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RW-1015 Manual

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2. 9 8 NOTE HAND PUMP MUST BE PRIMED AT FINAL INSTALL SEE SECTION 4 6 2 NOTE FOR ELECTRICAL DIAGRAM SEE DRAWING 600601 REAR 10 18 11 REDRAWN TO SHOW PICTORIAL VIEWS ADDED KIT COLUMN IN 110 6 11 ADDED PRIMING REFERENCE SWITCHED PORTS A amp B WHERE SHOWN NEH ADDED LOCKING VALVE W ORIFICE amp FTGS 600611 CHG D LOCKING VALVE DETAIL amp REMOVED ITEM 2 FTGS ADDED DIRECTIONAL VALVE PORT REFERENCES DESCRIPTION TOLERANCES TITLE UNLESS SPECIFIED ASS Y RW 1015 HYDRAULIC SYSTEM RW 1015 XX DIVERSIFIED METAL FABRICATORS INC 404 875 1512 0 DRAWN APPD BY DATE DRAWING NUMBER SURF FINISH 125 MICRO THREADS 2A AND 2B JBG 6 01 09 600550 12VDC I e a TERMINAL X BLOCK lt 207 IGNITION RED22 MAIN PWR CT 5 MASTER PNK22 WITHOUT IN CAB CONTROL TERMINAL BLOCK 16GA GXL 4GA to 1 0 WELDING WIRE KIT 600709 INCLUDES ITEMS 5 THRU 21 SELECTOR A 89 w G JB T B gt 16 4 50 8 DRAWING 600550 4 DETAIL FOR WIRIN
3. AS VIEWED FRONT gt WELD AS WELD AS DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 3 61 NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD ENSURE THAT WELDS DO NOT INTERFERE WITH OPERATION OF THE RAILGEAR I lt WELD ENTIRE LENGTH OF ADJ lt gt Q L BRACKET TO REAR FRAME A BRACKET ALONG THE REAR SIDE I RAIL WHEELLOAD ALIGNMENT ADJUSTMENT T IS ACHIEVED BY MOVING THE ADJ L BRACKETS VERTICALLY SEE SECTION 3 4 ALIGNMENT ADJUSTMENT IS ACHIEVED BY WAY OF MOVING THE ADJ L BRACKETS FORE AND AFT 708 4X sq washers 8X flat washers 6X lock nuts amp 6X 2 75 long bolts REAR FRAME BRACKET ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 SECTION A A NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS
4. u N N 5 a N I FOR INSTALLATION USE DWG 1015103 RAILSWEEP ASS Y FRONT REAR SET P N 600236 REDRAWN 600412 QTY 2 CHANGED TO 600412 DS AND 600429 PS 600364 WAS B 10 19 12 600336 A 8 29 11 600340 QTY 2 CHANGED TO 600340 DS AND 600349 PS REV DATE DESC RIPTION BY TOLERANCES IME UNLESS SPECIFIED FRAC MACH 132 RW 1015 FRAC OTHER 1 16 x 063 020 DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 KIT 600708 VERTICAL PLATE TO TRUCK FRAME AND HARDWARE auae or i SURF FINISH 125 MICRO KIT 600714 VERTICAL PLATE RAILG EAR BRKT AND HARDWARE DA ANDR 10 06 09 600109 ASSY REAR 08 09 F2 350 FORD STW FORD F250 350 4WD FORD F250 350 2WD FRONT FRAME MOUNT BRACKET 600390 PS OUTER 600389 5 M 600391 X 600394 DS OUTER 00 PS OUTER 600392 600393 DS INNERN 00 5 600320 LONG PIVOT ARM 600311 SHORT PIVOT ARM REAR BRACKET 600364 LONG REAR BRACKET 600365 SHORT REAR BRACKET I REAR PIVOT ARM 600340 LONG PIVOT ARM DS 600349 LONG PIVOT ARM PS SAME AS 4
5. DATE DESCRIPTION BY APP NOTE LONGBED ASSY SHOWN purum THLE UNLESS SPECIFIED FRAG MACH 1 32 FRAC OTHER E RW 1015 x x DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES ANGULAR DRAWN BY APPD BY DRAWING NUMBER FOR INSTALLATION SEE DRAWING M1015107 TREADS NS NEH 600161 ASSY REAR 11C25 3500HD RW 1015 STW YOU ORDERED MANUAL PIN OFFS SEE SECTION 5 2 FOR DRAWINGS amp INSTALL INFORMATION RAILSWEEP ASS Y FRONT REAR SET P N 600236 PASSENGER SIDE Starting w serial 29900 use p n s 600264 or 600266 o M VEHICLE FRONT rm 2 PART NUMBER DESCRIPTION SW Comments Comments 600201 ref note ASSY RAILWHEEL STW WHEELSPINGLE TREAD 600264 266 has spindle w nut 600311 WLDMT PIVOT ARM FT RW 1015 600220 DETAIL SUSP PRIMARY RW 1015 BO FT FRAME BRACKET RW 1015 C25HD DETAIL SUSPENSION PRELOAD RW 1015 ASS Y CYLINDER 2 FT RW 1015 FLAT WASHER 1 STD SLOTTED HEX NUT 17 8 WELDMT PIVOT PIN FL RW 1015 1 2 13 X 6 LONG GR8 HX HD CAP SCREW FULL THD FLAT WASHER 1 2 DET SLOT FLAT BAR 1 2 KIT ALSO SEE NO 1 2 FLAT WASHER ALSO SEE NO NA ESNA LOCK NUT 1 2 13 ALSO SEE NO 1 2 13 HCS1 2 13X6 1 2GR8 1 2 13 X 6 50 LG GR8 HX HD CAP SCREW KIT ALSO SEE
6. HNUT 0 5000 13 D N 5 gt 5 NIH s sN OD PLACE SILICONE SEALANT ON INNER AND OUTER SURFACE OF INSULATOR SLEEVER SEE 1015106 FOR WHEEL AND SPINDLE EXPLODED VIEW AND ASSEM BLY PROCEDURE 9 4 12 P N 600214 WAS 600211 9 6 2011 SPINDLE ASM EXPLOSION AND BOM MOVED TO M1015106 DATE DESCRIPTION BY APP TOLERANCES UNLESS SPECIFIED FRAC MACH 132 FRAC OTHER 1 16 x 063 030 005 RW 1015 TLE MANUAL GEN3 AXLE SPINDLE WHEEL ASSY amp PARTS DIAG RAM RW 1015 DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 DRILL SIZES 015 ANGULAR SURF FINISH 125 MICRO DRAWING NUMBER M1015104 PARTNUMBER 500070 500075 500100 500144 QTY DESC RIPTION 4 DETAIL RAILWHEEL 1013HD 1 DETAIL RAILWHEEL RW 1013 15HD SIW 4 BEARING RACE TIMKEN 25520 1 TREAD RUBBER 600199 1 DETAILSPINDLE HD G EN3 10596 T WASHER TO NG UE TIMKEN K 91508 10599 al DET SLHN 1 9 16 18 AFBMAx14SL 2 1 1 1 4 4 1 RUBBER TREAD WHEEL RTW WHEEL ASSEMBLY PART 500071 WHL amp SPINDLE ASM PART 600271 500102 BEARING CONE 500108 SEAL N412920 C R22532 500073 BO HUBC AP SPACER 1015HD LO C KING 500078 BO HUBCAP 818425 LW 10 605009 SO CKETHEAD CAP SCREW 10 24 X 1 100263 PIN 1 8 X 2 1 2 Whe
7. DESCRIBED NOTE 3 DESCRIBED NOTE 3 SECTION 072 CLAY AND CNN NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT perce UNLESS ER EI PONTAS Nem MAC OTER 1 32 RW 1015 RW 1015 BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND THE MATE Tx ox DIVERSIFIED METAL 404 875 1512 OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE Eons DRAWING NUMBER REV TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE 05 fown Ja DATE THE WELD moo NEH 9 26 11 M1015109 B SHARP EDGES 4 KIT 600172 INCLUDES 6 1 2 13 X 2 3 4 GRADE 8 BOLTS 12 1 2 GRADE 8 FLAT WASHERS MATCH DRILL 1 2 HOLES 6 1 2 13 GRADE 8 NYLOCK NUTS THROUGH INNER FRAME WEB ONLY 3 EACH SIDE RAIL WHEEL LOAD ALIGNMENT ADJUSTMENT RAIL WHEEL LOAD ADJUSTMENT IS ACHIEVED BY MOVING THE L BRACKETS VERTICALLY SEE SECTION 3 4 r ALIGNMENT ADJUSTMENT IS ACHIEVED WAY DRIVER S SIDE 7 MOVING THE L BRACKETS FORE AND AFT ONCE THESE PROCEDURES HAVE BEEN COMPLETED AND VERIFIED WELD WASHERS AND 3 HOLE PLATETO THE ADJ L BRACKET ALONG FULL LENGTH OF TOP AND BOTTOM EDGES KIT 600714 INCLUDES 4 5 8 11 X 2 3 4 GR8 BOLTS SHORT BED 4 500510 SQUARE WASHERS NOTE SHOWN FOR VISUAL REFERENCE 4 SN INSTALLATION PROCEDURE IS COMPARABLE
8. DRAWING NUMBER REV DIAGRAM REFERENCE DRAWING 600161 9 13 11 M1015107 FOR INDIVIDUAL PARTS LIST OR PARTS ORDERING REFER DRAWING 600101 4 600706 M 600705 7 _ WELD ALL WASHERS TACK ON 4 SIDES 6 E ES dtp SPACERS ARE TO GO ON THE UPPER TWO SLOTS OF THE OUTBOARD SIDE OF THE INNER FRAME BRAC KET FOR BO TH THE PASSENG ER amp DRIVER SIDES INCLUDED IN KIT 600706 ALIGNMENT ADJ USTMENT THE SLOTS IN THE FRAME MOUNTING BRACKET ARE SLIG HTLY WIDER THAN THE BOLTTO ALLOW FOR SLIGHT ADJ USTM ENTS FORWARD OR BACKWARDS KIT 600706 8x sq washers 4x block spacers 4x lock nuts amp 4x 6 5 long bolts RAILWHEEL LOAD USIMENT MOUNTING SLOTS ONCE RAILWHEEL LOAD USIMENTAND V ALIG NMENT IS FINAL ALL WASHERS MUST BE LL WELDED INPLACE ON BOTH THE OUTBOARD amp 1 G INBOARD FRAME BRACKET FOR i DRIVER PASSENG ER SIDES a KIT 600705 4x flat washers 4x lock nuts 4x 6 25 long bolts 2x front frame mount brkts amp 4x tubes amp 4x rectangular plates df WELD ALL WASHERS TACK ON 4 SIDES IF SHIMS ARE REQUIRED BETWEEN U BRACKET AND FRAME
9. 07 SI 84445 WAWIXVW JHL 9NIQV3M 380438 ANIHDVW SIHL 3494340 LON OG _ 20 om o gt 2 MO m zu LF aa gt IG mo Zin o gt Za P ma En an m 22 o 3 TOIH3A 31 1 0 SIHL 40 SOILSIMSLOVYVHD 9NITONVH d39V9N3 SI 9201 ONIYSSLS ANY LHOIVULS 544 ONIYIILS JHL LVHL MI3HO NOILV 3dO 380438 DIVERSIFIED METAL FABRICATORS INC ATLANTA GA 404 875 1512 800161 ALUTISISIA YO 4004 dO SV3sVv NI ANY SINONENL HONOYHL SONISSOND LV WOVYL 435541 NO 44345 32034 IVNOS H3d 383A3S NI 110548 AVW OS Od OL 3snrTiv IWANVW 32IAMH3S SLUVd NV SNOI gt m 4 c e o lt gt lt m 4 E z rm lt m m 70 40 2 gt I 2 c c 25 IVNOSS3d 383A3S 110544 AVIA HI RAIL VEHICLE COMPLETED BY WITH APPLICATION OF HI RAIL AND FINISHED BODY THIS VEHICLE HAS POUNDS OF AVAILABLE PAYLOAD DATE OF COMPLETION OF HI RAIL EQUIPPED VEHICLE mo yr CAUTION THIS MUTIPURPOSE VEHICLE HAS SPECIAL DESIGN AND EQUIPMENT FEATURES FOR OFF ROAD USE IT HANDLES DIFFERENTLY FROM THE ORIGINAL VEHICLE 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
10. LONG BED 1 213 GRADE 3 HOLE PLATE TO BE FLIPPED NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME 39 UPSIDE DOWN INSTALLATION NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE REQUIRES BOLTS BE NEAR THE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 9 icm TOP OF THE GIVEN SLOTS WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL p d ka CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS p NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT 4 BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE S lt gt GEAR TO HIGHWAY POSITION ORDER COMPLETE THE WELD ENSURE WELDS DO INNER FRAME PLATES 73 NOT INTERFERE WITH GEAR OPERATION FLUSH TO TOP OF FRAME 7 2 SS KIT 600171 INCLUDES WELD REAR EDGE OF E gt 6 5 8 GR8 FLATWASHERS 5 ADJUSTABLE L AGAINST ADJ L BRACKET AND ALIGNED BRACKETS TO THE CROSSPLATE WITH CROSSPLATE WELD SPACERS gt CROSSPLATE ONE ANOTHER AND TO THE MAIN L CROSSPLATE AFTER FINAL ALIGNMENT p 5 MAX SPACERS AND RAIL WHEEL LOADS H
11. 515027 STEERING STOP PS 00 12 F 2 350 4X2 00 5 5 5 5 5 SUPPLIED W 10852 TORQUE 5 9 FT LBS 09 63 TORQUE 300 FT LBS TRUCK HUB REAR SHOWN STOCK LUG NUTS TORQUE TO 165 FT LBS Figure 1 Installation Exploded Parts Diagram 2012 DMF Inc All Rights Reserved Page 1 of 4 Recommended Tires Mud Snow All position Goodyear G622 225 70R19 5 Michelin XDS2 225 70R19 5 Steer Highway Goodyear G647 225 70R19 5 Installation Warning Never use anti seize on studs or lug nuts Hand torque all fasteners to the provided specifications using a torque wrench Improper installation or failure to perform a thorough check for clearances once this unit is installed may lead to damage to the chassis wheels tires or personnel Install TPMS sensor into 19 5 rims as shown in Figure 1 Install and Inflate 19 5 Tires a Mount and balance tires b Inflate tires to a cold pressure of 85 psi Remove Stock Wheels amp Tires a Lift the vehicle and properly support using jack stands b Remove the stock wheels and tires retaining the stock lug nuts for reuse Install Steering Stops a Install Steering Stops b Actuate steering to its extents in both directions and verify that the Steering Stops are contacting stop surfaces Install Adapters 19 5 Wheels amp Tires as shown in Figure 2 a Remove and disc
12. STOCK M14 60DEG 7 M14 STUDS CONENUTS iS Figure 2 Wheel Adapter Details 2012 DMF Inc All Rights Reserved Page 2 of 4 6 Clearance Check s a Verify that neither the rims nor tires contact any frame or suspension components in any combination of steering positions and axle droop jounce conditions b Verify that all brake ABS sensor and other wires or hoses are clear in all steering and suspension positions Restrain if necessary Relocate TPMS Receiver Module a Remove nuts from the main rear seat mounting studs If applicable b Carefully lift and remove the rear seat If applicable c Remove the trim panel on the driver s side B Pillar C Pillar on crew cab models d The TPMS Receiver Module will be located as shown in Figure 3 Figure 3 Original TPMS Receiver Location Detach the wiring connectors from the TPMS Receiver and carefully remove it Carefully pull back the insulation along the rearmost cab wall Reroute the TPMS Receiver wiring through the lowest portion of the driver s side rear vent as shown in Figure 4 Drill a small hole in the side of the provided enclosure and securely mount it to the underside of the bed on the driver s side just behind the cab as shown in Figure 4 Reconnect the appropriate wires and seal the enclosure using a bead of silicone and the provided hardware Replace interior insulation and trim ensuring that no wires are pinched or routed ina manner t
13. 6071 NOTE HAND PUMP MUST BE PRIMED AT FINAL INSTALL SEE SECTION 4 6 NOTE FOR ELECTRICAL DIAGRAM SEE DRAWING 600601 A 1018 11 REDRAWN TO SHOW PICTORIAL VIEWS ADDED KIT COLUMN IN BOM 10 6 11 ADDED PRIMING REFERENCE SWITCHED PORTS A amp B WHERE SHOWN ADDED LOCKING VALVE W ORIFICE amp FTGS 600611 CHG D LOCKING VALVE DETAIL amp REMOVED ITEM 2 FTGS 9 16 09 ADDED DIRECTIONAL VALVE PORT REFERENCES DESCRIPTION TITLE ASS Y RW 1015 HYDRAULIC SYSTEM EVE EUR RW 1015 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 p DRAWN BY BY DATE DRAWING NUMBER REV NOTE ALL HOSES SUPPLIED ARE FOR FRONT OF TRUCK MOUNTED PUMP dd DESCRIPTION 600502 600504 WELDMET CYLINDER BARREL FT RR RW 1015 DETAIL CYL GLAND 2 BORE x 1 ROD RW 1013 DETAIL PISTON 2 ID NYLOCK 5 8 18 NUT WELDMT CYL ROD RW 1015 O RING 5 8 ID 13 16 OD 3 32 W PISTON SEAL STD POLYPAK 1 5 8 ID 3 16 W ROD SEAL STD POLYPAK 1 ID 1 8 W ROD WIPER TYPE AN URETHANE 1 8 W O RING 1 3 4 ID 2 OD 1 8 W
14. KIT 600701 4 6 50 long bolts 4x flat washers SL 8x sq washers amp 4x lock nuts ia SEE M1015110 FOR ALTERNATE BRAC KET PART WELD ON EACH SIDE 8 50 FORD 4X4 7 00 FORD 4X2 BETWEEN U BRACKET AND VEHICHLE FRAME WELD SHIMS TO MATING SHIMS FRONT AND U BRACKET ONCE RAILWHEEL LOAD AND 5 ALIGNMENT ARE SET 1 See drawing M1015105 for Grease Guard parts NOTE INSTALL COOLER AFTER FINAL WEIG HT IS SET SPOTA HOLE THROUGH THE FRAME BRAC KET II ORIGINAL FRAME BRACKET HOLE IS COVERED UP 600326 2X 1 0 DIA SPACERS 600327 3X M8 x 45MM HEX HEAD BOLTS amp 5 16 LO CKWASHERS 2011 FORD DIESEL TRANS COOLER TO FRAME USE RETRO KIT P N 600324 ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 EN L WELD AS WELD AS A An DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 8 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIG SETTING INSTRUCTIONS DATE DESCRIPTION BY APP NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT 08 09 F2 350 FORD FRONTASSY INSTALL BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND RW 1015 OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE DVERSRED MERLFABRICATORSINC 80487552 TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE mu DATE DRAWING NUMBER SURF PNIS THE WELD pees 3 08
15. 7 16 11 REMOVED CYLINDER PART S FOR CYLINDERS GREATER THAN 04 5 DO REED SENDER ESTING HONING DESCRIPTION ALLOW CYLINDER TO BOTTOM DURING na 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 DATE DRAWING NUMBER REV SALE WAK 6 24 94 B DIVERSIFIED METAL FABRICATORS INC RW 1015 5 3 HYDRUALIC SYSTEM This page intentionally left blank 2015 DMF Inc All Rights Reserved 05 03 RW 1015 Hydrualic System doc 12VDC I e a TERMINAL X BLOCK lt 207 IGNITION RED22 MAIN PWR CT 5 MASTER PNK22 WITHOUT IN CAB CONTROL TERMINAL BLOCK 16GA GXL 4GA to 1 0 WELDING WIRE KIT 600709 INCLUDES ITEMS 5 THRU 21 SELECTOR A 89 w G JB T B gt 16 4 50 8 DRAWING 600550 4 DETAIL FOR WIRING SPECIFICS Y NOTE SEE SOLENOID NOTE FOR HYDRAULIC DIAGRAM SEE 1 600620 REF PUMP M3528 W EMERGENCY PUMP 00615 00616 ASSY REAR ELECTRICAL UP DWN SWITCH 22 00726 TERMINAL BLOCK DBL ROW 10 00720 ELEC ASSY TOGGLE
16. BRACKET AND ALIGNED WITH CROSSPLATE WELD SPACERS TO ONE ANOTHER AND TO THE MAIN CROSSPLATE AFTER FINAL ALIGNMENT AND RAIL WHEEL LOADS HAVE BEEN SET ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 STANDARD SPACERS AND PIVOT ARMS ola ym DESCRIBED IN NOTE 3 era VE N WELD AS DESCRIBED IN NOTE 3 AND 29 5 OPTIONAL SECONDARY SPACERS ALLOW FOR FRAME HEIGHTS UP TO 32 FOR APPLICATIONS OUTSIDE OF THESE RANGES PLEASE CONTACT DMF FOR SUPPORT ACCOMMODATE FRAME HEIGHTS BETWEEN 25 5 RAIL WHEEL LOAD ALIGNMENT ADJUSTMENT RAIL WHEEL LOAD ADJUSTMENT IS ACHIEVED BY MOVING THE L BRACKETS VERTICALLY SEE SECTION 3 4 r ALIGNMENT ADJUSTMENT IS ACHIEVED BY WAY OF MOVING THE L BRACKETS FORE AND AFT ONCE THESE PROCEDURES HAVE BEEN COMPLETED AND VERIFIED WELD WASHERS AND 3 HOLE PLATETO THE ADJ L BRACKET ALONG FULL LENGTH OF TOP AND BOTTOM EDGES KIT 4600714 INCLUDES 4 5 8 11 X 2 3 4 GR8 BOLTS 4 500510 SQUARE WASHERS 4 5 8 GR8 FLATWASHERS 4 5 8 11 GR8 NYLOCK NUTS 3 HOLE PLATE TO BE FLIPPED UPSIDE DOWN IF INSTALLATION REQUIRES BOLTS TO BE NEAR THE TOP OF THE GIVEN SLOTS WELD REAR EDGE OF ADJ L BRACKET TO CROSSPLATE OPTIONAL SECONDARY SPACER FOR TRUCKS WITH FRAME HEIGHTS BETWEEN 29 5 AND 32 MAX 4 SPACERS PER SIDE IF USED WELD TO ALL MATIN COMPONENTS CONTACT DMF PARTS DEPT KIT 601424 INCLUDES
