Gasket or equal ANNUALLY Change hydraulic oil filter element DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ATLANTA GA o OPERATION OF D M F GUIDE WHEEL SYSTEM TO PLACE VEHICLE ON RAIL 1 Drive vehicle on crossing centering it over tracks 2 Once centered over tracks remove front and rear safety pins 3 Lower rear wheels first A If rear is not completely centered within 4 rear rail wheels will center truck on rail B With rear wheels fully extended and properly seated on rail install safety pin into lower hole on both sides 4 Center front rail wheels over rail A If front is not completely centered over rail maneuver truck so that it is B Front vehicle wheels must be straight ahead C Lower front rai
131. l Sweeps 5 2 2 Doc Rear Remote Pin Offs See Section 5 4 13 5 2 3 Doc Front Remote Pin Offs See Section 5 5 7 5 2 4 Doc 818400 Air Brakes 5 2 5 M1630132 Behind Cab Air Brake Plumbing 5 2 6 Doc M1630106 2 Piece Wheel 5 2 7 Doc Steering Lock 5 3 1 M1630114 Valve Assemblies and Hydraulic Schematic 5 3 2 240256 RW 1630 50 Driver Side Rear Locking Valve Cylinder Assembly 5 3 3 240257 RW 1630 50 Passenger Side Rear Locking Valve Cylinder Assembly 5 3 4 241303 304 RW 1630 Rear Locking Valve Cylinder Extra Short Links 5 3 5 240099 100 RW 1630 Front Hydraulic Cylinder Assembly 5 3 6 PPOOS Cylinder Assembly Procedures 5 3 7 PPOO5 JIC Fitting Installation 5 3 8 PPO03 O Ring Fitting Installation 5 3 9 PPOOA Pipe Fitting Installation 2012 DMF Inc All Rights Reserved 05 00 RW 1630 Technical Details doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 4 Rear Railgear Parts 5 4 1 5 4 2 5 4 3 5 4 4 5 4 5 5 4 6 5 4 7 5 4 8 5 4 9 5 4 10 5 4 11 5 4 12 5 4 13 5 4 14 5 4 15 5 4 16 Doc M1630110 240256 240257 241303 304 M1630111 M1630107 M1630108 M1630109 M1630103 M1650103 M1630100 M1630113 M1630117 M1630118 M1630101 Before Ordering Parts Rear Railgear RW 1630 Pin Off Orientation RW 1630 50 Left Rear Side Locking Valve Cylinder Assembly RW 1630 50 Right Rear Side Locking Valve Cylinder Assembly RW 1630 Rear Locking Valve Cylinder Extra Short Links Link Dimensions Extra
132. l self locking rod nut on rod Tighten to 200 to 300 foot pounds torque Torque will vary based on rod amp nut size CYLINDER ASSEMBLY A Inspect cylinder ports for minimum three 3 threads and no burrs Deburr as neccessary Clean tube ID threads and bore and blow out with shop air Inspect threads for debris Support cylinder barrel assembly with gland end facing Maintain rod assembly in vertical position align piston with tube bore engage piston in tube bore strike rod end wit hammer until piston is below first cylinder port Slide gland down on rod engage gland threads into barrel by hand LQmTnImuocou A B C D E F G H Screw gland into barrel with spanner wrench until gland face contacts barrel tube end H Install two 2 hydraulic fittings into cylinder ports per PPO03 PRESSURE TESTING A Connect hydraulic power unit to cylinder P TEE B Operate cylinder through complete cycle to purge air and fill with clean hydraulic oil RE C Operate cylinder to full extension and retraction and maintain at 3300 PSI for 15 seconds at each extent While maintaining pressure at each extent visually inspect ports rod seal gland OD seal and cylinder bottom areas for leakage D Disconnect hydraulic power unit and install caps on port fittings E Impression sfamp cylinder bottom when all preceding steps have been successfully accomplished COMMENTS Specific assembly instructions on prints are pe
133. l wheels until cylinders are fully retracted Front rail wheels incorporate over center design and do not require safety pins in rail position 5 Double check all flanges to assure they are seated properly on rail and safety pins are installed 6 Engage steering wheel lock if equipped Safe operating speeds on rail will be governed by track conditions and existing railroad rules and regulations Under no conditions should vehicle be operated over 30 MPH on track DIVERSIFIED METAL FABRICATORS 404 875 1512 TO REMOVE VEHICLE FROM RAIL 1 Drive vehicle over road crossing 2 Either front or rear wheels may be activated first 3 Front rail wheels A Retract front rail wheels completely B Once retracted install safety pins 4 Rear rail wheels A Remove safety pins B Fully retract rear rail wheels C Re Install rear safety pins 5 Double check all safety pins are in proper location 6 Disengage steering wheel lock if equipped ATLANTA GA 800116 PART NO DESCRIPTION 1 800190 P N s 800113 800114 800116 800118 800119 amp 800122 2 2ea 5 800117 amp 800135 N CAUTION N SECURE RAILDOGS BEFORE OPERATING DUMP RELEASE BEFORE TRAVEL 800122 SAFETY INSTRUCTIONS Lock front wheels straight ahead for CAREFUL WORKER on rail travel IS THE BEST SAFETY DEVICE A CAUTION A RELIEF VALVE SETTINGS 2000 PSI FRONT 1500 PSI REAR DO NOT EXCEED 2500 PSI FRONT VALV
134. l widths are available please contact DMF 12 0 REF MUST ORDER CONPLETE BRACKET DIMENSION A SEE TABLE FRAME WIDTH 1 8 HALF A 21 5 REF 43 0 REF HOLD CENTER TO CENTER 1 563 REF 50 0 REF 1 2 FILLET WELD ON BOTH SIDES TYP 5 z NO WELDS ON ENDS TYP 3 8 FILLET WELD OTHER PLACES TYP A sai REVISED FRAME WIDTH TABLE ADDED ANGULAR REFERENCE FOLERANCES TITLE UNLESS SPECFED REAR MOUNTING 10 3 4 FORMED BRACKET ASSY PRCA EUN RW 1630 3 4 HEAVY DUTY PLATE vu DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES M DRAWN BY APPD BY DATE DRAWING NUMBER ANGULAR t1 namaos S JBG 4 29 10 M1630118 COBRA AIR BRAKE ASSEMBLY FRONT PASSENGER S SIDE COBRA AIR BRAKE ASSEMBLY REAR DRIVER S SIDE COBRA AIR BRAKE ASSEMBLY REAR PASSENGER S SIDE COBRA AIR BRAKE ASSEMBLY FRONT RETRO FIT KIT COBRA AIR BRAKE ASSEMBLY REAR RETRO FIT KIT COBRA AIR BRAKE ASSEMBLY COMPLETE RETRO FIT KIT F amp R NOTE 1 KIT P N 818445 AIR BRAKE PIVOT PIN w 2 ROLL PINS INCLUDES 5 818454 BRAKE SHOE PIVOT PIN QTY 1 amp 17 818509 ROLL PIN QTY 2 NOTE 2 1 NOTE 2 1 AIR BRAKE CHAMBER FRONT SEE NOTE 2 BOLT MOUNTING 1 2 13 1 1 2 Gr8 6 818456 1 COTTER 1 8 x 1 1 2 7
135. ld be performed See section 5 1 5 Wheels should be removed and the bore bearings races and insulation if applicable should be inspected for any damage For further wheel details see section 5 4 amp 5 5 for appropriate wheel amp axle assembly drawings Ensure axle threads are not stripped or damaged Any items noted should be repaired using Section 4 0 and 5 0 to ensure they are repaired to initial install standards Please contact DMF for any assistance you may require 2012 DMF Inc All Rights Reserved 03_00 RW 1630 Routine Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 5 Drawings amp Illustrations 3 5 1 Brake Adjustment Diagram ADJUST GAP WITH CLEVIS amp JAM NUT 1 8 MIN SHOE THICKNESS ADJUST TO 1 16 REPLACE SHOE IF UNABLE TO ADJUST TO MAX ALLOWED 1 4 Figure 3 5 1 A Brake Adjustment Diagram 3 5 2 Grease Point Locations See drawing on following page 2012 DMF Inc All Rights Reserved 03 00 RW 1630 Routine Maintenance doc 1 A 4 FRONT PIVOT ARM PIVOT PINS CENTER OF THE PIN HEAD L2 2 FRONT CYLINDER Ro CROSS TUBES 3 2 REAR BRACKET UPPER PIN CROSS TUBES 4 p 2 REAR AXLE LOWER PIN SADDLE BLOCK s E a REAR SCISSORS LINK MECHANISM O Le 2 REAR CYLINDER ROD CROSS TUBES RW 1630 50 FRONT MOUNT RW 1630 UNDER CAB RW 1650 BEHIND CAB LUBRICA