17. ITEM 7 DETERMINE THE POSTION FOR THE STOP WASHERS ITEM 9 TO LOCK BOTH STOWED AND DEPLOYED POSTIONS WELD WASHERS ITEMS 9 ONTO HANDLE DESCRIPTION RW 1015 TITLE ASSEMBLY FRONT PIN OFF OPTION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD BY DATE DRAWING NUMBER REV 4 29 2010 600716 PART NUMBER DESCRIPTION 600408 WELDMENT BRACKET PO DSR 1015 600409 WELDMENT BRACKET PO PSR 1015 600417 PIN OFF CROSS BAR DETAIL RW 1015 600418 PIN OFF LOCKING BAR DETAIL RW 1 600419 PIN OFF SLIDE MOUNTING TUBE DETAIL RW 1015 5 600453 OFF PLATE RW 1015 600456 BO PLATE KEYHOLE PO RW 101 ESNA1 2 13 ESNA 1 2 13 LOCK NUT FW1 2 FLAT WASHER 1 2 GRADE 8 95 eo ION GR8 HHCS1 2 13X1 1 2GR8 HEX HEAD GRADE 8 1 2 13 X 1 1 2 LONG CUT AND OR BEND PLATE AS NECESSARY ATTACH TO BUMPER OR BODY OPERATION LOCK amp PULL UNLOCK FOR BOTH THE STOWED amp DEPLOYED POSITIONS CUT AND OR BEND BAR AS NECESSARY REAR RAILGEAR PIN OFF OPTION DESCRIPTION IF MANUAL PIN OFF S ORDERED WITH RAILGEAR THE ABOVE COMPONEN
18. Insufficient Traction or Braking Rail Load set too high Tires worn Inspect Tires Set Rail Loads Replace tires Table 3 6 1 A Troubleshooting On track Problems 2015 DMF Inc All Rights Reserved 03 00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 3 0 MAI NTENANCE This page intentionally left blank 2015 DMF Inc All Rights Reserved 03 00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS I NC 4 0 4 tere SOO Fs BA RW 1015 4 0 INSTALLATION 4 0 INSTALLATION Installation Pre Install 1 1 Safety Statements 1 2 Installation Order 1 3 Installation Sheets 1 4 Receiving 1 5 Required Tools amp Materials Chassis Prep 2 1 Vehicle Condition 2 2 Alignment 2 3 Mount and Balance Tires 2 4 Tire Pressure Monitoring TPMS 2 5 Speedometer Recalibration 2 6 Re Springing 2 7 Exhaust Modifications 2 8 Tire Carrier Install Wheel Modification Kit 3 1 Safety Statement 3 2 Wheel Adapters 3 3 Spacers 3 4 Studs 3 5 Install Steering Stops 3 6 Wheelhouse Body Modifications Steering Wheel Lock Installation Install Electrical System 5 1 Locate Components 5 2 Route Wires 5 3 Electrical Insulation nstall Hydraulic System Route Hydraulic Hoses Install Emergency Hand Pump Prime Emergency Hand Pump 2015 DMF Inc All Rights Reserved 4 7 Install Rear Railgear 4 7 1 In
19. b Carefully lift and remove the rear seat If applicable c Remove the trim panel on the driver s side B Pillar C Pillar on crew cab models d The TPMS Receiver Module will be located as shown in Figure 3 Figure 3 Original TPMS Receiver Location Detach the wiring connectors from the TPMS Receiver and carefully remove it Carefully pull back the insulation along the rearmost cab wall Reroute the TPMS Receiver wiring through the lowest portion of the driver s side rear vent as shown in Figure 4 Drill a small hole in the side of the provided enclosure and securely mount it to the underside of the bed on the driver s side just behind the cab as shown in Figure 4 Reconnect the appropriate wires and seal the enclosure using a bead of silicone and the provided hardware Replace interior insulation and trim ensuring that no wires are pinched or routed in a manner that might cause them to be damaged Replace the rear seat and tighten the lower mounting bolts If applicable 2012 DMF Inc All Rights Reserved Page 3 of 4 Figure 4 Mounting Location NOTE The following steps must be performed at a dealer as modification of these settings requires a software update specific to your vehicle that must come directly from GM 8 Re calibrating Speedometer a The speedometer calibration is limited to stock tire sizes b Asthe tires we recommend are not a stock size for this vehicle the stock LT265 60R20 tire setting should b
20. 0 INSTALLATION 4 8 Install Front Railgear Safety Statements If the gear is in the highway position and not pinned off you haven t installed the pin offs yet it can drop if any of the fittings are opened or leaky The gear is heavy enough to hurt you badly Block up the gear before you crawl under it Refer to 5 1 Installation Guides 4 8 1 Remove Front Bumper See manufacturers manual for instructions on how to remove trucks bumper Be careful to retain all hardware Unless your Installation Sheet directs otherwise you can discard any underbody plastic parts Protect the radiator to prevent damage with cardboard 4 8 2 Install Front Gear The front Railgear may be installed as a unit if suitable lifting equipment is available Using a forklift pallet jack or floor jack position the front Railgear under the frame and attach with the provided hardware as shown in 5 1 Installation Guides Draw the gear up snug but not tight to allow later alignment Refer to 5 1 Installation Guides If lifting equipment is not available the gear can be partially disassembled and installed in parts Refer to the exploded diagrams in Section 5 1 4 8 3 Hook up Hydraulics Attach hydraulic lines to the locking valves and front cylinders per as shown in 5 3 Hydraulic System 4 8 4 Align Front Railgear to Rear Railgear Refer to 3 5 Alignment Align the front Railgear to the rear Railgear per the Alignment sheet Tack weld axle brackets to axle Be s
21. 1 25 10 SPLIT FRONT REAR LOOMS FOR UP DWN GRN BLK WHITE uc A 9 16 09 ADDED PORT REFERENCES TO DIRECTIONAL VALVES f 8 13 09 REMOVED RELAY 10 amp CHG D 10 GA TO 1 0 W 150 6 14 09 EDITED SWITCHBOX WIRE COLORS DATE DESCRIPTION TONLESS SPECFEEDI ba ASSY ELECTRICAL Wr WO RW 1015 RW 1015 i 950 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ANGULAR 3 DRAWN BY BY DATE DRAWING NUMBER REV pr 5 12 09 600601
22. 10 M1015102 TE FOR INDIVIDUAL PARTS LISTOR PARTS ORDERING REFER DRAWING 600109 KIT 600708 6X 3 LONG BOLTS 8X FLAT WASHERS 6X LOCK NUTS amp 4X SQ WASHERS KIT 600708 EXPERIENC E THE FULL STRUC TURAL LOAD SEEN BY THE REAR FRAME NO MORE THAN 4 TOTAL amp 1 DIFFERENCE FRO MTRIG HT TO LEFT ENSURE ALL SPAC ERS ARE FIRMLY AG AINSTAD J L BRACKET amp ALIG NED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO MOUNTING RAIL WHEEL LOAD ADJUSTMENT MOUNTING SLOTS ONCE RAILWHEEL LOAD ADJUSTMENT IS FINAL SEE SECTION 3 4 AND ALIGNMENT IS COMPLETE WELD 3 HOLE MOUNTING PLATE TO ADJUSTABLE L BRACKET WELD SPACERS IN PLACE amp WELD ADJUSTABLE L BRACKET TO THE REAR FRAME BRACKET ALONG THE LENGTH OF EACH SIDE SEE FIGURE BELOW FOR EXACT LOCATIONS amp REFERENCE NOTE 2 FOR WELDING INFO ALIGNMENT ADJUSTMENT THE SLOTS IN THE ADJ L BRACKET ARE SLIGHTLY WIDER THAN THE BOLT TO ALLOW FOR SLIGHT ADJUSTMENTS FORWARD OR BACKWARDS TRUCK FRAME NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE
23. ARMS TO LH RH A weno ADDED 600411 amp 600413 MODIFIED HARDWARE amp BOM ACCORDINGLY JBG REV DATE DESCRIPTION BY APP FRAC MACH FRAC OTHER x XXX DRILL SIZES ANGULAR SURF FINISH 125 MICRO THREADS 2 AND 28 TITLE RW 1015 ASSY REAR 08 C25HD RW 1015 RTW DRAWN BY APPD DATE WAK 11 07 08 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWING NUMBER 600102 YOU ORDERED MANUAL PIN OFFS SEE SECTION 5 2 DRAWINGS amp INSTALL INFORMATION 4X4 CONHGURATION SHOWN USE ALTERNATE BRAC KETAND PIVOT ARMS FOR 4X2 FORD PART 4X2 bos VEHICLE FRONT Starting w serial 29900 use p n s 600264 or 600266 RAILSWEEP ASSY FRONT REAR SET P N 600236 PART NUMBER DESC RIPTION COMMENTS NOTES 600201 SEE REF NOTE ASSY RAILWHEEL RTW WHEEL SPINDLE TREAD 600264 266 5 SPINDLE W REFER DWG M1015110 PIVOTARM REFER DWG M1015110 FRONT FRAME BRACKET 600220 DETAIL SUSP PRIMARY RW 1015 600501 ASSY CYLINDER 2 FT RW 1015 600501 ASSY CYLINDER 2 FT RW 1015 600381 DET FORMED FRAME BRACKET ADJ RW1015 09F2 350 500384 RW 1015 DETAIL SUPPORT TUBE 600215 WLDM T PIN AXLE PIVOT RW 1015 600360 WELDMT FT RW 1015 600221 DETAIL SUSPENSION PRELOAD RW 1015 600386 DETAIL F
24. FOR THE STOP WASHERS ITEM 9 TO LOCK w DRAWN BY APPD BY DATE DRAWING NUMBER REV BOTH STOWED AND DEPLOYED POSTIONS WELD WASHERS ITEMS 9 ONTO HANDLE F 1 2 JBG 10 20 2010 600719 OPERATION OF D M F GUIDE WHEEL SYSTEM DAILY Refer to Inspection and Maintenance legend prior to operating this equipment CHECKS See Parts and Service manual for detailed operation and adjustment guidelines TO Drive vehicle onto crossing centering rear tires on tracks PLACE Retract and lock front and rear manual pin offs Electric pin offs retract automatically VEHICLE Lower rear wheels first Note Front Rear Rail wheels cannot be actuated simultaneously A Enable Guide wheel Power switch in vehicle cab with engine running B Using electric switch in cab or at rear bumper Deploy rear wheels fully and properly engage with rail Guide wheels are over center and do not require rail mode pin offs Engage front wheels A Maneuver truck so front is centered over rail B Align front vehicle tires straight ahead C Using electric switch in cab or at front bumper Deploy front wheels fully and properly engage with rail Guide wheels are over center and do not require rail mode pin offs Double check all flanges to assure they are engaged properly with rail Engage steering wheel lock and verify its proper function Turn off Guide wheel Power switch Drive back and forth one truck length to test braking tracking and enga
25. FRAC OTHER 1 16 X 3 063 x ion DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 AR bevege DRAWN BY APPD BY DATE DRAWING NUMBER REV SURF FINISH 125 MICRO THREADS AND JBG 3 09 10 M1015103 B OLDER STYLE LOCKING VALVE gO dvd NOTE ALL HOSES SUPPLIED ARE FOR FRONT OF TRUCK MOUNTED PUMP KIT 600603 LOCKING VALVE w ORIFICE amp FITTINGS RW 1015 PRE JUNE 2010 A 600611 LOCKING VALVE w ORIFICE amp FITTINGS RW 1015 POST JUNE 2010 4 600501 REF ASSY CYLINDER 2 1015 1 ASSY CYLINDER 2 RR RW 1015 6 600625 REF EMERGENCY PUMP W HANDLE 7 600602 2 64 1 4 RHINOHIDE HYD HOSE 22 SECTIONS _ ______ 8 810622 6 1 4 RHINOHIDE HYD HOSE 38 SECTIONS 9 810642 4 1 4 RHINOHIDE HYD HOSE 62 SECTIONS 11 800510 Y EYYYYYY ETS j Soor 12 6 600511 6400 04 06 4JIX X 06 O RING STRAIGHT FTG 600711
26. Fittings With Tapered Pipe Threads PROCEDURE A Inspect port components to ensure that male and female threads are free of nicks burrs dirt etc Apply sealant lubricant to male pipe threads Use only Permatex 140 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 Fitting Pipe Thread Size Size NPT 1 8 27 1 8 27 1 4 18 3 8 18 1 2 14 3 4 14 3 4 14 1 11 1 2 1 1 4 11 1 2 1 1 2 11 1 2 COMMENTS Teflon Tape May Be Used In Certain Situations With Engineering al wr 264 Approval A Pipe Fitting 15 Limited To Or Two Re Uses DESCRIPTION TITLE PRODUCTION PROCEDURE 004 PIPE FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 1 065 005 ES ril DRAWN BY APPD BY DATE DRAWING NUMBER REV v l TSH 06 02 94 hyl 4 TITLE SAE JIC 37 Degree Fitting Installation ITEM PART NO DESCRIPTION pa PP PURPOSE To Establish Production Methods For The Installation Of SAE JIC Medium Pressure Hydraulic Fittings COMMON USAGE Hydraulic Systems Ope
27. GM 25 3500 W STEERING STOPS WHEEL ADAPTER STL 05 GM 10822 SPCR WHEEL 05 C2500 10825 LUGNUT SPLIT FLANGE M20 10826 STUD WHEEL 20MM E 11706 500913 STEERING STOP KIT TRUCK SET 00 10 GM HD PICKUP 500912 STEERING STOP 00 10 GM HD PICKUP 20716 FLAT WASHER 5 8 GR8 605017 LOCKNUT M16 TYPE C 551002 WHEEL SPACER 05 11GM ADAPTER 3 16 TRUCK HUB REAR SHOWN 00 5 5 5 5 5 5 5 SUPPLIED W 10837 TORQUE TO 10839 5 9 FT LB STOCK M14 60 BALL SEAT NUTS TORQUE TO 140 FT LBS TORQUE TO 300 FT LBS Figure 1 Installation Exploded Parts Diagram 2012 DMF Inc All Rights Reserved Page 1 of 4 Recommended Tires Mud Snow All position Goodyear G622 245 70R19 5 Michelin XDS2 245 70R19 5 Steer Highway Goodyear G647 245 70R19 5 Installation Warning Never use anti seize on studs or lug nuts Hand torque all fasteners to the provided specifications using a torque wrench Improper installation or failure to perform a thorough check for clearances once this unit is installed may lead to damage to the chassis wheels tires Railgear or personnel Install TPMS sensors into 19 5 rims as shown in Figure 1 Install and Inflate 19 5 Tires a Mount and balance tires b Inflate tires to a cold pressure of 85 psi Remove Stock
28. PLACE AS DESCRIBED IN CALL OUTS 18 MAX FRONT OF TRUCK FRONT OF TRUCK GROUND NOTE OPTIONAL LONG PIVOT ARM 600320 AVAILABLE FOR VEHICLES WITH FRONT FRAME HEIGHT MODIFIED HIGHER THAN STOCK FRAME HEIGHT AFTER RIDE HEIGHT MODIFICATION amp INSTALLATION OF 19 5 TIRES MUST NOT EXCEED 18 WHEN RAILGEAR IS IN HIGHWAY POSITION ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 54 MID LENGTH PIVOT ARM P N 601420 P NI 22 FOR FRAME HEIGHTS BETWEEN 15 5 AND 17 ELD AS 5 2 28 2012 600706 WAS 600705 DESCRIBED NOTE 3 DESCRIBED 3 2 10 7 2011 UPDATED WELD NOTES FOR CLARITY AND ADDED FRAME HEIGHT INFO AR SCALE 1 10 REVAL DATE DESCRIPTON Ev TAPE NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT UE TE BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND THE rm EZ MANUAL 1025 0500 FRONT ASSKEINSTA LL OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE MOVE THE GEAR HIGHWAY POSITION IN ORDER COMPLETE DRAWNG NUMBER THE WELD 1015109 KIT 600172 INCLUDES 6 1 2 13 X 2 3 4 GRADE 8 BOLTS 12 1 2 GRADE 8 FLAT WASHERS 6 1 2 13
29. Railgear maintenance and safety 3 1 1 Daily Maintenance Visually inspect for hydraulic leaks Verify that Railgear has not leaked down from highway position Check hydraulic fluid level at pump Verify that all threaded fasteners are secure paying special attention to axle bolts and end play nut e Spin all four guide wheels noting any bearing noise resistance or end play See section 5 2 for end play information e Inspect the general condition of guide wheels e Inspect the condition of tires and rims Pay special attention to inside tread to assure nothing is rubbing against tires e Check air pressure in tires and correct if necessary refer to section 5 5 e Visually inspect all Railgear components for any damage and or cracks 3 1 2 Weekly Maintenance In addition to the items listed 3 1 1 Daily Maintenance perform the following e Lubricate front amp rear pin off assemblies if equipped with a light lubricant WD 40 Tri Flow etc e Inspect guide wheel flange wear Uneven or excessive wear may indicate alignment or rail wheel load problem See section 3 5 or 3 4 Inspect condition of rubber or steel guide wheel treads e Visually inspect wheels amp tires See Section 3 3 Wheel Modification Kit Inspection amp Maintenance e Verify that ABS sensor wires and brake lines are restrained and not contacting the rims e Inspect rubber suspension e Grease and lubricate all grease fittings on front and r
30. TRUCK FRAME T NOTE 2 FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL ABE SE Ts LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SHIMS BRACKETS AND WASHERS IN PLACE AS DESCRIBED IN CALL OUTS FRONT OF TRUCK FRONT OF TRUCK 211 crown NOTE OPTIONAL LONG PIVOT ARM 600320 AVAILABLE FOR VEHICLES WITH FRONT FRAME HEIGHT MODIFIED HIGHER THAN STOCK FRAME HEIGHT AFTER RIDE HEIGHT MODIFICATION amp INSTALLATION OF 19 5 TIRES MUST NOT EXCEED 18 WHEN RAILGEAR IS IN HIGHWAY POSITION ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 MID LENGTH PIVOT ARM P N 601420 AND 17 2 28 2012 600706 WAS 600705 17 NI FOR FRAME HEIGHTS BETWEEN 15 5 T 2 ELDIAS A A 10 7 2011 UPDATED WELD NOTES FOR CLARITY AND ADDED FRAME HEIGHTINFO
31. WELD SHIMS TO ALL MATING SHIMS AND U BRACKET I 2 x ME Heo I L l PASSENGER SIDE g C r 13 DRIVER SIDE SECTION A A SCALE 1 8 H e H H H ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 1 EH Lau pr Fa f LI H H H it Nl a WELD AS DESCRIBED NOTE 3 DESCRIBED NOTE 3 VIEWING FRONT OF VEHICLE NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SHIMS BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS POSITION VEHICLE FRONT KIT 600707 FRONT FRAME BRACKET MOUNTING 4x sq washers 4x lock nuts 4x flat washers amp 4x 2 long screws A 1
32. in charts are for Cadmium Multiply by 1 87 for Zinc ANGUUR DATE DRAWING NUMBER REV F Never re use a highly stressed torqued fastener IT MAY FAIL READS 06 02 94 Ty PPoo6 DIVERSIFIED METAL FABRICATORS INC RW 1015 5 1 INSTALLATION DRAWINGS This page intentionally left blank 2015 DMF Inc All Rights Reserved 05_01 RW 1015 Installation Drawings doc PART DESCRIPTION TIN KIT 600358 WLDMT FT FRAME BRACKET DS OUTER RW 1015 200382 DELFORMED FRAME BRACKET ADJ ____ 1015 600357 WLDMT FT FRAME BRACKET PS OUTER 200354 WLDMT FT FRAME BRACKET PS INNER WIDMT FT FRAME BRACKET DS INNER 600355 WOES lh 600356 DETAIL FRM SPACER RW 1015 08 GM 600706 600360 WELDMT PIVOT PIN 1015 601420 WLDMT MID LENGTH PIVOT ARM 600320 FRONT RW 1015 600273 ASSY WHEEL amp AXLE STEEL 600272 WHEEL RUBBER TREAD WHEEL 600220 DETAIL SUSP PRIMARY RW 1015 600221 DETAIL PRELOAD RW 600501 ASS Y CYLINDER 2 RW 1015 600507 DET PIN CYL ROD RW 1015 FT 600421 DETAIL BUMPER BRACKET RW 1015 08 600215 WLDMT PIN AXLE PIVOT RW 1015 238112 FLAT WASHER 1 GR5 900495 FLAT WASHER 3 4 GR5 20716 FLAT WASHER 5 8 GR8 500691 FLAT WASHER 1 2 GR8 818127 SLOTTED HEX NUT 1 8 GRS 605005 SLOTTED
33. needed After any alignment changes return to 3 4 to re verify rail wheel loads 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 5 Alignment Over time your Railgear may require adjustment to ensure safe operation and to prevent excessive wear If your Railgear is running on the flanges excessively or derailing the alignment should be checked Refer to Section 3 5 6 There are two methods of alignment Alignment Method 1 is known as string lining and is preferred where possible Alignment Method 2 may be more suitable for checking in the field but produces good results when done carefully 3 5 1 Alignment Overview RW 1015 Railgear is aligned in the following order e Rear Railgear to Rear Vehicle Axle e Front Railgear to rear Railgear 3 5 2 Alignment Adjustments Rear bracket The rear bracket must be aligned prior to drilling the frame There is some play in the slots that allows for minor adjustments Front Bracket The front Railgear is bolted to the frame The slots allow for minor adjustments Axle Tubes The front and rear axles must be centered and aligned prior to welding to the axle brackets The welds can be ground and re welded if later adjustment is required 3 5 3 Alignment Method 1 This method is preferred and requires a string and stands Set up a string line on an actual or simulated rail It is critical that the lin
34. oriented properly Verify that the Railgear does not operate with the power switch in the off position Follow Section 2 4 to verify emergency pump function Load test vehicle to GVWR and verify Railgear function Note If there is any cross functionality such as front controls operating rear a wiring error should be suspected Typically this is at the terminal strip or the solenoids 4 14 Road Test Before road testing inspect steering stops wheel and tires Verify that the lug nuts have been torqued to the value in section 5 5 Verify that all bodywork is replaced and secure In a parking lot or open area verify that the steering stops prevent the tire or rim from contacting the frame suspension or other items Inspect brake lines and ABS sensor lines to verify clearance from rim Check for any rattles and vibration Verify soeedometer calibration by timing a distance GPS or from another vehicle This may not be necessary for every install 4 15 Final Inspection Verify that the hydraulic fluid is full Verify that the reservoir is labeled Touch up paint as necessary Lubricate Pin off pins if equipped with a light lubricant Verify decals are installed on wheels Verify that the decals are installed at bumper switches Verify that the decals are installed in cab Verify that the manual is in the cab Verify that the emergency pump handle is stowed Check the tire inflation Verify that all bodywork is replac
35. position the rear Railgear under the rear bracket and attach with the provided hardware and plate washers See section 5 1 Clamp Railgear position and align to rear vehicle axle 4 7 2 Set Initial Rail Wheel Load amp Rear Bracket Height Using slide plate provided drill required holes in frame Drill holes to place Railgear at the SET UP HEIGHT and to allow use of slots for Rail Wheel Load adjustment See 5 1 Installation Guides for details for your specific chassis Draw the gear up snug but not tight to allow later alignment If spacers are required they must be solid steel pieces because they will experience the full structural load seen by the rear frame 4 7 3 Install Hydraulic Lines Attach hydraulic lines to locking valves and rear cylinders as shown in 5 3 Hydraulic System 4 7 4 Align Rear Gear Check and adjust rear Railgear axle to the rear vehicle axle Tack weld axle brackets to axle Be sure to set the spindle bolts horizontally Axle brackets will be fully welded during the Final Alignment step 4 7 5 Set Rail Wheel Load Set Rail Wheel Load using procedure in section 3 4 4 7 6 Set Rail Sweeps The rail sweeps should be set to allow the sweep rubber to contact the rail when adjusted to the top of the slots This allows adjustment when the rubber wears 4 7 7 Exhaust Modifications See Section 4 2 7 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4
36. rims on 2011 GM 2500HD and 3500HD SRW trucks for use on rail This kit is not compatible with 2011 Suburban Yukon s which continue to use DMF Wheel Adapter kit 509029 Kit Contents PART DESCRIPTION 509033 WHEEL MOD KIT 11 GM HD PICKUP W RIMS amp TPMS 10833 TPMS SENSOR 07 12 GM Truck Set 600617 WIRING ENCLOSURE BOX 4 7 X 2 2 X 3 3 10836 TPMS SENSOR KIT 07 12 GM per wheel TPMS ADAPTER WASHER GM TPMS ADAPTER GROMETT GM TPMS SENSOR GM 07 12 20158 WHEEL ACCURIDE 28680 50180 W DECAL WHEEL ACCURIDE 28680 50180 DECAL 05 GM WHEEL ADAPTER 509034 WHEEL ADPT 11 25 3500 W STEERING STOPS WHEEL ADAPTER STL 11 GM C K 25 3500 10819 DETAIL WHEEL ADAPTER 11 GM C K25 3500 10825 LUGNUT SPLIT FLANGE M20 10826 STUD WHEEL 20MM E 11706 500915 11 GM HD PICKUP 1013 15 STEERING STOP KIT TRUCK SET 500937 STEERING STOP 11GM25HD DS 500938 STEERING STOP 11GM25HD PS 20716 FLAT WASHER 5 8 GR8 605017 LOCKNUT M16 TYPE C 10839 m gt gt c 5 5 5 10838 10837 TRUCK HUB REAR SHOWN SUPPLIED W 10837 TORQUE TO STOCK M14 60 BALL SEAT NUTS TORQUE TO 140 FT LBS 10825 TORQUE TO 300 FT LBS Figure 1 Installation Exploded Parts Diagram 2012 DMF Inc All Rights Reserved Page 1 of 4 Recommended Tires Mud Snow All position Goodyear G622
37. 0 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIGHT SETTING INSTRUCTIONS REV DATE DESCRIPTION BY APP TOLERANCES TITLE UNLESS SPECIFIED 09 GM 25HD FRONT ASSY INSTALL FRAC MACH 132 FRAC OTHER 1 16 x 2 063 RW 1015 XX 030 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 XXX 005 QAAE DRAWN APPD BY DATE DRAWING NUMBER REV SURF FINISH 125 MICRO macs JBG 110 02 qu M1015100 FOR INDIVIDUAL PARTS LIST PARTS ORDERING REFER TO DRAWING 600102 RAIL WHEEL LOAD ADJUSTMEN KIT 600708 4X sq washers 8X flat washers 6X lock nuts amp 6X 2 75 long bolts KIT 600 SPACERS USED MUST BE SOLID STEEL PIECES BECAUSE THEY WILL EXPERIENCE THE FULL STRUCTURAL LOAD SEEN BY THE REAR FRAME NO MORE THAN 4 TOTAL SHIM NO MORE THAN 1 DIFFERENCE FROM DRIVER SIDE TO PASSENGER SIDE SHIM THICKNESS aa ENSURE ALL SPACERS ARE FIRMLY AGAINST ADJ WELD WASHERS TO ADJ L BRACKET L BRACKET amp ALIGNED WITH THE REAR MOUNTING 4 BRACKET FULLY WELD SPACER TO REAR FRAME BRACKET AS SHOWN IF MULTIPLE SPACERS ARE USED SPACERS NEED TO BE WELDED TO ONE ANOTHER REAR FRAME BRACKET KIT 600714 4X sq washers 4X flat washers 4X lock nuts amp 4X 2 75 long bolt A E DRIVER SIDE PASSENGER SIDE
38. 00249 WELDM ENT 600238 WELDM ENT 600239 WELDM ENT P N 600250 FRONTTRUCK SETW HARDWARE A A REV DATE DESCRIPTION APP LERANCES TITLE UNLESS SPEC IFIED FRAC MACH FAG MATE RW 1015 MANUAL FRONT REAR G REASE G UARD SETS x b DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DR ES h B DRAWING NUMBER ANGULAR 1 SURF FINISH 12 THREADS Seer M1015105 DIVERSIFIED METAL FABRICATORS INC RW 1015 5 2 RAILGEAR ASSEMBLIES This page intentionally left blank 2015 DMF Inc All Rights Reserved 05 02 RW 1015 Railgear Assemblies doc 1 600603 __ LOCKING VALVE w ORIFICE 8 FITTINGS RW 1015 PRE JUNE 2010 A LOCKING VALVE w ORIFICE amp FITTINGS RW 1015 POST JUNE 2010 600620 1 HYD PUMP W 10 CAVITY HAND PM M3528 MAS 10 2HP 4 600501 REF ASSY CYLINDER 2 CYLINDER 6 600625 REF EMERGENCY HAND PUMP W HANDLE 7 600602 2 RHINOHIDE HYD HOSE 22 SECTIONS s 810622 8 64mm 14 RHINOHIDE HYD 38 SECTIONS s 81062 4 64MM RHINOHIDE HYD HOSE 62 SECTIONS Se 11 600510 6 6500 04 04 waMJIC 4FJIC SWIVEL9ODEGETG 600717 LOCKING VALVE 12 600511 6 6400 04 06 ORING STRAIGHT FTG
39. 1015 09 GM 25HD FRONTASSY INSTALL OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE x DIVERSIFIED METAL FABRICATO RSINC 404 875 1512 TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD ort is DATE DRAWING NUMBER 1 10 02 1015100 TREADS FOR INDIVIDUAL PARTS LIST OR PARTS ORDERING REFER TO DRAWING 600102 KIT 600708 4X sq washers 8X flat washers 6X lock nuts amp 6X 2 75 long bolts SPACERS USED MUST BE SOLID STEEL PIECES BECAUSE THEY WILL EXPERIENCE THE FULL STRUCTURAL LOAD SEEN BY THE REAR FRAME NO MORE THAN 4 TOTAL SHIM NO MORE THAN 1 DIFFERENCE FROM DRIVER SIDE TO PASSENGER SIDE SHIM THICKNESS RAIL WHEELLOAD ALIGNMENT ADJUSTMENT RAIL WHEEL LOAD ADJUSTMENT IS ACHIEVED BY MOVING THE ADJ L BRACKETS VERTICALLY SEE SECTION 3 4 ALIGNMENT ADJUSTMENT IS ACHIEVED BY WAY OF MOVING THE ADJ L BRACKETS FORE AND AFT IT 600708 4X sq washers 8X flat washers 6X lock nuts amp 6X 2 75 long bolts 2X WELDS 1 4 x 1 WELD 2 TRUCK FRAME p NOTE 1 GRADE 8 BOLTS MUST USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED WARNING DO NOT AT
40. 1401 RW 1015 600340 PIVOT ARM REAR DS RW 1015 600349 PIVOT ARM REAR PS RW 1015 600274 WHEEL amp AXLE ASSY STEEL WHEEL 600270 RUBBER TREAD WHEEL 600220 DETAIL SUSP PRIMARY RW 1015 600221 DETAIL SUSPENSION PRELOAD RW 1015 600218 WLDMT PIN AXLE PIVOT RW 1015 600362 WELDMT PIVOT PIN RR RW 1015 600344 BO PIVOT BOSS REAR RW 600503 ASSY CYLINDER 2 RR RE 1015 600509 DET PIN CYL ROD RW 1015 RR 300612 FLAT WASHER 5 8 8 500691 FLAT WASHER 1 2 GR8 238112 FLAT WASHER 1 GR5 900495 FLAT WASHER 3 4 5 76317 LOCK WASHER 1 2 SPRING GR5 600171 18551 LOCKNUT 5 8 11 ESNA GR8 600714 600172 600714 600171 600714 600172 605006 HEX HEAD SCREW 1 2 13 X 2 GR8 818367 HEX HEAD CAP 2227 1 2 13 X 1 1 2 av 605004 HEX HEAD TAP BOLT 1 2 13 X 6 GR8 605003 HEX HEAD 22 5 8 11 X 2 3 4 113014 LOCKNUT 1 2 13 ESNA GR8 818127 SLOTTED HEX NUT 1 8 GR5 605005 SLOTTED HEX NUT 3 4 10 GR5 108078 COTIER 3 16 X 2 818105 GREASE FITTING 1 4 28 1641 8 818235 GREASE FITTING 1 8 NPT STRAIGHT 500510 DET SLOT FLAT BAR 5 8 601407 DETAIL WASHER PLATE LB REAR FRAME BRACKET 11GM 25 3500 RW 1015 600714 600172 N N 00
41. 15105 FOR GREASE GUARD PARTS SECTION A A A 12 10 2012 UPDATED DRAWING VIEWS SHOW NEW PARTS 600365 WAS 600331 JDI A 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIG HT SETTING INSTRUCTIONS ARJ REV DATE DESCRIPTION BY APP TOLERANCES TITLE UNLESS SPECIFIED FAC MACH drm RW 1015 08 09 FORD F2 350 REAR ASSY INSTALL FRAC OTHER 1 16 X 3 063 x ion DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 AR bevege DRAWN BY APPD BY DATE DRAWING NUMBER REV SURF FINISH 125 MICRO THREADS AND JBG 3 09 10 M1015103 B DESCRIPTION 600417 PIN OFF CROSS BAR DETAIL RW 1015 600419 PIN OFF SLIDE MOUNTING TUBE DETAIL RW 1015 600453 BO PIN OFF PLATE RW 1015 600455 DET PIVOT PIN PO 1015 FT 600456 BO PLATE KEYHOLE PO RW 1015 ESNA1 2 13 ESNA LOCK NUT 1 2 13 FW1 2GR8 FLAT WASHER 1 2 GRADE 8 CUT AND OR BEND PLATE AS NECESSARY ATTACH TO BUMPER OR BODY OPERATION TO LOCK amp PULL TO UNLOCK FOR BOTH THE STOWED amp DEPLOYED POSITIONS CUT AND OR BEND BAR AS NECESSARY FRONT RAILGEAR PIN OFF OPTION IF MANUAL PIN OFF S ORDERED WITH RAILGEAR THE ABOVE COMPONENTS WILL BE ASSEMBLED amp WELDED TO YOUR RAILGEAR INSTALLER TO LOCATE AND MODIFY HANDLE amp RETENTION PLATE TO SUIT APPLICATION ATTACH RETENTION PLATE
42. 245 70R19 5 Michelin XDS2 245 70R19 5 Steer Highway Goodyear G647 245 70R19 5 Installation Warning e Never use anti seize on studs or lug nuts e torque all fasteners to the provided specifications using a torque wrench e Improper installation or failure to perform a thorough check for clearances once this unit is installed may lead to damage to the chassis wheels tires Railgear or personnel Install TPMS sensors into 19 5 rims as shown in Figure 1 Install and Inflate 19 5 Tires a Mountand balance tires b Inflate tires to a cold pressure of 85 psi Remove Stock Wheels amp Tires a Liftthe vehicle and properly support using jack stands b Remove the stock wheels and tires retaining the stock lug nuts for reuse Install Steering Stops as shown in Figure 2 a Remove Lower Kingpin Nut from each side b Install Steering Stop on each side using provided M16 Type C nut C Actuate steering to its extents in both directions and verify that the Steering Stops are contacting stop surfaces Install Adapters 19 5 Wheels amp Tires as shown in Figure 2 a Remove and discard the factory lug retaining clips Mount the Wheel Adapters using the stock lug nuts Torque as specified in Figure 1 Mount the 19 5 rims with 19 5 tires to the Wheel Adapter using the provided M20 Split Flange Nuts Torque as specified in Figure 1 CLIPS REMOVES STOP SURFACES K STOCK STEERING STOP KINGPIN NUT
43. 8 SECONDARY SPACERS 4 5 8 11 X 4 1 2 GR8 BOLTS TO 160 LB FT TYP FOR ALL 5 8 11 GRADE 8 BOLTS NOTE LONG BED 8 BOX VERSION SHOWN A 10 7 2011 REV DATE UPDATED WELD NOTES FOR CLARITY REVISED WEIGHT SETTING INSTRUCTIONS ARJ DESCRIPTION APP ME JUNESSPECTES MANUAL 11 GM C 25 3500HD REAR ASSY INSTALL maa FRAC OTHER ue x 5 pd md DIVERSIFIED METAL FABRIC 404 875 1512 NOTE FOR INDIVIDUAL PART 5 AND EXPLODED DATE DRAWING DIAGRAM REFERENCE DRAWING 600161 M1015107 FOR INDIVIDUAL PARTS LIST PARTS ORDERING REFER TO DRAWING 600101 NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME SPACERS ARE TO GO ON THE UPPER TWO NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL SLOTS OF THE OUTBOARD SIDE OF THE INNER LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR FRAME BRACKET FOR BOTH THE PASSENG ER DUAL SHIELD MIG WIRE SHOULD BE USED amp DRIVER SIDES INC LUDED IN KIT 600706 WARNING DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL AUGNMENTAD USTMENT THE SLOTS IN THE CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS amp LEAD TO PRE MATURE BEARING FAILURE AD USIMENTS FORWARD OR BACKWARDS WELD ALL SHIMS BRACKETS AND WASHERS AS DESCRIBED IN C