136. leaf springs Spacer Distance Spring Bracket 4 Max um En 25 1 2 Spring Bracket Height T A Rear Mounting Pin B Long Arm 12 3 4 PR ec NOTE FOR THE 38 1 2 DIMENSION SHOWN ABOVE REF SECTION 4 5 1 FRAME EXT MEASUREMENT 38 ps INSTALL SHIM HERE MAX ALLOWABLE 1 4 CONTACT DMF IF OUTSIDE MAX RANGE NOTE SHIMS SHOULD BE PLACED ON BOTH PIVOT ARMS FOR A GIVEN SIDE OF THE TRUCK NOTE 22 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp WEIGHT SETTING HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED REFER TO SECTION 4 1 5 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PREMATURE BEARING FAILURE e MUST BE WELDED IN RAIL POSITION THE INBOARD SIDE OF THE OUTER PIVOT ARM FOR BOTH PASSENGER amp DRIVER SIDE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS ALL THE WAY AROUND ONCE FINAL ALIGNMENT amp WEIGHTS ARE SET e FRONT CROSS TUBE MUST BE FULLY WELDED COMPLETE STRUCTURAL WELDS TO TRUCK FRAME OR FRAME EXTENSIONS ALL THE WAY AROUND e F SHIMS REQUIRED FULLY WELD ALL SHIMS IN ALL LOCATIONS IN PLACE ONCE ALIGNMENT IS ACHIEVED IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED AT LOCATION SHOULD NOTE 3 BE WELDED TO ONE ANOTHER
137. mation Dual Shield Wire spec gt AWS E71T 1 Low Hydrogen spec gt AWS E 7018 Low Hydrogen Electrodes AWS E 7018 Manufacturer Equivalent Rod Air Products AP 7018 7018IP Airco 7018C 7018 A1 Arcos Ductilend 70 Air Products 170 LA SW 47 616 Chemtron 170 LA SW 47 616 Hobart 718 718 SR Marquette 7018 McKay Co 7018 Reid Avery 7018 Uniblaze 7018 Westinghouse Wiz 18 Lincoln Jetweld LH 70 Table 4 1 5 A Manufacturer Equivalent Welding Rod 4 1 6 Purchased Fastener Torque Specifications See drawing in section 5 1 7 2012 DMF Inc All Rights Reserved RW 1630 04_00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 2 Initial Instructions 4 2 1 Work Area The area in which the Railgear installation is to occur should meet minimum requirements in order to facilitate the process and provide adequate conditions in which the work can be completed safely accurately and in a timely manner Floor The floor should be level in order to provide good measurements required to check the alignment of the Railgear e Lighting The work area should be adequately lighted e Space There should be enough space to maneuver the Railgear components into position and to safely work around other equipment 4 2 2 Truck Condition Before installation the truck should be checked in some important areas e Tires The tire pressure
138. mount of space required and in many cases fit within the existing boundaries of the vehicle The front units however sometimes require a bolt on frame extension to complete the installation Rear RW 1630 Railgear mounts below the top of frame and directly behind the rear axle spring hangers Brakes The optional RW 1630 rail brakes are of the air actuated external Cobra shoe type The rail brakes use a truck style air chamber to supply the clamping force Supply pressure comes from the vehicle s air system A pressure protection valve separates the Railgear and the truck s air systems preventing a failure in the rail brake system from adversely affecting truck braking The rail brakes are applied simultaneously with the truck brakes when the operator presses the brake pedal There is also a dashboard mounted switch that permits the operator to enable or disable the rail braking system Options There are several options available for RW 1630 Railgear The most commonly ordered options include rail wheel brakes for improved stopping on rail insulated wheels to prevent crossing signal actuation rail sweeps to clear the rail of potentially damaging materials and remote pin offs for ease of operation Other less common options are non standard track gauges slotted links for improved hi rail performance at crossings and two piece wheels for extreme conditions 2012 DMF Inc All Rights Reserved 01_00 RW 1630 General Information doc DIVERS
139. mounting brackets are shorter Installation of Rail Sweeps is done while the Railgear is in the rail position For standard Rail Sweeps without brakes weld the Mounting Bracket directly to the Railgear axle tube oriented so that the Rubber is flush with the rail For Rail Sweeps with Cobra Air Brakes bolt the shorter Mounting Bracket directly to the Air Brake structure On the front bolt on the side facing forward on the rear bolt to the top of the Air Brake which faces backward 818631 REAR RAILSWEEP ASSEMBLY BOLT ON USED w BRAKES FRONT RAILSWEEP ASSEMBLY nc BOLT ON USED w BRAKES REAR RAILSWEEP WELD ON USED w o BRAKES Li 818501 MOUNTING PLATE 818503 RUBBER SWEEP FRONT RAILSWEEP ASSEMBLY USED w UNDER CAB RAILGEAR Figure 5 2 1 A Rail Sweeps REAR RAILGEAR Figure 5 2 1 B Rail Sweep Position RAIL SWEEP RAIL SWEEP VA NP ER 2012 DMF Inc All Rights Reserved 05 02 Options doc DIVERSIFIED METAL FABRICATORS INC RW 1630 5 2 2 Options Rear Remote Pin Offs See Section 5 4 13 for Drawing 5 2 3 Options Front Remote Pin Offs See Section 5 5 7 for Drawing 5 2 4 Options Brakes DMF s RW 1630 Railgear uses an optional air braking system The same Cobra air braking system is used for both the front and rear Railgear For a detailed drawing of the Cobra Air Brake Assembly see Figure
140. mp Extreme Grease Factory Standard preferred for colder climates 2012 DMF Inc All Rights Reserved 03 00 RW 1630 Routine Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 3 Troubleshooting 3 3 1 Troubleshooting On track Problems Symptom Possible Cause Diagnostic Step Corrective Action Rail wheel vibration Damaged Inspect Replace wheel noise Tread Flange treads Flange Patterned Wear on Inspect Replace wheel Tread Flange treads Flange Loose Wheel Check wheel end Follow detailed play detailed instructions at instructions at Section 5 4 amp 5 5 Section 5 4 amp 5 5 for appropriate wheel amp axle assy drawings Vehicle tracking to Misalignment Check Alignment Adjust Alignment one side wandering see Section 5 1 5 Overload or load Visually inspect Unload and or imbalance scale vehicle redistribute load Un Even Rail Wheel Weigh Vehicle and Adjust Load Load Vehicle Load Check Rail Wheel Distribution and Re Load set Rail Wheel Load Excessive Wheel Adjust Alignment Wear Check Alignment and Replace Worn Wheel Wear Wheels Insufficient traction Rail Wheel Load set See Section 5 1 5 Set Rail Wheel Load or braking too low Tires worn Inspect Tires Replace tires Table 3 3 1 A Troubleshooting On Track Problems 2012 DMF Inc All Rights Reserved 03 00 RW 1630 Routine Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 4 Derailment In the case of a m
141. n be used in any combination The two different types are Cable operated Air operated Remote pin offs are not installed at the factory to prevent damage during shipment Note Remote Front Pin Offs Shown w amp w o Air Cylinder Once cables are installed to pins route cables to easily accessible location for operator use preferably as near as possible to the front Railgear control valve In this location mount two cable handle mounting plates not supplied These plates should have a 3 4 hole to attach the handle end of the cable to Remove the T handle and the 5 8 11 hex end cap Thread the cable through the mounting plate and replace the 5 8 11 hex end cap Replace the T handle on the cable _1 wor DESCRIPTION REMOTE PIN OFF CABLE MORSE REMOTE T HANDLE 2 818571 P N 818700 FRONT CABLE REMOTE PIN OFF ASSY P N 818757 PIN OFF HOUSING WELDMENT 1 4 FENDER FLAT WASHER 5 16 HEX NUT 5 8 HEX NUT 1 4 C HEX NUT P N 818758 PIN OFF PIN 4 x 3 4 DIA w 1 4 20 7 16 INTERNAL LOCK WASHER 7 16 END MOUNT INSIDE FOR NE P N 818785 PIN OFF HOUSING WELDMENT 1 4 FENDER FLAT WASHER P N 818599 5 16 24 HEX NUT 5 8 HEX NUT P N 818709 CABLE HANDLE MOUNT 7 16 LOCK WASHER 7 16 FLAT WASHER 7 16 C HEX JAM NUT SEAL L 5 8 C HEX JAM NUT 5 8 INTERNAL TOOTH LOCK WASHER m KIT P N 818763 CABLE P O 3 4 PIN FOR BRAZ