44. 9 FRONT ONLY A FRONT GUIDEWHEEL CONTROLS 800166 ON SUN VISORS OR INSTRUMENT PANEL 800160 800161 800163 800164 800165 800113 800167 800169 ON HARNESS BOX DRIVER S DOOR JAMB 800162 BEHIND SEAT 800170 AT REAR GUIDEWHEEL CONTROLS ON EACH WHEEL 800168 RW 1013 DECALS 800192 800166 EE EE EE TITLE Purchased Fastener Torque Specification PURPOSE To Establish Production Methods For Installation Of Commonly Purchased Threaded Fasteners COMMON USAGE Most Areas Of Multiple Part Assembly And Retention PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Most Common Sizes Of SAE J429 Grade 5 And 8 And Of ASTM A574 Alloy Bolts PROCEDURE A Identify The Fastener As Either Fine Or Coarse Thread Select The Appropriate Chart Below Identify The Fastener Size Diameter And Threads Per Inch Select The Appropriate Row The Chart Selected C Identify Grade Of The Bolt D Identify Whether The Bolt Is Plated Or Plain E Read Across The Size Row And Down The Grade And Plain Or Plated Column The Intersection Of Row And Column Gives Torque FINE THREAD BOLTS COARSE THREAD BOLTS RECOMMENDED TORQUE SAE J429 SAE J429 ASTM A574 FOR GR 8 W SAE J429 SAE J429 ASTM 574 GRADE 5 GRADE 8 ALLOY PREVAILING TORQUE NUT GRADE 5 GRADE 8 ALLOY 3 MARKS 6 MARKS KNURLED OD 3 MARKS 6 MARKS KNURLED OD SIZE FUN PLATE en PLAIN aa PLAI
45. ALL OUTS KIT 600706 600706 KIT 60070 8 sq washers 4x block spacers 4x lock nuts amp 4x 6 5 long bolts RAILWHEEL LOAD ADJ USTMENT MOUNTING SLOTS ONCE RAILWHEEL LOAD ADJ USTMENTAND 2 ALIGNMENT IS FINAL ALL WASHERS MUST BE WELD ALL WASHERS ELDED INPLACE ON BOTH THE OUTBOARD amp TACK ON 4 SIDES INBOARD FRAME BRACKET FOR Ih DRIVER PASSENG ER SIDES KIT 600705 4x flat washers 4x lock nuts 4x 6 25 long bolts 2x front frame mount brkts amp 4x tubes amp 4x rectangular mtg plates IF SHIMS ARE REQUIRED WELD ALL WASHERS BETWEEN U BRACKET AND TACK ON 4 SIDES FRAME WELD SHIMS TO ALL MATING SHIMS AND U BRACKET HIGHWAY POSITION VEHICLE FRONT PASSENGER SIDE DRIVER SIDE SECTION A A SCALE 1 8 P KIT 600707 FRONT FRAME BRACKET MOUNTING 4x Sq washers 4x lock nuts 4x flat washers amp 4x 2 long screws ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 1 WELD AS WELD AS DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 3 VIEWING FRONT OF VEHICLE E 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIG HT SETTING INSTRUCTIONS AR REV DATE DESCRIPTION BY NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND TUNES mE Free ETE RW
46. ARNING 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 PRE MATURE BEARING FAILURE WELD ALL SHIMS BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS VEHICLE FRONT See drawing M1015105 for Grease Guard parts NOTE INSTALL COOLER AFTER FINAL WEIG 5 SET SPOTA HOLE THRO UG H THE FRAME BRACKET IF ORIGINAL FRAME BRAC KET HOLE IS COVERED UP FORD DIESEL TRANS CO OLER 600326 2X 1 0 DIA SPAC ERS 600327 8 x 45MM HEX HEAD BOLTS amp 5 16 LO C KWA SHERS 2011 FORD DIESEL TRANS COOLER TO FRAME USE RETRO KIT P N 600324 UNLESS SPECIFIED FRAC MACH FRAC OTHER x DRILL 925 ANGULAR SURF FINISH THREADS 1 32 1 16 2 063 030 005 015 125 MICRO 2A AND 2B RW 1015 A 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIGHT SETTING INSTRUCTIONS REV DATE DESCRIPTION BY APP TOLERANCES TITLE 08 09 2 350 FORD FRONT ASSY INSTALL DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWN BY APPD By JBG DATE DRAWING NUMBER 3 08 10 M1015102 REV FOR INDIVIDUAL PARTS LISTOR PARTS ORDERING REFER DRAWING 600109 KIT 600708 6X 3 LONG BOLTS 8X FLAT WASHERS 6X LOCK NUTS amp 4X SQ WASHERS KIT 600708 EXPERIENC E THE FULL STRUC TURA
47. AST 1 2 A TURN IF ROTATED HEAVILY BY HAND REV DATE DESCRIPTION BY b NO SIGNIFICANT ENDPLAY CAN BE FELT BY ROCKING THE WHEEL IN AND OUT ME 6 REPEAT IF USTMENT IS NEC ESSARY TT 55 WHEEL amp G SPINDLE 1015 STW SECURE W PIN ITEM 4 DIVERSIFIED METAL FABRICA TORS INC 404 875 1512 L FILL OUTBOARD CAVITY COMPLETELY omus o RUN A BEAD OF SIUCONE ON BOTH MOUNTING SURFACES OF THE SPACER N INSTALL HUBC AP WITH PROVIDED SCREWS uus 2 1015106 DRAWING NUMBER PARTNO HRFL1 4X1 1 2 DESCRIPTION HR FLAT 1 4 THICK x 1 1 2 WIDE 600237 WIDE GAGE ADAPTER 2X 3 8 16 x 1 HEX HD SC REW 2X 3 8 16 x 1 25 HEX HD SC REW 2X 3 8 TYPE B WASHER RAILSWEEP ASSY 2X 3 8 16 HEX NUT 2X 3 8 LOCKWASHER 2X 3 8 TYPE B WASHER 818503 RAILSWEEP RUBBER REF 600712 WIDE GAGE SWP ADAPT HDWRE KIT REV DATE TOLERANCES UNLESS SPECIFIED DESCRIPTION FRAC MACH BY TLE FRAC OTHER RW 1015 XX XXX DRILL 925 WIDE GAG E RAILSWEEP ADAPTER DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWING NUMBER 600237 600255 GREASE GUARD 600259 REAR TRUCK SETW HARDWARE 600255 G REASE GUARD 600247 WELDM ENT 600248 6
48. ATORS INC RW 1015 3 0 MAINTENANCE 3 5 9 Alignment Troubleshooting Sometimes alignment problems will be combinations of angle and offset It is often helpful to draw a sketch similar to the examples shown in below Tips for Alignment e Ifa truck s chassis is out of alignment it can make it difficult and sometime impossible to align the Railgear Inquire about the vehicles behavior on the highway Occasionally new trucks have to be sent back for alignment to get the rear axle square with the chassis e It is very important to get the rear alignment correct before attempting to align the front REAR ALIGNMENT TROUBLESHOOTING 1 a i e me 1 1 0 LONG 57 SHORT LONG 5 SHORT SY AR Sr NG N ES AR ER RMLGEAR re 2 RALGEAR 5 gt REAR NOT PARALLEL REAR OFFSET COMBINATION RIGHT FRONT ALIGNMENT TROUBLESHOOTING RAILGEAR RAILGEAR 1 2 1 1 INDICATES EQUAL MEASUREMENT 1 _ REAR AXLE _ REAR _ 1 i gt i RAILGEAR RAILGEAR T TALE m 1 1 REAR CORRECT REAR CORRECT FRONT NOT FRONT CORRECT GARSEEEL Figure 3 5 9 A Alignment Troubleshooting 2015 DMF Inc All Rights Reserved 03_00
49. AVE BEEN SET OPTIONAL SECONDARY SPACER FOR TRUCKS lt TD E SPACER KIT PROVIDED WITH FRAME HEIGHTS PART 601423 BETWEEN 29 5 AND 32 1 2 3 AS VIEWED FROM MAX 4 SPACERS PER SIDE IF USED WELD TO ALL MATIN TORQUE 160 LB FT REAR OF TRUCK ONLY ADJUST WITHIN GUIDLINES COMPONENTS TYP FOR ALL 5 8 11 1 1 7 GIVEN IN SECTION 3 4 GRADE 8 BOLTS CONTACT DMF PARTS DEPT H KIT 601424 INCLUDES 8 SECONDARY SPACERS NOTE LONG BED 8 BOX VERSION SHOWN 4 5 8 11 X 4 1 2 GR8 BOLTS STANDARD SPACERS AND PIVOT ARMS ol ACCOMMODATE FRAME HEIGHTS BETWEEN 25 5 7 Fa 2 AND 29 5 OPTIONAL SECONDARY SPACERS A 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIGHT SETTING INSTRUCTIONS WELD AS WELD AS ALLOW FOR FRAME HEIGHTS UP TO 32 FOR DAE DESCRIPTION APP APPLICATIONS OUTSIDE OF THESE RANGES DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 3 PLEASE CONTACT DMF FOR SUPPORT TLE MANUAL 11 GM C25 3500HD REAR ASSY INSTALL LERANCES UNLESS SPECIFIED FRAC MACH RW 1015 2 06 DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 NOTE FOR INDIVIDUAL PART S AND EXPLODED
50. BACK UP RING 1 3 4 ID 2 OD 1 8 W FRONT RW 1015 REAR RW 1015 1 GREASE FITTING STRAIGHT CYLINDER CYLINDER SOCKET HD SET SCREW 1 4 20 X 5 16 NYLON 1 8 MPT X 04 JIC 90 DEG LONG KIT 600710 INCLUDES ITEMS 6 THRU 11 5 94 CLOSED 10 09 OPEN 4 16 STROKE LL x 0 e AAA mi 674 pa gt gt Ea lg 417 y A 2 FRONT RW 1015 Age a 4 750 r m GEA XQ 55 4 05 CLOSED 8 09 OPEN 4 16 5 TORQUE 145 ft lbs 6 12 12 UPDATED PISTON O RING LOCATION 5 1 12 UPDATED STROKE ADDED DRAWING NUMBERS 10 26 10 VIEWS UPDATED TO REFLECT CURRENT WELDMENT CYLINDER GEOMETRY 6 30 09 ITEM 11 WAS 8 226 ITEM 8 WAS 2500 1000 375 DESCRIPTION TITLE REAR RW 1015 lt ET RW 1015 ASSY CYLINDERS RW 1015 FRAC OTHER 1 16 x 0 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES 4 5 E ANGULAR 1 DAS DRAWING NUMBER SURF FINISH Dez WAK 6 5 09 600501 503 PART NUMBER DESCRIPTION 600612 1015 LOCKING VLV BODY ONLY 7024840 241016 VALVE LOCKING CPD 084P PARKER 6801 4 4 04 X 04 O RING 90 FITIING 6400 04 04 04 IC MALE X 04 O RING MALE 6602 04 04 04 T 4J IC X 4 IC F SWIVEL X 4 IC 600613 ORIFICE 070 7051 070 IT
51. BELTS AT ALL TIMES EACH OPERATOR MUST BE FAMILIAR WITH THE HANDLING CHARACTERISTICS BEFORE OPERATING THIS VEHICLE EITHER ON OR OFF ROAD BEFORE OPERATING THIS VEHICLE EITHER ON OR OFF ROAD OPERATORS SERVICE AND PARTS MANUAL 800162 TRUCK GVWR a S S SP SP SP SP SP S SP S ee cetera aat N 9 0 Se 900256200 NOT OVERLOAD THE HI RAIL VEHICLE DO EXCEED A GROSS AXLE WEIGHT RATINGS GAWRs OF VEHICLE B GROSS VEHICLE WEIGHT RATING GVWR OF VEHICLE C LOWER RATING OF TIRE OF WHEEL MAX CAPACITY D 700 POUND MAXIMUM GUIDE WHEEL RATING EACH RAILWHEEL 000005 4 READ OPERATING INSTRUCTIONS PRIOR USE BE AWARE OF REQUIRED STOPPING DISTANCES 1 KEEP HANDS FEET AND LOOSE CLOTHING CLEAR OF EQUIPMENT WHILE 1 OPERATION FOLLOW ESTABLISHED SAFETY PROCEDURES AT ALL TIMES CAREFUL WORKER 15 THE GUIDEWHEEL RELAY BREAKER EMPTY WT FULL FUEL 0 BOX MAX PAYLOAD 800169 SAFETY INSTRUCTIONS VISUALLY INSPECT DAILY FOR TIRE AND WHEEL DAMAGE CHECK WHEEL NUT TORQUE AT 50 MI THEN 6 05 2000 CHECK TIRE PRESSURE DAILY SAFETY INSTRUCTIONS VISUALLY INSPECT DAILY FOR TIRE AND WHEEL DAMAGE CHECK WHEEL NUT TORQUE AT 50 MI THEN 6 05 2000 CHECK TIRE PRESSURE DAILY SAFETY INSTRUCTIONS VISUALLY INSPECT DAILY FOR TIRE AND WHEEL DAMAGE CHECK WHEEL NUT TORQUE AT 50 MI THEN 6 MOS 2000 MI C
52. D OR BACKWARDS FRAME BRACKET FOR DRIVER PASSENG ER SIDES ALTERNATE BRAC KET FOR 4X2 KIT 600701 4x 6 50 long bolts 4x flat washers 8 sq washers amp lock nuts mec EE m 600701 4x 6 50 long bolts 4x flat washers _ gt 8 sq washers amp 4x lock nuts it ee 23 SEE M1015110 FOR H e 4 ALTERNATE BRAC ALL WASHERS WELDED WELD ON EACH SIDE IF SHIMS ARE REQUIRED BETWEEN U BRACKET AND VEHICHLE FRAME WELD SHIMS TO MATING SHIMS AND U BRACKET ONCE RAILWHEEL LOAD AND ALIGNMENT ARE SET SEE 1015110 FOR ALTERNATE PIVOTARM PART ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 VEHICLE FRONT WELD AS WELD AS A DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 3 SECTION A A SCALE 1 12 NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD 8 50 FORD 4X4 7 00 FO RD 4X2 NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 42 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED W
53. DIVERSIFIED METAL FABRICATORS gt Installation and Parts amp Service Manual RW 1015 May 2015 NOTE Please refer to the serial numbers when ordering parts or inquiring about warranty items DMF 665 Pylant Street Atlanta Georgia 30306 Parts 404 607 1684 Parts Fax 404 879 7888 parts dmfatlanta com Service Department 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com PREFACE 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 www dmfatlanta com info dmfatlanta com Ship to 668 Drewry St NE Atlanta GA 30306 How to use this manual Please read this manual carefully If you are an operator you need to concentrate on the operation amp maintenance section Installers and Up fitters should become familiar with the entire manual paying special attention to the Installation Sheet that corresponds to your specific chassis The current i
54. EM NO 1 2 3 4 5 6 NOTE ORIENTATION BEVELED SIDE IS INTO HOLE AND AWAY FROM VALVE CARTRIDGE A 6 28 11 ADDED EXPLODED VIEW amp ORIFICE ORIENTATION NOTES CHANG ED FROM DC 08 40 REV DATE DESCRIPTION BY TOLERANCES TIME UNLESS SPECIFIED i LOCKING VALVE W ORIFICE amp FITTINGS FRAC MACH 132 FRAC OTHER 1 16 063 p 0 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES 015 3 le ANGUAR 4 DRAWING NUMBER Taane 8 19 2010 600611 REAK SIARP EDGES 0030 XA MAX 722 joa 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 wrench
55. Front Assy 09 Ford F250 F350 SRW 5 2 6 600109 Rear Assy 09 Ford F250 F350 SRW 5 2 7 M1015110 RW 1015 Ford Pivot Arms and Brackets 5 2 8 M1015104 RW 1015 Axle Spindle Wheel Assembly 5 2 9 M1015106 RW 1015 Wheel Assembly 5 2 10 600237 Wide Gage Railsweep Adapter 5 2 11 M1015105 Front Rear Grease Guard Sets 2015 DMF Inc All Rights Reserved 05 00 RW 1015 Technical Details doc DIVERSIFIED METAL FABRICATORS INC RW 1015 5 0 TECHNICAL DETAILS 5 3 Hydraulic System 5 3 1 600550 5 3 2 600501 503 5 3 3 600611 5 3 4 5 3 5 4 5 3 6 5 5 3 7 1015 Hydraulic System 1015 Hydraulic Cylinders 1015 Locking Valve w Orifice amp Fittings SAE O Ring Fitting I nstallation National Pipe Thread NPT Fitting I nstallation SAE JIC 37 Degree Fitting I nstallation Cylinder Assembly 5 4 Electrical System 5 4 1 600601 RW 1015 Electrical Schematic 5 5 Chassis Wheel Modifications 5 5 1 509029 5 5 2 509033 5 5 3 509048 5 5 4 509049 GM Suburban 07 to 12 and C 2500 3500 707 to 10 Wheel Adapter Kit GM C K2500 3500 11 to present Wheel Adapter Kit Ford F 2 350 4x2 Wheel Adapter Kit 10 to present Ford F 2 350 4x4 Wheel Adapter Kit 10 to present 2015 DMF Inc All Rights Reserved 05 00 RW 1015 Technical Details doc NOTE FOR INDIVIDUAL PART S AND EXPLODED RAIL WHEEL LOAD RENT DRIVER S SIDE TRUCK FRAME FULL
56. G SPECIFICS Y NOTE SEE SOLENOID NOTE FOR HYDRAULIC DIAGRAM SEE 1 600620 REF PUMP M3528 W EMERGENCY PUMP 00615 00616 ASSY REAR ELECTRICAL UP DWN SWITCH 22 00726 TERMINAL BLOCK DBL ROW 10 00720 ELEC ASSY TOGGLE SWITCH SPDT 6FC64 73 00721 10AMP CIRCUIT BREAKER CB 10A 150AMP CIRCUIT BREAKER 185 150 00723 BUMPER SWITCH RUBBER BOOT 00722 STRAIN RELIEF 450 560 FOR PUMP SOLENOID 00724 1 0 2 WELD BATTERY CABLE W TERMINALS 00725 1 0 10 WELD BATTERY CABLE W TERMINALS 221 10 410 22 18 WIRE 032 ADHESIVE 1 8 QUICK DISCONNECT 16 14 GA 239 10 RINGTERM 10 SHRINK 16 225 14 1 4 16 14 WIRE 032 TERMINAL 00 1 4 SPLIT 1 4 SPLIT WIRE LOOM WIRE16 3SO WIRE 16GA 3 COND SO CABLE 16GA WIRE GXL RED 16GA WIRE GXL BLACK 21 WRE16GA GXL_GRN 1 16GA WIRE GXL GREEN A A w PIL 3 333313 2 31313 8 I 1 1 or FEL ig C 229 SOLENOID DOWN d iz OK GROUND cd 9 b SOLENOID A NOTE UP WIRING SHOWN TYP FOR BOTH VALVES A 4 15 15 REMOVED REDUNDANT COPY OF 501779 EFT 600615 616 600304 305 ADDED 16GA GRN WIRE 10 12 11 REDRAWN SHOWING PICTORIAL REPRESENTATIONS NEH Ax
57. GRADE 8 NYLOCK NUTS MATCH DRILL 1 2 HOLES THROUGH INNER FRAME WEB ONLY 3 EACH SIDE DRIVER S SIDE FRAME RAIL 1 2 13 GRADE BOLTS LONG BED NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME SHORT BED NOTE SHOWN FOR VISUAL REFERENCE INSTALLATION PROCEDURE IS COMPARABLE NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD ENSURE WELDS DO NOT INTERFERE WITH GEAR OPERATION WELD REAR EDGES OF ate ADJUSTABLE L BRACKETS TO THE CROSSPLATE 5 MAX SPACERS AS VIEWED FROM REAR OF TRUCK il SPACER KIT PROVIDED 601423 INNER FRAME PLATES TO BE FLUSH TO TOP OF FRAME ENSURE SPACERS ARE PRESSED FULLY AGAINST ADJ L
58. HECK TIRE PRESSURE DAILY oe SAFETY INSTRUCTIONS VISUALLY INSPECT DAILY FOR TIRE AND WHEEL DAMAGE CHECK WHEEL NUT TORQUE AT 50 MI THEN 6 MOS 2000 MI CHECK TIRE PRESSURE DAILY on SAFETY INSTRUCTIONS VISUALLY INSPECT DAILY FOR TIRE AND WHEEL DAMAGE CHECK WHEEL NUT TORQUE AT 50 MI THEN 6 MOS 2000 CHECK TIRE PRESSURE DAILY 300186 800192 Lx 2550 RSH RO XS EERE VOLES 5550562 5050 250 050 05050 050 050 0505050 SK LI A AFTER FIRST 50 MILES EVERY 6 MONTHS OR 2000 MILES WHEEL NUT TORQUE APPLICATION 00 09 GM C25HD SUBURBAN RIM ACCURIDE 28680 19 5x6 75 ADAPTER 10822 LUGNUTS 8 STOCK 14 60 8 M20 2 PC LUGTORQUE 140 FT LBF ADAPTER HUB 250 ADAPTER RIM SPACERS 0 19 REAR ONLY APPLICATION 00 09 FORD F2 350 RIM ACCURIDE 28680 19 5x6 75 ADAPTER 10821 LUGNUTS 8 STOCK M14 2 PC 8 M20 2 PC LUGTORQUE 165 FT LBF ADAPTER HUB 250 ADAPTER RIM SPACERS NONE APPLICATION 99 04 FORD 2 350 RIM 10808 OTR RIM 19 5x6 0 LUGNUTS STOCK M14 2 PC FLANGED LUG TORQUE 165 FT LBF SPACERS 135 THK FRONT ONLY APPLICATION 99 04 GM 25HD SUBURBAN RIM 10813 OTR RIM 19 5x6 0 LUGNUTS STOCK 60 M14 LUGNUTS LUG TORQUE 140 FT LBF SPACERS 10
59. HEX NUT 3 4 10 GR5 600318 DET SLOT FLAT BAR 1 2 605004 HEX HEAD TAP BOLT 1 2 13 X 6 GR8 605007 HEX HEAD CAP SCREW 1 2 13 X 6 1 4 GR8 605008 HEX HEAD CAP REN 1 2 13 X 6 1 2 500384 RW 1015 DETAIL SUPPORT TUBE 600385 DETAIL PLATE SLOT ADJ 1 1 2 AJOJN 600705 N e 600706 600705 600706 600705 600705 600705 600706 NI N N NIT NIT ND NOTE LONGBED ASSEMBLY SHOWN 113014 LOCKNUT 1 2 13 ESNA GR8 108078 COTTER 3 16 X 2 o DATE DESCRIPTION BY APP TOLERANCES UNLESS SPECIFIED TITLE ASSY FRONT 11C25 3500HD RW 1015 STW FRAC MACH 1 32 FRAC OTHER 1 16 RW 1015 x x DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRILL SIZES 0 DRAWN APPD DATE DRAWING NUMBER FOR INSTALLATION SEE DRAWING M1015109 2 PART DESCRIPTION IN KIT 601414 INNER FRAME PLATE DRIVER S SIDE 601417 LONGBED SHORTBED 601415 INNER FRAME PLATE PASSENGER S SIDE 601418 LONGBED SHORTBED 601405 ADJ L BRACKET DRIVER S SIDE 601411 LONGBED SHORTBED 601406 ADJ L BRACKET PASSENGER S SIDE 601412 LONGBED SHORTBED WLDMT AUREL REAR TTGM 25 3500 60
60. Is the installer responsible for exhaust modifications Is the installer responsible for a spare tire carrier 1 5 Chassis Spec Sheets Please complete the following Chassis Spec Sheet and include with any orders 2015 DMF Inc All Rights Reserved 01 00 RW 1015 General Info doc TIRE MAKE WEIGHT FRONT TIRE MODEL WEIGHT REAR BODY INFO WHEEL OFFSET WHEEL amp TIRE NOTES INVDICE FRONT SUSPENSION i CUSTOMER MOD ATIO FRONT SERIAL MODIFICATIONS SUBMITTED BY WHEELS amp TIRES Ea j YES NID CL AXLE CL AXLE TRACK TRACK REAR 9 1 S og ee es a E RR NU RN E FT N i FRAME SECTION WIDTH REAR FRAME HGT FRAME WIDTH REAR REAR WHEELBASE DS FRAME mad rs FRONT DESCRIPTION DS RAN TITLE T CEN f RW 101 PICKUP TRUCK MEASUREMENT SHEET REAR SHIMS USED IND YU UU q DS x xod i DIVERSIFIED METAL FABRICATORS INC 4049875 1512 3 1015 DRAWN BY APPD BY DATE DRAWING NUMBER REV p pistes pa 9 2 2 1 hyl 800955 DIVERSIFIED METAL FABRICATORS INC RW 1015 1 0 GENERAL INFORMATION This page intentionally left blank 2015 DMF Inc All Rights Reserved 01 00 RW 1015 General Info doc DIVERSIFIED METAL FABRICATORS I RW 1015 2 0 Operations 2 0 OPERATIONS 2 0 OPERATIONS 2 1 Familiarize yourself with the Railgear 2 2 Operation on the Road 2 2 1 Hig
61. L LOAD SEEN BY THE REAR FRAME NO MORE THAN 4 TOTAL amp 1 DIFFERENCE FRO MTRIG HT TO LEFT ENSURE ALL SPAC ERS ARE FIRMLY AG AINSTAD J L BRACKET amp ALIG NED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO MOUNTING RAIL WHEEL LOAD ADJUSTMENT MOUNTING SLOTS ONCE RAILWHEEL LOAD ADJUSTMENT IS FINAL SEE SECTION 3 4 AND ALIGNMENT IS COMPLETE WELD 3 HOLE MOUNTING PLATE TO ADJUSTABLE L BRACKET WELD SPACERS IN PLACE amp WELD ADJUSTABLE L BRACKET TO THE REAR FRAME BRACKET ALONG THE LENGTH OF EACH SIDE SEE FIGURE BELOW FOR EXACT LOCATIONS amp REFERENCE NOTE 2 FOR WELDING INFO ALIGNMENT ADJUSTMENT THE SLOTS IN THE ADJ L BRACKET ARE SLIGHTLY WIDER THAN THE BOLT TO ALLOW FOR SLIGHT ADJUSTMENTS FORWARD OR BACKWARDS TRUCK FRAME NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS 3 HOLE PLATE 600365 ALTERNATE BRAC KET FOR 4X2 BRAC KETAS SHO WN IF MULTIPLE SPAC ERS ARE USED S
62. LANTA GA 404 875 1512 800160 ANHVSS3O3N dl NOILISOd 16 ANHVSSON dl NOILISOd 16 991008 991008 INSPECTION AND MAINTENANCE OF D M F GUIDE WHEEL SYSTEM DAILY refer to Parts and Service manual for details Visually inspect rail gear for hydraulic leaks loose fasteners and excessive wear Spin all four rail wheels noting any bearing noise or resistance Compare left and right wheels for wear particularly diagonal flanges Check for correct tire pressure Inspect tires and rims for damage Check level of hydraulic oil Maintain guide wheel loads during operation within 350 to 700 pounds each OS OG OL 38N 11V4 LINYLSNI 9NI LVe3dO WEEKLY Grease pin off fitting One 1 on front assembly One 1 on rear assembly BI ANNUALLY OR 2000 MILES 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 bead of Form A Gasket or equal Check road wheel lug nut torques Refer to Wheel Nut Torque sticker ONINSVMVW ee NOLLOVEL ISVIHINI S32NYLSIO VW ONINSVM N ANNUALLY Clean hydraulic oil pump strainers JHL YVITINVS 340238 NOILVYIdO QVO 380438 9334 avosriivs
63. LVE STEM VS 925A TPMS SENSOR 10 12 FORD WHEEL ACCURIDE 28680 50180 W DECAL F 2 350 00 12 WHEEL ACCURIDE 28680 50180 DECAL 05 112 FORD WHEEL ADAPTER 509041 WHEEL ADPT 05 12 FORD F 2 350 4X4 W STEERING STOPS WHEEL ADAPTER STL 05 12 F 2 350 10821 SPCR WHEEL ADAPTER 05 12 F2 350 10825 LUGNUT SPLIT FLANGE M20 10826 STUD WHEEL 20MM E 11706 515062 STEERING STOP KIT 05 12 FORD F 2 350 4X4 RW 1013 15 515021 STEERING STOP 05 12 F 2 350 4X4 m gt o 5 5 5 5 5 gt TRUCK HUB REAR SHOWN SUPPLIED W 10852 TORQUE TO 5 9 FT LBS STOCK LUG NUTS TORQUE 165 FT LBS 10825 TORQUE TO 300 FT LBS Figure 1 Installation Exploded Parts Diagram 2012 DMF Inc All Rights Reserved Page 1 of 4 Recommended Tires Mud Snow All position Goodyear G622 225 70R19 5 Michelin XDS2 225 70R19 5 Steer Highway Goodyear G647 225 70R19 5 Installation Warning e Never use anti seize on studs or lug nuts Hand torque all fasteners to the provided specifications using a torque wrench e Improper installation or failure to perform a thorough check for clearances once this unit is installed may lead to damage to the chassis wheels tires or personnel Install TPMS sensor into 19 5 rims as shown in Figure 1 Install and Inflate 19 5 Tires a Mount and balance tires b Inflate ti
64. N DIA TPI FTLB FTLB te mem se P T gt wa s DEE KER KE mes 19 m pw n m hatet gt 2 um x Fel pes qe ps lt MER ss 0 e a s pons of EC KE NN esee v eme nn Me m 5 Fore values specified are for bolts with residual oils or no special lubricants pplied If special lubricants of high stress capacity such as Never Seez d e Jer nn red graphite and oil molybdenum disulphite colloidal copper or white lead are applied 12 2999 ADDED RECOMMENDED TORQUE CHART D ultiply the torque values in charts by 0 90 The use of Loctite does not affect the DESCRIPTION By APP values in charts oS B All values are in Foot Pounds FTLB Multiply by 12 for Inch Pounds oR DUIS ii ib pe ig OTHER FASTENER TORQUE SPECIFICATION C Flat washers of equal strength must be used x D Bolt manufacturer s specs should be used when available k DIVERSIFIED METAL FABRICATORS INC 404 875 1512 E Plated values
65. NO 00215 3 WLDMT PIN AXLE PIVOT RW 1015 00459 CYL ROD RW 1015 SLOTTED NUT 3 4 16 o oo u o o4 699 SLHN3 4 16 FW3 3 4 FLAT WASHER 1 2 13 X 2 LONG GR8 HX HD CAP SCREW N KIT ALSO SEE NOTES 4 HCS1 2 13X2GR8 00353 BO CYL BOSS BRACKET RW 1015 08C25HD 00382 DELFORMED FRAME BRACKET ADJ RW1015 SOLD IN KIT ALSO SEE NOTES 3 X 6 25 LONG GR8 HX HD CAP SCREW SOLD IN KIT ALSO SEE NOTES HCS1 2 13X6 1 4GR8 1 2 600385 ALSO SEE NOTES DE AIL PLATE SLOT ADJ 1 1 2 LD IN KI SO RW 1015 DETAIL SUPPORT TUBE SOLD IN KIT ALSO SEE NOTES 41 1 DI N 45 SARIN SIA ND 600356 5 8 WIDE FLAT WASHER SOLD IN DETAIL FRM SPACER RW 1015 08 GM ALSO SEE NOTES P N 600705 FRONT RAIL PRESSURE ADJ KIT includes 13 qty 4 14 qty 4 22 qty 2 23 qty 4 24 qty 4 amp 25 qty 4 P N 600706 FRONT FRAME ALIGNMENT ADJ KIT includes 12 qty 8 14 qty 4 15 qty 4 amp 27 qty 4 P N 600707 FRONT FRAME BRACKET MOUNTING KIT includes 12 qty 4 13 qty 4 14 qty 4 amp 20 qty 4 DRIVER SIDE FOR ASSEMBLY amp INSTALL USE DWG M1015100 IF ANY WORK IS PERFORMED NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME NOTE 2 FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN
66. OMPASSED 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 a C Use Blue Assemblee Goo 19260 to aid in 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 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 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 certain that O ring seats in counterbore Install self locking rod nut on rod Tighten to 200 to 300 foot pounds torque Torque will vary based on rod
67. ORD PLATE SLOTAD 1 1 2 600507 DET PIN CYLROD RW 1015 FT 500510 DET SLOTFLATBAR 5 8 IN HARDWARE KIT 600701 20716 5 8 FLAT WASHER 238112 FLAT WASHER 1 GR5 500691 FLATWASHER 1 2 GR8 113014 LOCKNUT 1 2 13 ESNA GR8 100260 HEX SLOTTED NUT 1 8 605005 HEX SLOTTED NUT 3 4 10 900495 FLAT WASHER 3 4 GR8 605007 HEX HEAD CAP SCREW 1 2 13 X 6 1 4 GR8 605011 HEX NUT 1 2 13 GR8 605004 HEX HEAD TAP BOLT 1 2 13 X 6 GR8 605004 HEX HEAD TAP BOLT 1 2 13X6 GR8 500691 N IS AININ 4 IS N P S S FLATWASHER 1 2 KIT 600701 13 QTY 4 14 QTY 4 15 8 amp 17 QTY 4 See drawing M1015105 for Grease Guard parts FOR ASSEMBLY amp INSTALL USE DWG 1015102 8 50 4X4 7 00 4X2 10 10 11 ADDED 4X2 FRONT BRACKET REV DATE DESCRIPTION BY TOLERANCES IME UNLESS SPEC IFIED 5 rt 132 om RW 1015 x 063 ASSY FORD 4X4 FRONT RAILG EAR 09 030 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 2 005 DRILL 925 015 ANGULAR B SURF FINISH 125 MICRO THREADS 2A AND 20 5 22 09 D
68. ORS INC RW 1015 2 0 Operations 12 Do not exceed the maximum rated capacity of the equipment 13 Do not attach tow straps or other equipment to the Railgear 2 3 3 Getting off the Rail 1 2 3 Drive vehicle to road crossing Enable Guidewheel Power Switch in cab Either front or rear wheels may be actuated first Note Front Rear Guide wheels cannot be actuated simultaneously Front Guidewheels a Retract front rail wheels completely using switch in cab or at front bumper b Once retracted engage amp lock manual pin offs if equipped Rear Guidewheels a Retract rear rail wheels completely using switch in cab or at rear bumper b Once retracted engage amp lock manual pin offs if equipped Disengage Steering Wheel Lock Drive vehicle off of crossing onto road surface Verify proper Pin off operation 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1015 2 0 Operations 2 4 Emergency Pump Operations The emergency pump is provided to allow a malfunctioning vehicle to be removed from the rail in the event of an electrical fault or pump failure The emergency pump switch located near the hand pump must me held while pumping to position the valves The Emergency Pump Switch is held up to enable flow to the front Railgear amp down for the rear Railgear Note The emergency pump is only intended to stow the Railgear It is not designed or i
69. PACERS NEED TO BE WELDED TO ONE REA RERA ME BRACKET 0 ANOTHER WELD WASHERS 1 BRAC KET 0 AFTER RAIL WHEEL LOAD AND KIT 600714 ALIGNMENTISSET TACK ON 4 4X 2 3 4 LONG BOLTS 4X FLAT WASHERS SIDES 2 LOCK NUTS amp 4X SQ WASHERS WELD ENTIRE LENGTH L BRAC KETTO REAR FRAME BRAC KETON REAR SIDE ASVIEWED REAR OF TRUCK lt WELD AS DESC RIBED IN NO TE 3 WELD AS DRIVER SIDE DESCRIBED IN NOTE 3 PASSENG ER SIDE NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD ENSURE WELDS DO NOT INTERFERE WITH OPERATION OF GEAR ONLY USTWITHIN GUIDELINES GIVEN IN SECTION 3 4 REAR FRAME BRACKET WELD ENTIRE LENGTH OF 3 HOLE PLATE ON BOTH THE TOP amp BOTTOM SIDES RAIL POSITION VEHIC LE FRONT SEE DRAWING 1015105 FOR GREASE GUARD PARTS SECTION A A A 12 10 2012 UPDATED DRAWING VIEWS SHOW NEW PARTS 600365 WAS 600331 JDI A 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIG HT SETTING INSTRUCTIONS ARJ REV DATE DESCRIPTION BY APP TOLERANCES TITLE UNLESS SPECIFIED FAC MACH drm RW 1015 08 09 FORD F2 350 REAR ASSY INSTALL
70. RAWING NUMBER 600107 PARTNUMBER 3 DESCRIPTION COMMENTS NOTES 600503 ASSY CYLINDER 2 RR RE 1015 600225 ASSY RAILWHEEL RTW WHEEL SPING LE TREAD 600412 DET DS REAR BRACKET 08F2 3 PU RW1015 600509 DET PIN CYL ROD RW 1015 RR 600429 DET PS REAR BRAC KET 08F2 3 PU RW1015 500510 DET SLOTFLATBAR 5 8 IN 600714 600422 DETAIL SLIDE PLATE REAR BRACKET RW 1015 08 FORD 600220 DETAIL SUSP PRIMARY RW 1015 600221 DETAIL SUSPENSION PRELOAD RW 1015 238112 FLATWASHER 1 GR5 500691 FLATWASHER 1 2 GR8 900495 FLATWASHER 3 4 GR5 20716 FLATWASHER 5 8 GR8 IN KIT 600708 amp 600714 818127 HEX SLOTTED NUT 1 8 605005 HEX SLOTTED NUT 3 4 10 818367 HHCS 1 2 13 X 1 1 2 GR5 605004 HHCS 1 2 13 X 6 FULLY THREADED 605003 HHCS 5 8 11 X 2 3 4 GR8 IN KIT 44600708 amp 600714 76317 LOCK WASHER 1 2 GR5 113014 LOCKNUT 1 2 13 GR8 18551 LOCKNUT 5 8 11 GR8 IN KIT 44600708 amp 600714 600364 600365 REAR BRAC KET WELDMENT 08 FORD 2 350 4 4 4 2 600340 WELDMENT REAR DS RW 1015 600349 WELDMENT PIVOTARM REAR PS RW 1015 600362 WELDMT PIVOTPIN RR RW 1015 600218 WLDMT PIN AXLE PIVOT RW 1015 108078 COTTER PIN 3 16 X 2 600344 BO PIVOTBOSS PIVOTARM REAR RW 1015 Ble 2 8 0 oo m m w m m ES m Uu a a m
71. ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE ONCE ALIGNED FULLY WELD COMPLETE STRUCTURAL WELD ALL THE WAY AROUND THE INBOARD SIDE OF THE AXLE BRACKET ON BOTH DRIVER amp PASSENGER SIDES ALL FLAT WASHERS MUST BE WELDED IN PLACE TO THE FRAME BRACKET ON BOTH THE INBOARD amp OUTBOARD FRAME BRACKETS FOR BOTH THE DRIVER amp PASSENGER SIDES TACK WELD ON ALL 4 SIDES OF EACH WASHER IF SHIMS REQUIRED FULLY WELD ALL SHIMS IN ALL LOCATIONS IN PLACE ONCE ALIGNMENT 15 ACHIEVED IF MORE THAN ONE SHIM PER LOCATION THEN ALL SHIMS USED AT LOCATION SHOULD BE WELDED TO ONE ANOTHER SEE ALSO M1015100 DESCRIPTION TITLE RW 1015 ASSY RW 1015 09GM 25HD FRONT DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DATE DRAWING NUMBER REV qu 600101 1 10 09 DRAWN WAK APPD BY SUBURBAN PARTS KIT 600708 VERTICAL PLATE TO TRUCK FRAME HARDWARE KIT 600714 VERTICAL PLATE TO RAIL GEAR BRKT HARDWARE PART NUMBER J DESCRIPTION 600331 WLDMT BRACKET REAR RW 1015 600274 600270 RTW ASSY WHL AXLE REAR DBL INSUL GEN SPDL RW 1015 STW 600340 WELDMENT PIVOT ARM REAR RW 1015 600349 WELDMENT PIVOT ARM REAR RW 1015 600220 DETAIL SUSP PRIMA
72. RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 6 Derailment In the case of a minor derailment the cause of the derailment should be determined and corrective steps taken The vehicle should be inspected to determine if repairs or adjustments are required This 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 railwheels 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 e Perform all inspection items as listed above in the Minor Derailment section e Inspect all pivot arms and frame brackets to ensure they are not bent cracked or broken e Ensure all welds are intact and show no signs of cracking or breaking e Ensure all mounting hardware and brackets are securely fastened and are not bent cracked or damaged in any way e A full alignment should be perform
73. RY RW 1015 600221 DETAIL SUSPENSION PRELOAD RW 1015 600218 WLDMT PIN AXLE PIVOT RW 1015 600362 WELDMT PIVOT RR RW 1015 600344 BO PIVOT BOSS PIVOT ARM REAR RW 1015 600503 ASSY CYLINDER 2 RR RE 1015 600509 ISI D i ia I7 2 DET PIN CYL ROD RW 1015 RR 76317 1 2 LOCK WASHER GR5 605012 HEX HEAD CAP SCREW 1 2 13 X 1 1 2GR8 605004 HEX HEAD TAP BOLET 1 2 13 X 6 605003 HEX HEAD CAP SCREW 5 8 11 X 2 3 4 IN KIT 600714 600708 238112 1 FLAT WASHER 900495 3 4 FLAT WASHER GR5 300612 5 8 FLAT WASHERCRB 500691 1 2 FLAT WASHER 8 300612 5 8 FLAT WASHERGR8 IN KIT 600714 600708 818127 RW 1630 FRONT HEX NUT SLOTTED SLHN 1 8 605005 SLOTTED HEX NUT 3 4 10 108078 COTTER 3 16 2 818105 GREASE FITTING 1 4 28 1641 8B 818235 GREASE FITTING FOR REAR LINKS 1 8 1610 BL 113014 LOCKNUT 1 2 13 ESNA 8 600411 DETAIL REAR BRACKET 08 RW 1015 600413 DETSLIDE PLATE RR BKT O8GM25HD RW 1015 500510 4 SIN Elo DET SLOT BAR 5 8 IN KIT 600714 600708 18551 5 5 8 11 NYLON LOCK NUT IN KIT 600714 600708 FOR INSTALLATION USE DWG M1015101 9 1 2011 ADDED 600344 2 BOM AND CHANGED PIVOT
74. SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS 3 HOLE PLATE 600365 ALTERNATE BRAC KET FOR 4X2 BRAC KETAS SHO WN IF MULTIPLE SPAC ERS ARE USED SPACERS NEED TO BE WELDED TO ONE REA RERA ME BRACKET 0 ANOTHER WELD WASHERS 1 BRAC KET 0 AFTER RAIL WHEEL LOAD AND KIT 600714 ALIGNMENTISSET TACK ON 4 4X 2 3 4 LONG BOLTS 4X FLAT WASHERS SIDES 2 LOCK NUTS amp 4X SQ WASHERS WELD ENTIRE LENGTH L BRAC KETTO REAR FRAME BRAC KETON REAR SIDE ASVIEWED REAR OF TRUCK lt WELD AS DESC RIBED IN NO TE 3 WELD AS DRIVER SIDE DESCRIBED IN NOTE 3 PASSENG ER SIDE NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET YOU MAY HAVE TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE THE WELD ENSURE WELDS DO NOT INTERFERE WITH OPERATION OF GEAR ONLY USTWITHIN GUIDELINES GIVEN IN SECTION 3 4 REAR FRAME BRACKET WELD ENTIRE LENGTH OF 3 HOLE PLATE ON BOTH THE TOP amp BOTTOM SIDES RAIL POSITION VEHIC LE FRONT SEE DRAWING 10