142. n off measurement here probably means the front truck axle is misaligned and needs to be corrected After these alignment checks and after ensuring there are sufficient clearances the Frame Mounting Brackets can be tack welded to the Frame Extensions NOTE Do not attach the welding machine ground clamp onto the Rail Wheels This will cause arcing across the bearings inside the wheels and lead to premature bearing failure Raise the front Rail Wheels just above the floor enough to slide the front Installation Rails into place under the Rail Wheels Because the Railgear Axle assembly is not fixed to the Pivot Arms outside pivot arms will be completely welded to axle on inboard side at final weld out the Rail Wheels need to be centered To center measure the distance from the inside of the Rail Wheel to the truck frame If the measurements are off slide the Rail Wheels and Axle assembly to one side the Axle Tube will slide through the holes in the Pivot Arms Depending on the brake configuration used the Axle Tube will need to be rotated in order to locate front Railgear components in the right position The possible configurations are Without Brakes If the Railgear is not supplied with any brakes the Steering Wheel Locks must be aligned When the front Railgear is in the rail position these Steering Wheel Locks prevent the front truck wheels from interfering with the Railgear operation With Cobra Brakes If the Railgear is
143. neral and Section 3 0 Routine Maintenance In Section 3 0 you will find information about routine maintenance and inspection items on a daily weekly and bi annual basis 1 1 4 Repair Once you have read this entire manual there are some key sections that you may want to mark for convenient future reference including Section 1 0 General Section 4 0 Installation and 5 0 Technical Details In Section 5 0 Technical Details you will find several sections mainly composed of detailed system and assembly drawings Refer to the section that is related to your specific repair Also refer to Section 4 0 Installation and the related area within to ensure you are properly performing the repair as per initial installation requirements 2012 DMF Inc All Rights Reserved 01 00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 2 General Description DMF s RW 1630 Railgear is our original and very successful Railgear for large trucks The front guide wheel assembly attaches to the frame and front axle and lifts the front truck tires off the track thus utilizing the vehicle s front suspension This design supports the vehicle as it was intended and helps the truck navigate curves smoothly and damps out the effects of track irregularities The rear assembly attaches directly to the truck frame behind the rear axle tandem spring hangers It deploys with an articulating dual scissor action that allows the r
144. nment of the wheels to the rail you can also use the valve handles independently to lower one side at a time to engage the rail at which point you can then lower the opposite side This will cause your vehicle to side shift and align itself with the rail 8 When both wheels are in rail position and properly engaging rail replace safety pin off pins 2 3 3 Lower Front Guide Wheels 9 If necessary drive the truck into position to line up the front guide wheels with the rail 10 Ensure that the PTO is engaged this was engaged during the lowering of the rear Railgear 11 Ensure front safety pin off pins are removed 12 Check and make sure that the front guide wheels line up with the rail 13 Push valve handle to lower wheels and engage rail 14 If you do not require the use of the PTO for additional equipment it can now be disengaged 15 Disengage the truck s parking brake when you are ready to proceed NOTE The front guide wheel assembly is an over center design and does not require safety pin off pins engaged in rail mode 2012 DMF Inc All Rights Reserved 02_00 RW 1630 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1630 2 3 4 On the Tracks Do not exceed posted track speed limit and at no time exceed 30 MPH while on the track Be aware that some Railgear is insulated and will not operate the crossing gate circuits You are responsible for knowing if your Railgear equipped vehicle has insulated or non i
145. nsulated wheels To assist in identifying insulated rail wheels a grooved ring is machined around the inside of the front and rear driver s side wheels railroad rules and safety guidelines should be observed Reduce speed while in reverse and or at all crossings curves branch lines switches and frogs no more than a slow walking pace is recommended Traction is reduced on the track Braking distance is increased on the track Do not slide tires or guide wheels on the tracks as this will cause premature wear Do not exceed the maximum rated capacity of the equipment On newer trucks with Anti Lock braking systems the amber ABS dash light may remain on with the front wheels elevated This will not affect rear truck braking or rail wheel braking 2 4 Getting off of the Rail 2 4 1 Removing Truck from Track wu Q Safely pull onto the track crossing paying attention to traffic and other obstacles Set the truck parking brakes and engage the PTO Leave the truck running and the transmission in neutral gear Lift both sets of Railgear there is no preference for removal order Engage all 4 safety pin off pins in highway position passenger and driver side for both front and rear Railgear Disengage the switch that controls the Railgear brakes if applicable Disengage the PTO and the parking brakes Make sure surrounding area is free and clear of any obstacles and vehicles before pulling off of the rail and
146. nt mounting configurations to supply our customers with the perfect fit for their application These configurations fall into three main categories as listed below Each of these categories though similar requires varying installation procedures Please identify which category pertains to your application and familiarize yourself with the installation procedure prior to beginning 4 5 1 Traditional Long Arm Assembly This style of assembly is the most common and attaches to the front axle by way of a bracket attached to the leaf springs and to the chassis frame with a stationary pin This design allows the front rail wheels to ride on the chassis suspension alleviating vibration from track irregularities 4 5 2 Cargo Arm Assembly This style of assembly is normally used when chassis components such as a low hanging radiator or steering components prohibit the use of the traditional long arm configuration Itis attached to the chassis by way of brackets on the front leaf springs 4 5 3 Mid Mount Assembly This style of assembly is mounted either under or behind the chassis cab and is often used to meet strict curvature requirements For more information on Mid Mount Assemblies please see Section 4 9 and 4 10 2012 DMF Inc All Rights Reserved 04_00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 6 Traditional Long Arm Assembly Installation 4 6 1 General Information There are several items
147. olved in your order DMF offers both insulated and non insulated wheels Please confirm which wheel you need before ordering Insulated wheels can be identified by a grooved ring machined around the inside of the Rail wheel This grooved ring can been seen and felt and is located about an inch in from the outside tread DMF s links come in 3 sizes x short short and long The sizes cannot be mixed between upper and lower links i e Long upper link can only be used with long lower link Each link has a slotted version as well Links are sold individually unless you require an entire set of 8 4 front 4 rear See drawings for additional clarification on link type i e long short or extra short and the appropriate part numbers for ordering Note Short links are DMF s default configuration for our Railgear 2012 DMF Inc All Rights Reserved 05 04 01 Before Ordering Parts Rear Railgear doc DIVERSIFIED METAL FABRICATORS INC RW 1630 Cylinders Brakes also see drawing on next page e When ordering rear cylinders it is important to note which way the pin offs are facing if they are facing toward the rear of the truck then this is considered our standard mounting configuration then driver s side and passenger s side terminology is consistent with the layout of the vehicle HOWEVER if the pin offs are facing toward the front of the truck i e underneath the truck which is usually done to accommodate clearance is