75. SWITCH SPDT 6FC64 73 00721 10AMP CIRCUIT BREAKER CB 10A 150AMP CIRCUIT BREAKER 185 150 00723 BUMPER SWITCH RUBBER BOOT 00722 STRAIN RELIEF 450 560 FOR PUMP SOLENOID 00724 1 0 2 WELD BATTERY CABLE W TERMINALS 00725 1 0 10 WELD BATTERY CABLE W TERMINALS 221 10 410 22 18 WIRE 032 ADHESIVE 1 8 QUICK DISCONNECT 16 14 GA 239 10 RINGTERM 10 SHRINK 16 225 14 1 4 16 14 WIRE 032 TERMINAL 00 1 4 SPLIT 1 4 SPLIT WIRE LOOM WIRE16 3SO WIRE 16GA 3 COND SO CABLE 16GA WIRE GXL RED 16GA WIRE GXL BLACK 21 WRE16GA GXL_GRN 1 16GA WIRE GXL GREEN A A w PIL 3 333313 2 31313 8 I 1 1 or FEL ig C 229 SOLENOID DOWN d iz OK GROUND cd 9 b SOLENOID A NOTE UP WIRING SHOWN TYP FOR BOTH VALVES A 4 15 15 REMOVED REDUNDANT COPY OF 501779 EFT 600615 616 600304 305 ADDED 16GA GRN WIRE 10 12 11 REDRAWN SHOWING PICTORIAL REPRESENTATIONS NEH Ax 1 25 10 SPLIT FRONT REAR LOOMS FOR UP DWN GRN BLK WHITE uc A 9 16 09 ADDED PORT REFERENCES TO DIRECTIONAL VALVES f 8 13 09 REMOVED RELAY 10 amp CHG D 10 GA TO 1 0 W 150 6 14 09 EDI
76. TACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEEL 8 LEAD TO PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS 3 HOLE PLATE 5 8 11 GRADE 8 HEX HEAD BOLTS INSURE NUTS amp BOLTS SECURELY FASTENED TO BOLT SPEC 154 LBF FT WELD 3 HOLE PLATE ADJ L BRACKET ALONG ENTIRE LENGTH OF TOP AND BOTTOM Suburban Parts Suburban Parts ENSURE ALL SPACERS ARE FIRMLY AGAINST ADJ L BRACKET 8 ALIGNED WITH THE REAR MOUNTING BRACKET FULLY WELD SPACER TO REAR FRAME BRACKET AS SHOWN IF MULTIPLE SPACERS ARE USED SPACERS NEED TO BE WELDED TO ONE ANOTHER KIT 600714 4X sq washers 4X flat washers 4X lock nuts amp 4X 2 75 long bolts REAR FRAME BRACKET WELD ENTIRE LENGTH OF 7 L BRACKET TO REAR FRAME BRACKET ALONG THE REAR SIDE PASSENGER SIDE DRIVER SIDE ONLY ADJUST WITHIN GUIDLINES GIVEN IN SECTION 3 4 1 POSITION AS WEWED FRONT OF ae WELD AS WELD AS DESCRIBED IN NOTE 3 DESCRIBED IN NOTE 3 SECTION A A VEHICLE FRONT NOTE 3 SET AND VERIFY RAIL WHEEL LOADS AND RAILGEAR ALIGNMENT 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIGHT SETTING INSTRUCTIONS BEGINNING WITH GEAR IN RAIL POSITION FULLY WELD AROUND ECAN DATE By OUTBOARD SIDE OF EACH LEG OF EACH AXLE BRACKET
77. TED SWITCHBOX WIRE COLORS DATE DESCRIPTION TONLESS SPECFEEDI ba ASSY ELECTRICAL Wr WO RW 1015 RW 1015 i 950 DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ANGULAR 3 DRAWN BY BY DATE DRAWING NUMBER REV pr 5 12 09 600601 DIVERSIFIED METAL FABRICATORS INC RW 1015 5 4 ELECTRICAL SYSTEM This page intentionally left blank 2015 DMF Inc All Rights Reserved 05 04 RW 1015 Electrical System doc WHEEL MOD 07 10 GM HD PICKUP 07 12 SUBURBANS TITLE W RIMS amp TPMS DRAWING 509029 BY BJF DATE 3 22 12 RW 1013 15 DIVERSIFIED METAL FABRICATORS INC 404 875 15 REV DATE DESCRIPTION 2007 2010 GM Pickup amp 2007 2012 Suburban Wheel Adapter Kit Description Diversified Metal Fabricator s 509050 Wheel Adapter Kit allows for the use of aftermarket 19 5 rims on 2007 2010 GM 2500HD and 3500HD SRW pickups and 2007 2012 GM Suburbans for use on rail Kit Contents PART DESCRIPTION 509029 WHEEL MOD KIT 07 10 GM HD PICKUP 07 12 SUBURBANS W RIMS amp TPMS 10833 TPMS SENSOR 07 12 GM Truck Set 600617 WIRING ENCLOSURE BOX 4 7 X 2 2 X 3 3 10836 TPMS SENSOR KIT 07 12 GM per wheel TPMS ADAPTER WASHER GM TPMS ADAPTER GROMETT GM TPMS SENSOR GM 07 12 20158 WHEEL ACCURIDE 28680 50180 W DECAL WHEEL ACCURIDE 28680 50180 DECAL 05 GM WHEEL ADAPTER 509014 WHEEL 00 10
78. THE BEARINGS INSIDE THE WHEELS amp LEAD TO PRE MATURE BEARING FAILURE WELD ALL SPACERS PLATES BRACKETS AND WASHERS AS DESCRIBED IN CALL OUTS Suburban Parts Suburban Parts 4X2 amp 4X4 3 HOLE PLATE 5 8 11 GRADE 8 HEX HEAD BOLTS INSURE NUTS amp BOLTS SECURELY FASTENED TO BOLT SPEC 154 LBF FT WELD 3 HOLE PLATE TO ADJ L BRACKET ALONG ENTIRE LENGTH OF TOP AND BOTTOM 2 RAIL POSITION VEHICLE FRONT A 10 7 2011 UPDATED WELD NOTES FOR CLARITY REVISED WEIG HT SETTING INSTRUCTIONS ARJ REV DATE DESCRIPTION BY APP TOLERANCES TITLE UNLESS SPECIFIED ETF 08 GM 25HD REAR ASSY INSTALL FAC RW 1015 X 063 x ron DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 ANGULAR DRAWN APPD DATE DRAWING NUMBER REV SURF FINISH 125 MICRO THREADS 2A AND 28 1 3 04 10 1015101 FOR INDIVIDUAL PARTS LISTOR PARTS ORDERING REFER DRAWING 600107 SECTION 5 2 RAILWHEEL LOAD USTMENT MOUNTING SLOTS ALIGNMENT AD USTMENT THE SLOTS IN THE FRAME ONCE RAILWHEELLCAD AD USIMENT MOUNTING BRACKETARE SLIGHTLY WIDER THAN THE IS FINAL SEC TION 3 4 ALL WASHERS MUST BE WELDED 2 BOLTTO ALLOW FOR SLIGHT ADJ USTMENTS FO RWARD PLACE ON BOTH THE OUTBOARD amp INBOAR
79. TS WILL BE ASSEMBLED amp WELDED TITLE TO YOUR RAILGEAR TTAF RW 1015 ASSEMBLY REAR PIN OFF OPTION INSTALLER TO LOCATED AND MODIFY HANDLE amp RETENTION PLATE TO SUIT APPLICATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ATTACH RETENTION PLATE ITEM 7 DETERMINE THE POSTION FOR THE STOP WASHERS ITEM 9 TO LOCK i T DRAWNBY APPDBY DATE DRAWING NUMBER REV BOTH STOWED AND DEPLOYED POSTIONS WELD WASHERS ITEMS 9 ONTO HANDLE F did we JBG 4 29 2010 600717 DESCRIPTION Y REAR 08 09 F2 350 FORD 4X4 RW 101 OFF DS A POEL PIN O OCKING BAR PIREOPE SLIDE MOUN N ROSS BAR D 2 OFF PLATE PLATE KEYHOLE RW 1015 FL A 13 LOCK NUT AT WA HEAD GRADE 8 1 2 13 X 1 1 2 LONG CUT AND OR BEND PLATE AS NECESSARY ATTACH TO BUMPER OR BODY OPERATION LOCK amp PULL TO UNLOCK FOR BOTH THE STOWED amp DEPLOYED POSITIONS CUT AND OR BEND BAR AS NECESSARY DESCRIPTION IF MANUAL PIN OFF S ORDERED WITH RAILGEAR THE ABOVE COMPONENTS WILL BE ASSEMBLED amp WELDED TITLE TO YOUR RAILGEAR RW 1015 ASSEMBLY 4X4 REAR PIN OFF OPTION INSTALLER TO LOCATED AND MODIFY HANDLE amp RETENTION PLATE TO SUIT APPLICATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 ATTACH RETENTION PLATE ITEM 7 DETERMINE THE POSTION
80. WD A A 10 19 12 REV DATE 600364 WAS 600336 600365 WAS 600331 JDI DESCRIPTION BY TOLERANCES UNLESS SPEC IFIED FRAC MACH 1 32 FRAC OTHER 1 16 x 2 063 XX 2 005 DRILL S S 015 B 125 MICRO TLE FORD 4X4 4X2 PARTS TABLE RW 1015 DIVERSIFIED METAL FABRIC ATORS INC 404 875 1512 2A AND 2B DRAWING NUMBER M1015110 FRONT AXLE ASSEMBLY 600273 STW 600272 RTW REAR AXLE ASSEMBLY 600274 STW 600270 RTW AN m 6 IPARTNUMBER DESCRIPTION 600222 DETAIL DOUBLE INSULATED AXLE TUBE RW 1015 600205 DET INSULATOR SPINDLE BOLTS RW 1015 600206 DET INSULATOR AXLE END RW 1015 600207 DET INSULATOR SPINDLE RW 1015 600210FRONT 600214 REAR WLDM T AXLE BRACKET PS RW 1015 600286FRONT 600214REAR WLDM T AXLE BRAC DS RW 1015 600275 STW 600271RTW ASSY WHEEL amp G EN3 SPINDLE 1015 STW RTW 600231 WELDMENT RAILSWEEP DS RW 1015 COo D O 600232 WELDM ENT RAILSWEEP PS RW 1015 m o 818503 RAILSWEEP RUBBER BELTING DETAIL mm Preferred Narrow FW 0 375 FLAT WASHER 12566 3 8 LOC KWASHER 88 HBOLT 0 3750 16x1 25x1 N HNUT 0 3750 16 D N mm Ui Preferred Narrow FW 0 5 FLAT WASHER HBOLT 0 5000 13x4 25x1 25 N
81. Wheels amp Tires a Lift the vehicle and properly support using jack stands b Remove the stock wheels and tires retaining the stock lug nuts for reuse Install Steering Stops as shown in Figure 2 a Remove Lower Kingpin Nut from each side b Install Steering Stop on each side using provided M16 Type C nut c Actuate steering to its extents in both directions and verify that the Steering Stops are contacting stop surfaces Install Adapters 19 5 Wheels amp Tires as shown in Figure 2 Remove and discard the factory lug retaining clips Mount the Wheel Adapters using the stock lug nuts Torque as specified in Figure 1 Mount the 19 5 rims with 19 5 tires to the Wheel Adapter using the provided M20 Split Flange Nuts Torque as specified in Figure 1 gy UPPER gv ARM p RETAINING i REMOVES STEERING A KINGPIN NU STOCK STOCK Mi460DEG SS M14 STUDS ag NU Figure 2 Wheel Adapter Details 2012 DMF Inc All Rights Reserved Page 2 of 4 Clearance Check s a Verify that neither the rims nor tires contact any frame or suspension components in any combination of steering positions and axle droop jounce conditions b Verify that all brake ABS sensor and other wires or hoses are clear in all steering and suspension positions Restrain if necessary Relocate TPMS Receiver Module a Remove nuts from the main rear seat mounting studs If applicable
82. Y WELD BUMPER EXTENSION DIAGRAM REFERENCE DRAWING 600165 gys PLATE TO FRAME BRACKET ON BOTH RAIL WHEEL LOAD ADJUSTMENT IS DRIVER AND PASSENGER SIDES ACHIEVED BY MOVING THE FRAME BRACKETS VERTICALLY SEE SECTION 3 4 ALIGNMENT ADJUSTMENT IS ACHIEVED BY MOVING THE FRAME BRACKETS FORE AND AFT ALL WASHERS WELDED ef LL 4 1 2 13 X 6 1 2 GRE BC D 5 4 1 2 13 X 6 1 2 GR8 BOLTS WELD ON ALL SIDES Av 4 600356 SPACERS 14 4 600318 SQUARE WASHERS 4 1 2 13 GR8 NYLOCK NUTS KIT 4600705 INCLUDES ALL WASHERS WELDED 4 1 2 13 X 6 1 4 GR8 BOLTS WELD ON ALL SIDES 600385 PLATE WASHERS J 500384 SUPPORT TUBES gt 1 2 GR8 FLAT WASHERS 1 2 13 GR8 NYLOCK NUTS IF SHIMS ARE REQUIRED OPTIONAL LONG PIVOT ARM P N 600320 BETWEEN UBRACKET AND FOR FRAME HEIGHTS BETWEEN 17 AND 18 SHIMS TO MATING SHIMS NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME AND U BRACKET RAILWHEEL LOAD AND NOTE 42 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL ALIGNMENRARE SEN LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL WELDS EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED 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 PRE MATURE BEARING FAILURE WELD ALL SHIMS BRACKETS AND WASHERS IN
83. YOU MAY HAVE AES FETED TO MOVE THE GEAR TO HIGHWAY POSITION IN ORDER TO COMPLETE FRAC OTER THE WELD ENSURE THAT WELDS DO NOT INTERFERE WITH OPERATION OF THE RAILGEAR RW 1015 08 GM 25HD REAR ASSY INSTALL DIVERSIFIED METAL FABRICATORS INC 404 875 1512 DRAWING NUMBER M1015101 ANGULAR SURE FINI TREADS 3 04 10 AND 28 INDIVIDUAL PARTS PARTS ORDERING REFER DRAWING 600107 SECTION 5 2 NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME RAILWHEEL LOAD AD USTMENT MOUNTING SLOTS NOTE 2 AT FINAL INSTALLATION AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT amp RAIL WHEEL ALGNMENT AD era Een HE ME c ONCE RAILWHEELLOAD ADJ USTMENT LOAD SETTINGS HAVE BEEN COMPLETED FOR ALL STRUCTURAL WELDS EITHER LOW HYDROGEN ROD OR PE Ad MUST EE WEDEDIN E DUAL SHIELD MIG WIRE SHOULD BE USED BOLTTO ALLOW FOR SLIG HT AD USIMENTS FORWARD PLACE ON BOTH THE OUTBOARD amp INBOARD f M Ie A OR BACKWARDS PREME PRA CRET FOR DRIVER PASSENGER SIDES TERNATE BRACKET 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 PRE MATURE BEARING FAILURE 4x 6 50 long bolts 4x at washers WELD ALL SHIMS BRACKETS AND WASHERS AS DESCRIBED CALL OUTS 8 sq washers amp 4x lock nuts P 001
84. ally performed by a dealer Please refer to the TPMS amp Wheel Modification information in section 5 5 for your specific chassis Provide this information to the dealer when having the re calibration done 4 2 5 Speedometer Recalibration If your truck requires a wheel modification kit it is typically going from a 16 or 17 inch rims and tires to 19 5 inch rims and tires This changes the rolling radius of the tires significantly requiring the speedometer to be recalibrated Dealerships are able to perform this work at a moderate cost There are tools available to allow an installer to perform the calibration but they are expensive and often model specific Speedometer re calibration is usually done at the same time as the TPMS re calibration See section 5 5 for information specific to your chassis 4 2 6 Re Springing Some vehicles need to be re sprung in order to improve ground clearance to stiffen the vehicle to stabilize mounted equipment or stiffen the truck to allow better rail operation near max GVWR If re springing a vehicle is necessary it should be done before Railgear installation If not the rail wheel loads will have to be checked and adjusted Re springing asymmetrically for cranes or other equipment is not recommended It can lead to uneven rail wheel wear and difficulty in aligning and setting the suspensions 4 2 7 Exhaust Modifications Some vehicles require the exhaust to be modified to clear the Railgear Usually the
85. 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 8 Slide gland down rod engage gland threads into barrel 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 PP003 PRESSURE TESTING A Connect hydraulic power unit to cylinder P 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 Impression sfamp cylinder bottom when all preceding steps have been successfully accomplished COMMENTS Specific assembly instructions on prints are performed with preference over this procedure A 5 25 12 USE 19260 INSTEAD OF HYDRAULIC OIL
86. and dynamic clearance envelope drawing for your rail You need to know the limiting curvature for your rail 1 3 4 Equipment The weight stability requirements and location of any additional truck equipment must be accounted for This allows the suspension settings and alignment to be done more accurately If equipment is to be added later provide the installer with the weight and location to allow for proper set up After any change in equipment or operating payload the vehicle should have the rail wheel load checked and re set prior to use 1 3 5 Railgear Weight The installed weight of the Railgear must be considered Typical installed weights are Front 293 lbs Rear 354 lbs RW 1015 1 3 6 Railgear Options You need to know what options you require such as Rail Sweeps typical Steel vs Rubber Rail Wheels In Cab controls typical 2015 DMF Inc All Rights Reserved 01 00 RW 1015 General I nfo doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 1 0 GENERAL I NFORMATI ON 1 4 Questions Installers Should Ask What is this vehicle to be used for What types of tires are required Highway fronts Mud amp Snow on rear Does the customer specify a particular brand of tires Is any equipment to be added to the truck after Railgear installation o Where is it going and how much does it weigh o Where will customer prefer pump installation bumper body Are there any restrictions on the location of the switchbox in the cab
87. and forth to assure flange engagement On the Track Recommendations given here are for welded rail in good condition Jointed rail or rail in poor condition require further reductions in speed and additional caution All railroad speed rules should be observed but in no case should you exceed 40 MPH while on the track Operator is responsible for determining Safe speed Be aware that RW 1015 Railgear is typically insulated and may not operate the crossing gate circuits unless it is equipped with a shunt kit Reduce speed at all crossings curves switches and frogs Spring frogs should be taken at walking speed or less If a passenger is available it is advisable to have someone monitor progress of guide wheel through the spring frog Tight curves 218deg or 320 R should be taken at less than 15 mph Extremely tight curves should be taken at walking speed with a person monitoring guide wheel progress and vehicle tire coverage Braking distance is increased on the track Do not slide tires or guide wheels on the tracks Braking distance is further reduced in wet or icy conditions Monitor track condition and look for obstacles on above and near the track Even small obstacles should be removed before proceeding Monitor the engine temperature gauge when reversing for long distances Extended operation in reverse may cause overheating 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICAT
88. ard the factory lug retaining clips b Mount the Wheel Adapters using the stock lug nuts Torque as specified in Figure 1 c Mount the 19 5 rims with 19 5 tires to the Wheel Adapter using the provided M20 Split Flange Nuts Torque as specified in Figure 1 STOCK M14 M20 SPLIT STUDS 195 RIM FLANGE NUT Figure 2 Wheel Adapter Details 6 Clearance Check s a Verify that neither the rims nor tires contact any frame or suspension components in any combination of steering positions and axle droop jounce conditions Verify that all brake ABS sensor and other wires or hoses are clear in all steering and suspension positions Restrain if necessary 2012 DMF Inc All Rights Reserved Page 2 of 4 NOTE The following steps must performed dealer as modification of these settings requires a software update specific to your vehicle Re calibrating Soeedometer a The speedometer calibration is limited to stock tire sizes b As the tires we recommend are not a stock size for this vehicle the stock LT265 60R20 tire setting should be selected as it is the most comparable in size Program Tire Pressure Monitoring System a The TPMS system must be reprogrammed to correspond with the correct pressure settings for use with these wheel modifications b Ensure that the dealer sets the TPMS for a nominal pressure of 85 psi Re establish sensor positions a Ensure that the dealer has re established the sensor lo
89. be more difficult When in doubt check with your customer for their preferences e Determine the bumper switch locations 4 5 2 Route Wires e Route the electrical harness according to 5 4 Electrical Schematics Observe the following guidelines We recommend running the wires in split loom Route wires away from the drive train exhaust and any moving parts Ensure that wires do not interfere with Railgear motion Wires can be routed inside the frame Support and restrain wires with wire ties or wire clips o Tie up bumper switches until they are mounted e All electrical terminations should be protected with liquid electrical tape or other means e Heat shrink terminals are provided and should be used wherever possible e Pay attention to Bumper switch route and orientation e Run wires from chassis locations bumpers cab pumps pin offs to the terminal strip under the hood e All bulkhead or firewall penetrations must be protected with grommets e Attach wires to the terminal strip as shown in 5 4 Electrical System e Attach the 2 Battery Source leads and the 1 Ignition Source Lead The ignition source iS made using the provided mini ATO fuse tap e Where possible attach grounds to the battery posts or remote ground provided 000006 4 5 3 Electrical Insulation All Electrical terminations should be protected with a spray or brush on electrical insulation product This includes the bumper switches the pin off grounds pu
90. c to your vehicle Re calibrating Soeedometer a The speedometer calibration is limited to stock tire sizes b As the tires we recommend are not a stock size for this vehicle the stock LT265 60R20 tire setting should be selected as it is the most comparable in size Program Tire Pressure Monitoring System a The TPMS system must be reprogrammed to correspond with the correct pressure settings for use with these wheel modifications b Ensure that the dealer sets the TPMS for a nominal pressure of 85 psi Re establish sensor positions a Ensure that the dealer has re established the sensor locations b This step may also be performed by referring to the vehicle s owner s manual Testing 1 It is the responsibility of the installer to certify that the truck complies with all applicable State and Federal regulations 2 In particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance Inspection amp Maintenance 1 Visually inspect wheels amp tires both prior to and after use on rail look for damage loose hardware etc 2 Checkthe fastener torque 50 miles after wheel tire change and every 2000 miles or 6 months 2012 DMF Inc All Rights Reserved Page 3 of 4 Page left intentionally blank 2012 DMF Inc All Rights Reserved Page 4 of 4 DMF Limited Warranty Policy RW 1015 Railgear Diversified Metal Fabricators DMF products are
91. cations b This step may also be performed by referring to the vehicle s owner s manual Testing 1 It is the responsibility of the installer to certify that the truck complies with all applicable State and Federal regulations 2 particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance Inspection amp Maintenance 1 Visually inspect wheels amp tires both prior to and after use on rail look for damage loose hardware etc 2 Checkthe fastener torque 50 miles after wheel tire change and every 2000 miles or 6 months 2012 DMF Inc All Rights Reserved Page 3 of 4 Page left intentionally blank 2012 DMF Inc All Rights Reserved Page 4 of 4 lt i gt TITLE WHEEL MOD KIT 10 12 F 2 350 4X4 W RIMS amp TPMS DRAWING 509049 BY BJF DATE 3 23 12 RW 1013 15 DIVERSIFIED METAL FABRICATORS INC 404 875 15 REV DATE DESCRIPTION 2010 Ford F 2 350 4x4 Wheel Adapter Kit Description Diversified Metal Fabricator s 509049 Wheel Adapter Kit allows for the use of aftermarket 19 5 rims on 2010 Ford F 2 350 4x4 vehicles for use on rail Kit Contents PART DESCRIPTION 509049 WHEEL MOD KIT 2010 F 2 350 4X4 W RIMS amp TPMS 10851 TPMS SENSOR KIT 10 12 F 2 350 Truck Set TPMS SENSOR KIT 10 12 F 2 350 PER WHEEL TPMS ADAPTER WASHER GM TPMS ADAPTER GROMET GM DILL VA
92. d 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 ATLANTA Diversified Metal Fabricators Inc 665 Pylant St Atlanta Georgia 30306 404 875 1512 404 875 4835 fax info dmfatlanta com www dmfatlanta com 2015 DMF Inc All Rights Reserved NOTE FOR INDIVIDUAL PART S AND EXPLODED TOAN el DRIVER S SIDE TRUCK FRAME FULLY WELD BUMPER EXTENSION DIAGRAM REFERENCE DRAWING 600165 PLATE TO FRAME BRACKET ON BOTH RAIL WHEEL LOAD ADJUSTMENT IS DRIVER AND PASSENGER SIDES ACHIEVED BY MOVING THE FRAME 1 La BRACKETS VERTICALLY SEE SECTION 3 4 ALIGNMENT ADJUSTMENT IS ACHIEVED BY MOVING THE FRAME BRACKETS FORE AND AFT KIT 600706 INCLUDES 4 1 213 X 6 1 2 GR8 BOLTS 4 600356 SPACERS 4 600318 SQUARE WASHERS 4 1 2 13 GR8 NYLOCK NUTS ALL WASHERS WELDED WELD ON ALL SIDES 4 1 2 13 X 6 1 4 GR8 BOLTS WELD ON ALL SIDES 600385 PLATE WASHERS 4 500384 SUPPORT TUBES 1 2 GR8 FLAT WASHERS 1 2 13 8 NYLOCK NUTS IF SHIMS ARE REQUIRED OPTIONAL LONG PIVOT ARM P N 600320 BETWEEN U BRAGKET AND FOR FRAME HEIGHTS BETWEEN 17 AND 18 gt SHIMS TO E AND U BRACKET ONCE NOTE 1 GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO
93. designed to provide the utmost service and reliability Competent workmen guided by stringent quality standards manufacture the products from high grade material DMF warrants products of its manufacturer to be free of defects in material and workmanship under normal use and service for a period of TWO CALENDAR YEARS DMF s obligation under this warranty is limited to repairing or replacing at its factory or other location designated by us any part or parts there of which shall within 30 DAYS of the date of failure or notice of defect be returned and which upon examination shall appear to DMF s satisfaction to have been defective Such repair or replacement does not include the cost of installing the new part or any other expenses incident thereto however the outbound direct ground freight on the part will be prepaid to locations within the continental United States and Canada DMF shall not be liable for other loss damage or expense directly or indirectly arising from the use of its products Ordinary wear and tear abuse misuse neglect or alteration is not covered by this warranty DMF assumes no liability for expenses or repairs made outside its factory except by written consent Warranty is null and void if instructions and operating procedures 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 an
94. dware etc 2 Check the fastener torque 50 miles after wheel tire change and every 2000 miles or 6 months 2012 DMF Inc All Rights Reserved Page 4 of 4 lt i gt TITLE WHEEL MOD KIT 2010 F 2 350 4X2 W RIMS DRAWING ft 509048 BY BJF DATE 3 23 12 RW 1013 15 DIVERSIFIED METAL FABRICATORS INC 404 875 15 REV DATE DESCRIPTION 2010 Ford F 2 350 4x2 Wheel Adapter Kit Description Diversified Metal Fabricator s 509048 Wheel Adapter Kit allows for the use of aftermarket 19 5 rims on 2010 Ford F 2 350 4x2 vehicles for use on rail Kit Contents PART DESCRIPTION 509048 WHEEL MOD KIT 2010 F 2 350 4X2 W RIMS amp TPMS m gt 10851 5 SENSOR KIT 10 12 2 350 Truck Set TPMS SENSOR KIT 10 12 F 2 350 PER WHEEL TPMS ADAPTER WASHER GM TPMS ADAPTER GROMET GM DILL VALVE STEM VS 925A TPMS SENSOR 10 12 FORD WHEEL ACCURIDE 28680 50180 W DECAL F 2 350 00 12 DECAL 05 12 FORD WHEEL ADAPTER WHEEL ACCURIDE 28680 50180 509040 WHEEL ADPT 05 12 FORD F 2 350 4X2 W STEERING STOPS WHEEL ADAPTER STL 05 12 F 2 350 10821 SPCR WHEEL 05 12 F2 350 10825 LUGNUT SPLIT FLANGE M20 STEERING STOP 00 12 FORD F 2 350 4X2 RW 1013 15 515060 10826 STUD WHEEL 20MM E 11706 515025 STEERING STOP DS 00 12 F 2 350 4X2
95. e selected as it is the most comparable in size 9 Program Tire Pressure Monitoring System a The TPMS system must be reprogrammed to correspond with the correct pressure settings for use with these wheel modifications b Ensure that the dealer sets the TPMS for a nominal pressure of 85 psi 10 Re establish sensor positions a Ensure that the dealer has re established the sensor locations b This step may also be performed by referring to the vehicle s owner s manual Testing 1 Itisthe responsibility of the installer to certify that the truck complies with all applicable State and Federal regulations In particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance Inspection amp Maintenance 1 Visually inspect wheels amp tires both prior to and after use on rail look for damage loose hardware etc 2 Checkthe fastener torque 50 miles after wheel tire change and every 2000 miles or 6 months 2012 DMF Inc All Rights Reserved Page 4 of 4 TITLE WHEEL MOD 116 HD PICKUP W RIMS amp 5 gt DRAWING 509033 WAK DATE 3 15 11 RW 1013 15 DIVERSIFIED METAL FABRICATORS INC 404 875 15 REV DATE DESCRIPTION A 3 22 12 Reformatted Corrected 2011 GM HD Pickup Wheel Adapter Kit Description Diversified Metal Fabricator s 509033 Wheel Adapter Kit allows for the use of aftermarket 19 5
96. ear Railgear and guide wheel assemblies NOTE There are six 6 locations on front assembly and ten 10 locations on rear assembly 3 1 3 Bi Annual Maintenance or as required In addition to the items listed in 3 1 1 Daily Maintenance and 3 1 2 Weekly Maintenance perform the following e Disassemble inspect repack and reassemble rail wheel bearings as shown in Section 5 2 e Check torque on wheel adapters and wheels as described in section 5 5 3 1 4 Annual Maintenance or as required addition to the items listed in 3 1 1 Daily Maintenance 3 1 2 Weekly Maintenance and 3 1 3 Bi annual Maintenance perform the following Disassemble inspect repack and reassemble rail wheel bearings as shown in Section 5 2 2015 DMF Inc All Rights Reserved 03 00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE e Check rail wheel loads as described in section 3 4 e Verify the operation of the emergency hand pump If pump does not operate check that the pump is primed as described in section 4 6 TOUCHING UP PAINTED RAILGEAR RUBBER SUSPENSIONS SHOULD NEVER BE COMPLETELY PAINTED BUT MINOR OVERSPRAY IS ACCEPTABLE 3 2 Lubricant amp Fluids Specs Hydraulic oil e Unax RX 46 hydraulic oil or equal Wheel bearings Grease Fittings Factory Standard Citgo Syndurance Premium Synthetic 460 2 e Warm Climates Mystik J T 6 Hi Temp Multi Purpose Grease 2 or equivalent 3 3 Whe
97. ecs 3 Wheel Modification Kit Inspection amp Maintenance 3 1 Wheel Mod Kits 3 Rail Wheel Load 4 1 Warnings 4 2 When to check Rail Wheel Load 4 3 How to check Rail Wheel Load 4 4 Target Rail Wheel Loads 4 5 Adjusting Rail Wheel Load 4 6 After Setting Rail Wheel Loads UJ Alignment Alignment Overview Alignment Adjustments Alignment Method 1 Alignment Method 2 After Setting Alignment Rail Test after Alignment Alignment Diagram Method 1 Alignment Diagram Method 2 Alignment Troubleshooting Derailment 11 Troubleshooting On track Problems 01 n n n n n n Un O I O QI B QQ N H WD w w w w w L9 w n UO w L9 DJ U UO Q QU Q Wr 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 1 Recommended Maintenance amp Inspection Frequency The following are instructions for routine inspections recommended by Diversified Metal Fabricators If your Railgear vehicle is used heavily or under extreme conditions such as operation in mountainous regions or extreme temperatures the inspections listed below may need to be performed more frequently than stated Additionally government or corporate regulations may require that 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
98. ed See section 3 5 e Wheels should be removed and the bore bearing races and insulation if applicable should be inspected for any damage For further wheel details see section 5 2 for appropriate wheel amp axle assembly drawings e 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 If there is no apparent cause for derailment the vehicle may have an alignment problem or rail wheel load problem See Section 3 4 Rail wheel load and Section 3 5 Alignment Please contact DMF for any assistance you may require 2015 DMF Inc All Rights Reserved 03 00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS I NC 3 6 1 Troubleshooting On track Problems RW 1015 3 0 MAI NTENANCE Symptom Possible Cause Diagnostic Step Corrective Action Rail wheel vibration noise Damaged Tread Patterned Wear on Tread Loose Wheel Inspect treads Inspect Bearings amp Suspension Inspect Suspension Bearing and Spindle Tighten adjust or replace Tighten adjust or replace Vehicle tracking to one side wandering Misalignment Overload or load imbalance Un Even Rail Load Vehicle Load Check Alignment Visually inspect scale vehicle Weigh Vehicle and Check Rail Loads Adjust Alignment Unload and or redistribute load Adjust Load Distribution and Re set Rail Loads
99. ed and secure Verify lug nut torque Verify grease fittings have been lubricated Verify final weld out has been performed as per section 4 11 Final Weld Out 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 4 0 INSTALLATI ON This page intentionally left blank 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 5 0 TECHNICAL DETAILS 5 0 TECHNICAL DETAILS 5 1 Application Installation Drawings 5 1 1 M1015109 Install Front 11 GM Chevrolet 25HD 3500SRW 5 1 2 M1015107 Install Rear 11 GM Chevrolet 25HD 3500SRW 5 1 3 M1015100 Install Front 09 GM Chevrolet 25HD Suburban 3500SRW 5 1 4 M1015101 Install Rear 09 GM Chevrolet 25HD Suburban 3500SRW 5 1 5 M1015102 Install Front 09 Ford F250 F350 SRW 5 1 6 M1015103 Install Rear 09 Ford F250 F350 SRW 5 1 7 600716 Assembly Front Pin Off Option 5 1 8 600717 Assembly Rear Pin Off Option 5 1 9 600719 Assembly 4x4 Rear Pin Off Option 5 1 10 800192 Instruction and Safety Decals 5 1 11 PPOO6 Purchased Fastener Torque Specifications 5 2 Railgear Assemblies 5 2 1 600165 Front Assy 11 GM Chevrolet 25HD 3500SRW 5 2 2 600161 Rear Assy 11 GM Chevrolet 25HD 3500SRW 5 2 3 600101 Front Assy 09 GM Chevrolet 25HD Suburban 3500SRW 5 2 4 600102 Rear Assy 09 GM Chevrolet 25HD Suburban 3500SRW 5 2 5 600107
100. el Bearing Grease Factory Standard Citgo Syndurance Premium Synthetic 460 2 Warm Climates Mystik J 6 Hi Temp Multi Purpose Grease 2 or equivalent 4 OYU1 3 02 NI a 4 STEEL TREAD WHEEL STW WHEEL ASSEMBLY PART 500076 WHL amp SPINDLE ASM PART 600275 WHEEL ASSEMBLY PROC 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 PLACE WHEEL ON AXLE F FILL CAVITY BETWEEN BEARINGSAND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE INSERT BEARING IN OUTBOARD SIDE OF WHEEL H INSTALL TO NG UE WASHER ITEM 6 LINE THE TAB UP WITH KEYWAY IN SPINDLE I INSTALL WHEEL NUT ITEM 7 AND TIGHTEN HEAVILY BY HAND UST BEARING 1 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 LO O SENS 3 BACK OFF NUT ITEM 7 APPROXIMATELY 1 8 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 ADJ USTM ENT WITH A DIAL INDICATOR IF AVAILABLE OR MANUALLY AS FOLLOWS PROPERLY USTED WHEEL A 5 20 15 CHANGED GREASE STANDARD JDI a WILL SPIN FREE FOR ATLE