148. ome circumstances government or corporate regulations may require additional inspections be performed Please ensure that you are aware of any inspection requirements that pertain to your Railgear and that you abide by all local and national laws regarding Railgear maintenance and safety 3 1 1 Daily e Visually inspect for hydraulic fluid leaks e Check and make sure that all threaded fasteners are secured NOTE All hex nuts are either nylon insert or slotted hex nuts with cotter pins e Check and make sure all tie straps that secure hoses from moving parts and exhaust systems are in place Replace if cracked or worn Inspect wheel flanges for excessive wear primarily noting differences in wear between wheels on the same axle or diagonally If an abnormal pattern is noted check Railgear alignment see alignment procedure in Section 5 1 5 e Inspect wheel end play Placing one hand at the 9 o clock position and your other hand at the 3 o clock position firmly grab the wheel and push and pull it a few times There should be no discernable movement in and out and the wheel should rotate freely If you feel there is too much movement in and out or if the wheel does not rotate freely a detailed inspection should be performed See Sections 5 4 amp 5 5 for appropriate axle assembly drawings Throughout the day inspect wheel temperature If extremely hot this could indicate bearing adjustment is too tight For adjustment informa
149. omponents DMF Behind Cab Front Railgear uses the RW 1650 axle and wheels Front Railgear mounted to truck frame behind the vehicle cab with 16 guide wheels GVWR Range 33 000 Ibs and above for heavy load applications Approx Installed Weight Front 1800 Ibs Capacity 70 000 pounds per Railgear axle 9 20 MPH For detailed drawings see Section 5 0 and for installation instructions see Section 4 0 2012 DMF Inc All Rights Reserved 01 00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 3 3 Under Cab Front Railgear Components DMF Under Cab Front Railgear uses the RW 1630 axle and wheels Front Railgear mounted to truck frame underneath the vehicle cab with 16 guide wheels GVWR Range 33 000 Ibs and above Approx Installed Weight Front 1700 Ibs Capacity 40 000 pounds per Railgear axle 20 MPH For detailed drawings see Section 5 0 and for installation instructions see Section 4 0 2012 DMF Inc All Rights Reserved 01_00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 1 4 Rear Railgear 1 4 1 Rear Railgear Components Including RW 1630 and RW 1650 DMF offers two different variations of Rear Railgear RW 1630 and RW 1650 The components are the same other than the axles and wheels which have different weight capacities RW 1630 GVWR Range 33 000 Ibs and above Approx Installed Weight Rear 1185 Ibs C
150. ontact DMF for replacements If torque indicators have moved you must follow this procedure to remedy the situation 1 The driver would remove the yellow torque indicator retorque the loose nut see torque specifications below and then replace with a red torque indicator DMF provides one red torque indicator per wheel This identifies the loose nut to the maintenance shop at a simple glance and they will know that the whole wheel must be carefully serviced To install a torque indicator place it over the nut with the raised collar resting against the wheel Push with both thumbs or a socket flush to the wheel 2 Most of the inspection stations know this system and will realize that the driver is aware of the loose nut and will pass him through to go to a maintenance shop e If the torque indicators have not moved this means that the nuts are secure and safe No torquing is required which means less tear on the nut and valuable time and money is saved e Ifa replacement bolt is needed DMF requires that you replace both bolt and nut at the same time Replace broken bolt with a 5 8 11 x 4 grade 8 bolt and replace nut with 5 8 11 Type C Prevailing Torque Nut A hardened washer must be used beneath the nut e The bolts that hold the Rail wheel tread to the Hub should be torqued to 120 foot pounds See drawings of DMF s two piece wheels on the following page Please contact DMF if you have any questions regarding our two piece wheels
151. ound to under the truck frame between the frame marks Subtract 29 from this measurement This is the amount of solid spacer flat bar only to be welded to each frame mounting bracket shelf This sets the bracket shelf at 29 when installed 4 9 2 Dismantle Now that you have determined where the Under Cab Railgear will install strip the truck frame in the area between the frame marks After the Railgear mounting brackets have been installed onto the frame mounted truck equipment tanks air dryers etc may be remounted over the Railgear mounts or they may be relocated further down the truck frame 4 9 3 Mounting The Railgear frame mounting brackets attach to the truck frame using 8 5 8 11 grade 5 bolts on each side These bolts use the same 4 hole mounting plates as used on the rear equipment installation After bolting the mounting brackets to the truck frame the 4 hole plates should be temporarily tack welded to the frame mounting brackets to prevent them from slipping and to allow for further adjustment during overall alignment by grinding off tack welds Final welding of these plates will be performed in Section 4 11 Overall Alignment Procedure 4 9 4 Axle Adjustment The rail axle may now be centered under the truck frame by sliding it transversely in the lower arm weldments Follow the established procedure for aligning Standard Front Railgear see Section 4 8 1 After centering the rail axle rotate the axle tubes to align t
152. ows the individual parts of the installed front Railgear Please familiarize yourself with these item descriptions as they will be used throughout this installation manual FRONT TRUCK 4 SPRING lt FRONT TRUCK AXLE TRUCK FRAME Item Description SPRING BRACKET SPACERS if required SPACER Top required RUBBER SPACER REAR MOUNTING PIN FRONT RAIL WHEEL PIVOT ARM FRONT CYLINDER LONG ARM FRONT MOUNTING PIN CROSS TUBE FRONT EXTENSION if required COBRA BRAKES if equipped Figure 4 6 2 A Diagram of Key Components OMANDUAWN pul 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 6 3 Frame Extension Installation Remove the truck s front bumper If frame extensions are not required please skip forward to section 4 6 6 Bolt the Frame Extension to the truck frame refer to Figure 4 6 5 A Make sure that the tilt of the cab s hood 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 Gr 8 or stronger bolts hardened steel washers and Gr 8 prevailing torque locknuts of the fasteners should be tightened per section 5 1 torque specs Also when choosing bolt make sure to use a bolt which has threads that begin past the joint seam See Fi
153. pends on the distance between the rear spring hanger and the web of the truck axle I beam The flat bar is to be welded securely to the spring hanger and attached to the axle U bolt as shown 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 8 Completing Front Installation 4 8 1 Align Front Railgear The front Railgear now is ready to be squared up and aligned Three measurements need to be taken to ensure that everything is aligned properly To align the Long Arms check 1 That they are parallel with each other and the truck frame The outside Long Arms should be the same distance apart at the Rear Mounting Pin as they are at the Front Mounting Pin This prevents the mechanism from binding during up down operation of the Railgear Also the distance from the Long Arms to the truck frame should be the same on each side 2 That they are the same distance forward Measure the distance from the Front Mounting Pin to a common point in the truck frame If the measurements are off square the Railgear by loosening the nuts on one spring hanger and moving forward on the truck spring and re tighten To check the Spring Bracket location check 3 That the Spring Bracket to truck axle distance is same on both sides Measure the distance from each Spring Bracket back to the truck axle Since the forward position of the Long Arms has been verified Check 2 a
154. r so that they can relay the information when placing your order e Returns DMF has a Return Authorization Procedure You must contact DMF for an RA before returning any parts for any reason Parts will not be credited without an RA e Labor In extremely rare situations on a discretionary basis and with prior approval DMF will reimburse certain specific labor costs If you feel this may apply in your situation you must contact DMF s Service Department for a Service Authorization Number SA No labor will be reimbursed without an SA SA must be included on your request for reimbursement e Please use driver s side passenger s side terminology instead of left right side when describing issues with your Railgear This ensures that everyone involved is clear about where the issue is occurring Other Considerations for Ordering Parts This is a list of considerations to make before placing a parts order with DMF There are many variations and customer requirements that we strive to accommodate and as a result the more information you can provide to us when placing an order the more likely that we will be able to help you quickly and efficiently e Cross Tubes Spring Hangers and Long Arms are available in a variety of sizes and lengths Please be sure to check drawings for details before placing your order Wheels e If you are a customer using special wheel profiles this is especially prevalent in Metros please
155. r Fine Or Coarse Thread Select The Appropriate Chart Below B Identify The Fastener Size Diameter And Threads Per Inch Select The Appropriate Row In The Chart Selected C Identify Grade Of The Bolt D Identify Whether The Bolt Is Plated Or Plain E Read Across The Size Row And Down The Grade And Plain Or Plated Column The Intersection Of Row And Column Gives Torque MATCHING FINE THREAD BOLTS COARSE THREAD BOLTS HEX NUTS RECOMMENDED TORQUE SAE J429 SAE J429 ASTM A574 FOR GR 8 W SAE J429 SAE J429 ASTM A574 GRADE 5 GRADE 8 ALLOY PREVAILING TORQUE NUT GRADE 5 GRADE 8 ALLOY 3 MARKS 6 MARKS KNURLED OD 3 MARKS 6 MARKS KNURLED OD E SIZE PLAIN PLATED PLAIN PLATED PLAIN DIA TPI TPI FTLB FTLB FTLB FTLB FTLB SIZE FT LB mae ee e op s ps CAES xm fo CNN TAES meu Je poer Jp jm we JD CN ENS CDM LUCAN EAEE IEEE ues BEA s uo oo f o sw SN T ZUM ELE EUN EON EUN LN j CONTRE ED UM GNE eae NEUES pa rier es wes v 11 4 12 1240 5 2010 1510 1885 1415 Ter
156. r information please see section 5 3 Hydraulic System Technical Information NOTE DMF only provides hydraulic hoses from front and rear control valves to Railgear cylinders Customer is responsible for all other system components tank diverter PTO pump filter pressure relief valve etc 4 3 1 New Hydraulic System for Vehicle without Hydraulic System If only DMF Railgear is to be installed and there is not an existing hydraulic system outfit the truck with a 5 to 7 GPM 2500 psi pump suction filter such as a Vickers OFSS 10 with an appropriate sized reservoir The tank should have a minimum of 1 one suction port 3 4 NPT 1 one 1 2 NPT return and a tank filler breather Fill the tank with Unax RX 46 hydraulic oil or equivalent If other equipment is to be installed in addition to your DMF Railgear you will need to adjust your tank specifications accordingly Once your new hydraulic system is installed if your vehicle is going to have multiple applications for the hydraulic system please proceed to Section 4 3 2 for instructions on installing a diverter valve Otherwise proceed to Section 4 3 3 4 3 2 Hydraulic System for Multiple Uses Railgear and other application s If the truck has an existing hydraulic system you must first install an appropriately sized pressure relief valve in the pressure line after the pump Install an appropriate sized diverter valve depending on pump volume in the pressure line after
157. rd side of the frame mounting brackets can be spaced out to a maximum clearance of 41 3 8 The Railgear is designed to fit a truck frame with as little as 29 G C 1 Measure from ground to 29 height between the frame marks on each side Determine what machinery probably transmission or plumbing is closest to the outside of the 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 frame along this horizontal 29 plane Measure on each side to determine what the closest distance is to the outside of the frame 2 If the nearest obstruction is more than 9 from the frame proceed to step 5 And use the truck frame width 3 Subtract the closest distance from the 9 shelf width This is how far you would space the frame mounting bracket out on that side to clear the obstruction 4 Add to the frame width of the truck twice the distance you figured for step 3 This will space both sides out equally 5 Is the distance from step 2 or step 4 less than 41 3 8 If not can you move Railgear to clear the obstruction Consult with DMF 6 The spacer distance found in step 3 will be added to the inboard side of each frame mounting bracket These spacers should be flat bar welded to the frame mounting bracket at each of the 4 vertical slots on each bracket Later you will drill through the slots spacers and truck frame to attach each bracket to the frame 7 Measure from the gr
158. re return to Section 4 12 for continued installation instructions With the front and rear Railgear both installed and each squared individually to the truck frame you must perform a final overall alignment of front to rear Railgear and also adjust the weight setting 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 12 Rail Test e Run vehicle forwards and backwards on rail e If available run the vehicle through curves and switches e Verify alignment by observing the wear pattern on the wheel and the behavior of the vehicle If adjustment is required refer to 4 11 Alignment 4 13 Final Weld out Front Railgear e Weld inboard side of outside pivot arm to axle tube all the way around e Fully weld on all sides front mounting blocks cross tubes to truck frame e If shims were required fully weld shims into place on all sides for each shim location Rear Railgear e Weld 4 hole mounting plate to rear frame bracket as shown in section 5 1 on Rear Installation Drawing e Ensure all spacers are firmly against side bracket and aligned with the rear mounting bracket then fully weld spacer to mounting bracket as shown in section 5 1 on Rear Installation Drawing e If multiple spacers are used spacers must be fully welded to one another on the rear and tack welded on the sides as shown in section 5 1 on Rear Installation Drawing 4 14 Install Dec
159. rformed with preference over this procedure A 5 25 12 USE 19260 INSTEAD OF HYDRAULIC OIL 7 16 11 REMOVED CYLINDER PART S FOR CYLINDERS GREATER THAN 04 5 DO NOT REED SENDER ESTING HONING DESCRIPTION ALLOW CYLINDER TO BOTTOM DURING J cR Eher ERATES PRODUCTION PROCEDURE 008 TESTING BLOCK ROD AGAINST GLAND WITH PIN 2255275 CYLINDER ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 AND 1 BLOCKS DRLL sizes 0 DRAWN BY APPD BY DATE DRAWING NUMBER REV SALE WAK 6 24 94 dy B DESCRIPTION L2 T TITLE SAE JIC 37 Degree Fitting Installation PURPOSE To Establish Production Methods For The Installation Of SAE JIC Medium Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 4000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With SAE JIC 37 Degree Flared Ends PROCEDURE A Inspect fitting components to ensure that mating parts are free of burrs nicks scratches or any foreign material B Align tube flare against nose of fitting body and screw on the nut finger tight clamping the tube flare between the fitting nose and the nut C Tighten the nut the indicated Flats From Finger Tight F F F T listed in the chart below Use a second wrench to hold the hose in proper alignment while tightening to avoid twisting the lay line
160. rode 8 AL7 10804 2 1 5 8 PIN OFF ASSY W CHAIN 17 108264 12 MOUNTING HEX NUTS 5 8 11 ESNA 8 108080 2 SLIDE TUBE WELDMENT 18 108266 16 STRAP MOUNTING BOLTS HHCS 5 8 11 x 1 1 4 Gr8 9 108100 4 HYDRAULIC CYLINDER ASSEMBLY 19 108268 16 LOCK WASHER 5 8 11 j 10 108200 1 BEHIND CAB AXLE ASSEMBLY 20 108045 2 PIN OFF ASSEMBLY AUXILIARY 11 108250 4 MARSHMALLOW SPRINGS CENTURY DM 0376 6 x 1 5 21 108044 2 CHAIN 3 16 x 127 22 787590 2 AIR BRAKE ASSEMBLY see PAGE 17 for MORE DETAILS 1650 amp BEHIND CAB WHEELS NON INSULATED 1650 WHEEL w RACES 800015 INSULATED 1650 WHEEL w RACES 800016 INSULATED 2 PIECE 1650 WHEEL w RACES 820496 NOTE SPECIAL PROFILE WHEELS PLEASE CALL 1650 amp BEHIND CAB BEARING RACE TIMKEN 6420 BEARING RACE 800125 Qn LOCATE HOLES TO CLEAR OTHER HARDWARE ON FRAME o o o o 8 11 10 CHANGED ITEM 7 108042 TO P N 108041 5 24 10 ADDED ITEM 15 NOTES amp PARTS LIST REFERENCE TABLES DESCRIPTION TOLERANCES 7 TITLE UNLESS SPECIFIED erae unes fE 1732 1 RW 1650 BEHIND CAB FRONT RAILGEAR ASSEMBLY DIVERSIFIED METAL FABRICATORS INC 404 875 1512 SEE DRAWING M1630103 FOR REAR PARTS amp WHEEL ASSEMBLY PROCEDURES ALIGNMENT PROCEDURE A STEPS 1 and 2 must be completed in listed order and are
161. ruck where crossmembers span the truck width over the frame Also space above the 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 frame brackets needs to maintained in order to provide access for hydraulic hose routing to the guide wheel unit cylinders 4 10 2 Dismantle Now that it has been determined where the behind cab unit will be installed strip the frame in the area between the frame marks It may also be necessary to remove one or two rows of truck crossmember bolts in order for the frame brackets to fit flush against the truck frame The Railgear attaching hardware will replace the crossmember bolts After the Railgear has been installed the frame mounted truck equipment may be re mounted partially over the Railgear frame brackets or farther down the truck frame NOTE Accessibility to the Railgear must be maintained for pin offs normal maintenance and or repairs 4 10 3 Installation The behind cab unit has been shipped to you completely pre assembled However do not attempt to install the unit on the truck as received First remove the lower axle straps and the elastomer springs including connecting rods This will detach the lower axle assembly which along with wheels and brakes will be installed later Using floor jacks raise each bracket assembly up against the pre determined frame location both sides Clamp the brackets securely to the tru
162. s should familiarize themselves with the modified clearance amp approach angles Pin off Systems and Locations Walk around vehicle and identify the location and type of pin off system s that are installed on this particular vehicle Please note that front and rear Railgear may have different types of pin off systems i e front may be manual while rear may be cable pin offs See section 5 2 for more information on pin offs DMF offers the following Pin Off options e Manual Pin Offs e Cable Remote Pin Offs e Air Remote Pin Offs NOTE DMF s Rear Cylinders are equipped with integral locking valves however pin offs are still required in both the rail and highway positions Operation Controls e Locate and familiarize yourself with the front and rear Railgear operating controls e Locate Power Take Off PTO toggle switch control and indicator light typically found on the dashboard e If your truck is equipped with Railgear brakes locate the brake switch on the dashboard of the truck e Identify the type of steering lock used on your truck 2012 DMF Inc All Rights Reserved 02 00 RW 1630 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1630 2 1 2 Daily Inspection Before operating your Railgear equipped vehicle whether for highway or rail use it is imperative that you perform a daily inspection see Section 3 1 1 for Daily Inspection List If any items found during your inspection do not conform to requirements
163. se the ABS light to illuminate In this condition the brakes will still function but the ABS system will not If the amber ABS dash light remains on during rail operation the truck engine must be turned off and restarted after returning to highway operation This will clear the ABS light after a few seconds If the amber light remains on during road operation the truck s brake system may have an active fault and should be checked out Please refer to the truck s operation manual 2012 DMF Inc All Rights Reserved 01_00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 amp RW 1630 50 This page intentionally left blank 2012 DMF Inc All Rights Reserved 01 00 RW 1630 General Information doc DIVERSIFIED METAL FABRICATORS INC RW 1630 2 0 OPERATIONS 2 0 Operations 2 1 Before You Operate the Railgear 1 1 Familiarize Yourself with the Railgear 1 2 Daily Inspection Highway Operation Getting on the Rail 1 Getting onto the Rail 2 Lower Rear Guide Wheels 3 Lower Front Guide Wheels 4 On the Tracks Getting off of the Rail 4 1 Removing Truck from Track 2 1 Before You Operate the Railgear 2 1 1 Familiarize Yourself with the Railgear Clearances amp Approach Angles The installation of Railgear typically reduces the ground clearance amp approach angle in the front and back In some installations the guide wheels extend slightly beyond the corners of the front bumper Operator
164. sh Production Methods For The Assembly Of Cylinders COMMON USAGE All Models PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE D M F Manufactured Hydraulic Cylinders With PolyPack Piston Seals ASSEMBLY PROCEDURE PISTON A Inspect for sharp edges Deburr as neccessary B Clean and blow off with shop air C Use Blue Assemblee Goo 19260 to aid assembly D Install two 2 seals with each lip o ring insert side facing the closer piston face GLAND A Inspect OD and bore for sharp edges Deburr as neccessary Clean and blow off with shop air n Use Blue Assemblee 9260 to aid in assembly Install wiper ring in bore with lip facing outboard Install seal in bore with lip o ring insert side facing inboard Inspect for seal damage Any shaved seal material requires replacement Install backing ring in O ring groove on OD with concave surface facing inboard Install O ring on inboard side of groove in Step G Inspect O ring for damage ROD ASSEMBLY Clean and inspect shaft surface for scratches and dings Install grease fitting in rod end per 1 Use Blue Assemblee Goo 19260 to aid in assembly Install gland assembly onto rod with the outboard side facing the rod end Install rod O ring onto threaded end of rod Inspect O ring for damage 1 Install piston assembly onto rod with the O ring counterbore facing O ring in Step E Be certain that O ring seats in counterbore Instal
165. sition Screw nut down to port face until finger tight F Tighten lock nut adjustable or fitting non adj the indicated Flats From Finger Tight F F F T in either the Adjustable chart or the Non Adjustable chart below One Flat on a hex is equal to 1 6th of a full turn Tolerance on tightening is plus or minus 1 4 flat 1 24th of full turn G Inspect to ensure that O Ring is not pinched and back up washer hex seats flat on face of port ADJUSTABLE FITTINGS EIE SNP Size Thread Size F F F T is x s xe fs NON ADJUSTABLE FITTINGS E Be en Size Threod Size F F F T a wem io 74 pem o s ewe is 0 ve AJ j DESCRIPTION OLERAN TITLE PRODUCTION PROCEDURE 003 O RING FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 FRAC ware 8 1 X 063 Xxx OR 304 ANGULAR 24009 DRAWN BY APPD BY DATE DRAWING NUMBER THREADS 2A AND 28 TSH 06 02 94 Ee T O Ef TITLE National Pipe Thread NPT Fitting Installation PURPOSE To Establish Production Methods For The Installation Of NPT Medium Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Operating With Petroleum Based Fluids At Pressures Below 3000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With Tapered Pipe Threads PROCEDURE A Inspect port components to ensure that male
166. sues when installing air remote pin offs terminology is reversed In that case the driver s side cylinder is actually on the passenger s side of the vehicle and should be ordered as the driver s side The reverse applies for the other side of the vehicle If you are unsure or have questions please speak to an DMF parts representative for clarification e Note that there are two sizes of rear cylinders Standard and Extra Short The only difference between these two cylinders is their barrel length so please confirm the length of your cylinder and select the appropriate drawing for part numbers Rear Mounting Bracket e tis important to know your rear frame width first and then refer to the Rear Frame Drawing and use the provided chart to find your part number e Itis also important to note the thickness of the rear mounting bracket flat plate because we offer different thickness e Please note the height of your rear mounting bracket side plates because we offer different heights Shims are available to adapt wider brackets to different frame widths If your exact measurements are not available on the parts list please discuss this with the DMF Parts department and we will work with you to get the appropriate rear bracket and necessary shims 2012 DMF Inc All Rights Reserved 05 04 01 Before Ordering Parts Rear Railgear doc PIN OFFS TO REAR OF TRUCK BEFORE ORDERING REAR CYLINDERS LINKS AND OR BRAKES ONLY STAND
167. supplied with Cobra Brakes factory installed then they need to be rotated around so that they are oriented in the correct position see Section 5 2 4 For the rest of the brake installation see Section 5 2 4 With the Axle Tubes now centered and brake configuration determined the Axle Tubes should be temporarily tacked to the inboard side of the outside pivot arm at final adjustment the 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 tacks can be ground off and the axle re adjusted if necessary Once final install is complete the axle tubes should be fully welded all the way around The inside Pivot Arms should not be welded to the Axle Tube to facilitate ease of disassembly for repair or future maintenance The front Railgear is ready to be lowered on the Installation Rails As the Railgear is lowered check the clearance from the truck tire to the Rail Wheels If there is any interference stop lowering the wheels and retrace the installation steps to fix the problem When the Railgear is completely lowered the front truck tires should be approximately 2 inches above the Installation Rails If Railgear will not lift the truck check that the cylinders are not cross plumbed that the system pressure relief valve if present is set high enough and that the pressure relief on the Front Railgear Valve is set high enough As a final review recheck the center alignm
168. t the Railgear installation process It is important to note that there is a difference between shims and spacers Shims are vertical fillers used to fill in the gaps between the truck frame and rear mounting bracket side plates Spacers are solid steel pieces varying in thickness used between the rear mounting bracket and the bottom of the truck frame to achieve proper weight settings between the truck tires and rail wheels while on rail Spacers see 4 4 6 used in adjusting the height of the rear bracket must be solid steel pieces because they will experience the full structural load seen by the rear frame When setting the height of the rear bracket using spacers you must be within the range of gt minimum to 3 of spacers maximum If you are outside of this range it may be necessary to change out your links See Section 5 4 for different link measurements and contact DMF for final consultation before ordering a different set of links DMF will not be responsible if the links are changed from the initial order without consulting with DMF Before permanently affixing your rear bracket to the truck frame including welding or drilling holes be aware that during the locating shimming if necessary spacing squaring and weight setting procedures your rear bracket will be making slight movements during each of these steps So you will want to only TEMPORARILY secure Railgear using clamps chains fork lift etc after each proce
169. the jack raise the spring hanger up toward the truck s leaf springs You will raise and lower the long arms until the Rear Mounting Pin is 12 3 4 1 2 from the floor See figure 4 6 5 A Once you achieve the desired height insert 1 x2 flat bar spacers between spring hanger and leaf spring up to a maximum of 4 If you need more than 4 of spacers a change of spring brackets may be required see section 5 5 for spring bracket information Contact DMF for assistance Once spacers are in place with spring bracket at the appropriate height attach the Spring Bracket to the truck spring using a Rubber Spacer already supplied directly on top of the leaf springs and then a 1 x 2 flat bar Spacer already supplied on top of the Rubber Spacer and two 3 4 10 hex nuts per stud The top Spacer has no effect on the height of the Railgear and is only used for clamping purposes The nuts should be tightened down until the Rubber Spacer begins to deform from the downward pressure Caution Do not over tighten Repeat process on passenger side ensuring that the back of spring hanger to front of axle web dimensions are equal on both sides Route and Attach Hydraulics 4 5 6 Route all hydraulic lines as shown in Section 5 3 1 Engage the PTO and allow hydraulic circuit to self bleed Inspect all connections for leaks and tighten as necessary Mounting Front Spring Bracket 1 2 Ensure that both spring bracket h
170. tion see Section 5 4 amp 5 5 for appropriate axle assembly drawings If your vehicle is equipped with DMF two piece wheels check the bolt torque indicators the tabs around each bolt to ensure that they have not moved If torque indicators are missing or damaged please contact DMF for replacements If torque indicators have moved you must check bolt torque see Section 5 2 6 for additional information 2012 DMF Inc All Rights Reserved 03 00 RW 1630 Routine Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1630 3 1 2 Weekly Perform standard daily inspection points as listed above and then check the following Grease and lubricate all grease fittings on front and rear Railgear and guide wheel assemblies NOTE There are six 6 locations on front assembly and fourteen 14 locations on rear assembly See Drawing 3 4 2 for details e Check level of hydraulic oil and all other fluids e Check air pressure in tires and inflate to proper inflation pressure if necessary Inspect brakes and adjust if necessary Refer to Section 3 5 1 e Brake Testing Operate the vehicle on a test track With the on off toggle valve on and the ball valve s open check that 1 When the vehicle brake pedal is depressed the guide wheel brakes clamp the Rail wheel enough to begin slowing its rotation but not enough to totally lock the Rail Wheel The Rail Wheels should not be allowed to lock up since that will cause a
171. to note before you begin the installation of the front Railgear Railgear unit that we have shipped to you has been designed for your specific truck However before starting the front Railgear installation check the vehicle s front tire spacing The front Railgear operates between the front steering tires therefore you must have a minimum of 65 between the tires If this is not the case contact DMF e Check to see if Frame Extensions are needed As seen in figure 4 6 5 A measure your long arm from front to rear mounting pin hole to determine dimension C Starting from approximate installed location of rear mounting pin point B on figure 4 6 5 A extend a tape measure to the length found in dimension C Raise end of tape measure up toward truck frame if you contact suitable mounting location no frame extensions should be needed If the end of the tape measure is beyond the front of the truck frame then front frame extensions are likely required Please contact DMF if you have any questions or for ordering information Also see section 4 6 3 for Frame Extension installation instructions e Check for sufficient clearances to prevent interference with Railgear and other parts of the truck ie Frame steering boxes shocks oil filters etc See section 4 6 7 for complete Clearance Note If notable clearance issues are found please contact DMF prior to continuing installation 4 6 2 Diagram of Key Components Figure 4 6 2 A sh
172. uctions of the pin off assembly See Drawing on Next Page 4 9 7 Completion Finish installing rear Railgear options hydraulic system etc as per the standard Railgear installation instructions 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc REMOTE AIR PIN OFF OPERATION PIN ENGAGE PUSH TO PIN DIS ENGAGE Ay RED LIGHT ENGAGE GREEN LIGHT ps O O O ns PULL TO s 7 DIS ENGAGE O Ps 818754 FRONT VIEW OF LEGEND PLATE APPLY ANTI SEIZE TO LOCK PIN SEE INSTALLATION NOTE ADJUST TO I UU LE WIRING DIAGRAM EACH SIDE NOTE EACH SIDE MUST BE INDEPENDENT OF THE OTHER IN ORDER TO FUNCTION PROPERLY DO NOT WIRE IN SERIES ITEM PART NO DESCRIPTION AL 818743 2 HOUSING WELDMENT AIR PIN OFF A 2 818747 2 PIN OFF PIN 2 81878 2 TRAVEL STOP amp JAM NUT CRR 270 818755 2 AIR CYLINDER 1 1 16 BORE x 1 STROKE 818751 4 PROXIMITY SWITCH NNB2 12GM50EO 81872 2 REDLED 818733 2 GREENLED 9 8187 4 1 LEGEND PLATE 10 81856 2 JAMNUT 5 8 18 11 818587 AIR PIN OFF FITTINGS 269PMT 4 2 1869 45 12 818591 4 AIRLINE FOR REMOTE PIN OFF 1 4 SYNFLEX 04 13 81853 1 AIR CONTROL VALVE BUYERS VALVE NOT SHOWN APPLY LOCKTIGHT TO THREADS OF CYLINDER ROD BEFORE INSERTING INTO ITEMS 2 amp 3 THIS SENSOR CONNECTS TO THE GREEN LED 5 ADJUST SWITCH TO GAP SHOWN THIS SENSOR CON
173. ween the cross tubes amp the bottom of the frame to obtain the desired 25 1 2 from ground to Front Mounting Pin 4 6 6 Mount Front Railgear Mounting spring bracket hangers 1 Remove the truck s front bumper 2 Slide the front Railgear under the truck frame positioning the spring bracket hangers as close as possible to the front truck axle Make sure at least half of the spacer is seated on the leaf spring closest to the front truck axle If the spacer is not at least half seated move spring bracket hanger forward to next leaf spring 3 Once positioned place a floor jack under the outboard and inboard long arm close to the spring hanger on the driver s side Using the jack raise the spring hanger up toward the truck s leaf springs You will raise and lower the long arms until the Rear Mounting Pin is 12 3 4 1 2 from the floor See figure 4 6 5 A 4 Once you achieve the desired height insert 1 x2 flat bar spacers between spring hanger and leaf spring up to a maximum of 4 If you need more than 4 of spacers a change of spring brackets may be required see section 5 6 for spring bracket information Contact DMF for assistance 5 Once spacers are in place with spring bracket at the appropriate height attach the Spring Bracket to the truck spring using a Rubber Spacer already supplied directly on top of the leaf springs and then a 1 x 2 flat bar Spacer already supplied on top of the Rubber Spacer and two 3 4
174. y Installation 4 7 1 Front Cargo Arms 4 7 2 Diagram of Key Components Front Mounting Dimensions 4 7 3 Mount Front Railgear 4 8 Completing Front Installation 4 8 1 Align Front Railgear 4 8 2 Final Steps 4 9 Under Cab Front Unit Installation 4 9 1 Under Cab General Information 4 9 2 Dismantle 4 9 3 Mounting 4 9 4 Axle Adjustment 4 9 5 Welding 4 9 6 Remote Air Pin Off Installation 4 9 7 Completion 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 10 Behind Cab Front Unit Installation 4 10 1 Behind Cab General Information 4 10 2 Dismantle 4 10 3 Installation 4 10 4 Completion 4 11 Overall Alignment Procedure 4 11 1 Overall Alignment Procedure and Final Weight Adjustment 4 12 Rail Test 4 13 Final Weld out 4 14 Install Decals 4 15 Installation Review Checklist 2012 DMF Inc All Rights Reserved 04 00 RW 1630 Railgear Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1630 4 1 Pre Install NOTE The proper installation of this equipment is solely the responsibility of you the installer When in doubt contact DMF for assistance NOTE During Railgear installation there are 3 different alignments front Railgear to truck frame rear Railgear to truck frame and a final procedure that aligns both sets of Railgear to each other 4 1 1 Safety Statements e Always block up gear before getting underneath e Always use jack stands when j
175. y that obstructions such as PTO components or pumps will be a problem Furthermore the mounting shelf of each frame bracket is only 4 wide which eliminates any horizontal protrusion into the area between frame members at the 29 plane Measure from the ground to under the truck frame between the established frame marks Subtract 29 from this measurement This is the amount of solid spacer flat bar only to be welded to each frame mounting bracket shelf This sets the bracket shelf at 29 when installed and also adds to the clearance under possible obstructions between the truck frame rails The design width of the behind cab unit between the inboard side of the frame mounting brackets is 35 To determine the amount of space required between the truck frame and Railgear each side measure the outside width of the truck frame and subtract that distance from 35 This amount divided by 2 will space both sides out equally Flat bar shims are furnished to use as spacers Tf additional shims are necessary they must conform to the shape of the furnished part except for required thickness These shims are to be securely welded to the inside of the frame mounting brackets Depending on truck frame depth and vertical spacing required to achieve the 29 unit installation height the frame mounting brackets may protrude above the top of the truck frame by as much as 4 to 5 inches This must be taken into consideration if the unit is installed on a flat bed t

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RW-1630 & RW-1630/50*