101. el Modification Kit Inspection amp Maintenance 3 3 1 Wheel Mod Kits DMF offers wheel kits match to specific vehicles See section 5 5 for inspection and maintenance information 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 4 Rail Wheel Load Rail wheel load is the amount of weight carried by each rail wheel while on rail It is important that the rail wheel loads are set within the limits of safe operation as defined in section 3 4 4 Too little rail wheel load can lead to derailment Too much rail wheel load can cause premature wear or failure of the Railgear components It will also reduce traction and decrease braking performance 3 4 1 Warnings NEVER OPERATE A VEHICLE ON RAIL WITH RAIL WHEEL LOADS OUTSIDE OF THE LIMITS AS DESCRIBED IN TABLE 3 4 4 CHECK FOR PROPER TIRE INFLATION BEFORE USTI NG RAIL WHEEL LOADS OR OPERATING VEHICLE ON RAIL ADDING OR REMOVING EQUIPMENT WILL CHANGE RAIL WHEEL LOADS ALWAYS CHECK RAIL WHEEL LOADS BEFORE OPERATING THE VEHICLE ON RAIL 3 4 2 When to check Rail Wheel Load Once per year or more frequently as conditions dictate If you have changed the empty weight of your truck by adding or subtracting fixed equipment or tools If you suspect low rail wheel load If you are experiencing premature tread wear If the Railgear fails to deploy fully due to overloading If poor traction or brakin
102. es be aligned to the vehicle and parallel Refer to Figure 3 5 6 Alignment Method 1 3 5 4 Alignment Method 2 This method is easier to perform in the field and only require a tape measure and two persons Refer to Figure 3 5 7 Alignment Method 2 3 5 5 After Setting Alignment After making any changes to alignment during initial installation or maintenance return to section 3 4 to check your rail wheel loads and adjust as needed After any changes to rail wheel loads return to 3 5 to re verify alignment Once alignment and rail wheel loads are set correctly put Railgear into rail position then tack weld Railgear including axle brackets spacers and mounting brackets and plates Final weld out see Section 4 11 will not be performed until after vehicle has been rail tested See Section 3 5 6 3 5 6 Rail Test after Alignment After rail wheel loads and alignment have been set and verified paint wheels then perform track test on straight rail Things to consider during track test e Only go forward while on rail before checking wheel wear Changing directions while performing the test does not provide accurate results e Observe marking on wheel is even on all 4 wheels If wear isn t even adjust alignment as necessary 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc 3 0 MAINTENANCE RW 1015 DIVERSIFIED METAL FABRICATORS INC 3 5 7 Alignment Diagram Method 1
103. g performance on rail is experienced 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 3 0 MAINTENANCE 3 4 3 How to check Rail Wheel Load Rail wheel loads can be determined by use of a bottle jack with an attached pressure gauge DMF recommends the use of a DMF 501749 Jack and Pump Assembly Fig 3 4 3 A Using this model will allow the gauge to display force directly PSI gauge pounds force If another jack is used you will need to determine the conversion factor to relate gauge pressure to force PULL WITH 5LBS FORCE SHEET OF PAPER WOOD BLOCK OR SIMILAR M1015108 501749 JACK AND PUMP ASSEMBLY Figure 3 4 3 A Checking rail wheel load Procedure 1 Confirm that the truck is at its operational weight the chassis and rail wheels are in alignment and that all 4 tires are inflated to 85 psi 2 Place truck on rail or simulated rail refer to 2 3 1 apply parking brake and shut off engine If using simulated rail verify that the rail wheel flange is not touching the ground DMF recommends using 2 x3 thick wall tubing Ensure that none of the rail wheel flanges are riding right up against the rail as this may affect weight settings Place the jack under the Railgear axle tube as close as possible to the rail wheel Support jack as necessary with wooden blocks so that the distance from the jack to the axle tube is less than 1 2 with the jack in the re
104. gement Max speed on rail 40MPH Operator is responsible for determining SAFE speed SNISSOSO NO NOILISOd 2 SNOILONULSNI SNOILONHLSNI S 1VO3Q 8VOF NI TYNNVIN NI 55 NO NOILISOd 72 HV39 lIVH LNO23 H3MOT1 S S 1IVO3G 8VO NI WNNVW NI LNO J YUIMOT S AYVSSAOAN Al NOILISOd 15 f QV dl NOILISOd 15 IN3N3OVON339NV14J t SNOILONYLSNI Q31IVL3G 3367 IN3N3OVON3 39NV 14 AdlH3A 79 IN3W3O9VON3 AONV 14 AJIH3A t HOLIMS YVSOTIVY YIMOT 8 SNOILONUYLSNI 9371139 335 L IN3N3O9VON3 JONV 14 9 HOLIMS Yad ANNE YVAOTIVY 6 TO 1 Drive vehicle onto road crossing REMOVE Either front or rear wheels may be activated first VEHICLE Front rail wheels Note Front Rear Railwheels cannot be actuated simultaneously FROM A Enable Guidewheel Power switch in vehicle cab with engine running RAIL B Retract front rail wheels completely using switch in cab or at front bumper C Once retracted engage and lock manual pin offs Electric pin offs engage automatically Rear rail wheels A Retract rear rail wheels completely using switch in cab or at rear bumper B Once retracted engage and lock manual pin offs Electric pin offs engage automatically Disengage steering wheel lock Turn off Guidewheel Power switch Drive vehicle off of crossing onto road surface DIVERSIFIED METAL FABRICATORS INC AT
105. hat might cause them to be damaged Replace the rear seat and tighten the lower mounting bolts If applicable 2012 DMF Inc All Rights Reserved Page 3 of 4 Figure 4 Mounting Location NOTE The following steps must be performed at a dealer as modification of these settings requires a software update specific to your vehicle that must come directly from GM 8 Re calibrate Speedometer a The speedometer calibration is limited to stock tire sizes b Asthe tires we recommend are not a stock size for this vehicle the stock LT265 60R20 tire setting should be selected as it is the most comparable in size 9 Program Tire Pressure Monitoring System a The TPMS system must be reprogrammed to correspond with the correct pressure settings for use with these wheel modifications b Ensure that the dealer sets the TPMS for a nominal pressure of 85 psi 10 Re establish sensor positions a Ensure that the dealer has re established the sensor locations b This step may also be performed by referring to the vehicle s owner s manual Testing 1 It is the responsibility of the installer to certify that the truck complies with all applicable State and Federal regulations In particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance Inspection amp Maintenance 1 Visually inspect wheels amp tires both prior to and after use on rail look for damage loose har
106. he vehicle onto the rails centering rear tires on the track Enable Guidewheel Power Switch in cab Engage the truck s parking brake to prevent the truck from rolling Retract and lock front and rear manual pin offs If equipped with pins Lower Rear Guidewheels first Note Front Rear Guidewheels cannot be actuated simultaneously Raise or top out rear Railgear to free pins if equipped with pins Using electric switch at rear bumper lower Guidewheels within 2 3 inches of railhead Verify alignment with rail move truck to adjust if necessary Using electric switch at rear bumper deploy rear wheels fully and properly engage the rail The Guidewheels are an over center design and do not require pin offs in the rail position Lower Front Guidewheels Note Front Rear Guidewheels cannot be actuated simultaneously Raise or top out front Railgear to free pins if equipped with pins Using electric switch at front bumper lower Guidewheels within 2 3 inches of railhead Verify alignment with rail move truck to adjust if necessary Using electric switch at front bumper deploy front wheels fully and properly engage the rail The Guidewheels are an over center design and do not require pin offs in the rail position Double check all flanges to assure that they are properly engaged with the rail Engage steering wheel lock and verify its proper function Turn off Guidewheel Power switch in cab Drive back
107. hway Locking System 2 2 2 Reduced Turning Radius 2 2 3 Clearances amp Approach Angles 2 2 4 Highway Speeds 2 3 Operation on the Rail 2 3 1 Getting on the Rail 2 3 2 On the Track 2 3 3 Getting off the Rail 2 4 Emergency Pump Operations 2 4 1 To Stow Railgear with Emergency Hand Pump 2 1 Familiarize yourself with the Railgear You should read the entire Operation section You should know where the following item parts are e Emergency Pump Exterior Bumper Switches e Emergency Pump Selector Switch e Hydraulic Reservoir e Cab Switches e Emergency Pump Handle 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICATORS I RW 1015 2 0 Operations 2 2 Operation on the Road If you operate a vehicle modified for on track use you need to keep in mind several factors 2 2 1 Highway Locking System DMF now offers a pilot operated check valve locking system to restrain the Railgear in the highway position This system will reduce maintenance and improve reliability The original pin off system is still offered to those who require it The pin off system prevents hydraulic leak down or a leaky connection or hose from allowing your gear to move from the highway position The operator should verify that the Railgear is pinned off properly before driving on the road If you have a problem with your locking valves or pin off system chain or strap the gear in the highway position in order to mo
108. ight switches Figure 4 4 A Steering Wheel Lock Installation Figure 4 4 B Steering Wheel Lock In Use 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 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 5 Install Electrical System Refer to 5 4 Electrical System 4 5 1 Locate Components e Determine location under the hood for the circuit breakers and terminal strip It should be accessible and protected from road spray High on the firewall along the inside of the fender and attached to the battery box are typical locations e Determine the location of the pump DMF recommends locating them in following locations in order of preference o Behind Bumper Inside tool cabinet or cross body tool box o Under cross body tool box o Underbody and attached to front of rear Railgear If placed in a toolbox or cabinet covers should be made to protect pumps and solenoids Covers must be easily removed for service e Determine switchbox location Consider safety and convenience when selecting the position for the switch box Pickup trucks usually provide several options but SUV s can
109. ing may be necessary E To align an adjustable fitting unscrew by desired amount but not more than one full turn Use wrench to hold in position Screw nut down to port face until finger tight F Tighten lock nut adjustable or fitting non adj the indicated Flats From Finger Tight F F F T in either the Adjustable 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 Ge Boe fer Size Thread Size s Je Jos wes Jo free NON ADJUSTABLE FITTINGS 28 en Size Thread Size F F F T e wes fis s fs AT DESCRIPTION TITLE PRODUCTION PROCEDURE 003 O RING FITTING INSTALLATION DIVERSIFIED METAL FABRICATORS INC 404 875 1512 005 ZEN DRAWN BY BY DATE DRAWING NUMBER REV TSH 06 02 94 Ty PART NO DESCRIPTION PO EGEN GE j 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
110. ingle Rear Wheel Models only 2015 DMF Inc All Rights Reserved 01 00 RW 1015 General I nfo doc DIVERSIFIED METAL FABRICATORS INC RW 1015 1 0 GENERAL INFORMATION 1 3 Specification Considerations There are many things to consider when specifying a vehicle for use with Railgear Attention to these factors during specification will prevent confusion delay and expense during the install It also will often result in a better truck for the operator 1 3 1 Rail Gage Wheel Track Probably the biggest factor determining the suitability of a chassis for use on the rail is the vehicle s track relative to the rail gage Wheel track is defined as the center to center distance between the tires on the same axle on steering and single wheel rear axles Full sized Pickups and SUVs nearly always require a Wheel Modification Kit to narrow the vehicle track to fit on the rail We provide Wheel Modification Kits as required for approved chassis for standard gage 56 5 If you require a wide gage or other solution please contact us 1 3 2 Body Requirements Most chassis require replacement or modification of the factory front bumper Occasionally modifications to the rear wheelhouse are required See section 4 0 for more information 1 3 3 Rail Clearance Any special clearance requirements such as third rail clearance catenary clearance and platform clearance should be investigated before ordering the chassis or Railgear Obtain a static
111. installer cuts the exhaust and has a muffler shop complete the work after the gear is installed If 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION multiple identical vehicles are being worked on you may want to have the exhaust modification done before the Railgear installation Flexible exhaust pipes can be used temporarily during the install but are not recommended as a permanent exhaust pipe In general EPA 07 diesel exhausts should only be modified aft of the after treatment device Every attempt should be made to preserve the back pressure so that the required pressure sensors are not affected This can be done using an equivalent length method Many systems use a diffuser tip to lower the exhaust temperature to safe levels Diffusers should be retained if modifications are necessary Please refer to the chassis vendor s body builder s information on exhaust modifications 4 2 8 Tire Carrier Often the vehicle s spare is located in the area to be occupied by the rear Railgear Installers are typically expected to provide a tire carrier in the bed for pickups or on the lift gate or in the cargo area for SUV s 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 4 0 INSTALLATI ON 4 3 Install Wheel Modification Kit In order for the tires to rest on the rail many vehicles will requ
112. ionally a vehicle will require modification to the wheelhouse If your vehicle requires wheelhouse modifications they will be explained in 5 5 chassis and wheel modifications 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I RW 1015 4 0 INSTALLATION 4 4 Steering Wheel Lock Installation DMF Velcro Steering Wheel Lock Operation 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 adhesive backed hook is placed on the steering wheel column and a second piece placed on the top flat of the steering wheel hub The 4 wide piece of loop fabric can then be applied to bridge the gap between column and wheel preventing the front tires from accidentally being turned while on the rail However in the event of an emergency the steering wheel can be forcibly turned and the Velcro fasteners will separate allowing the driver to steer the vehicle DMF Velcro Steering Wheel Lock Installation 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 l
113. ire replacement wheels with a greater inset negative offset These wheels are usually very heavy and a wheel dolly is recommended Some vehicles will also require spacers to get both the wheels over the rail These can be on one or both axles Some vehicles will also require stud replacement to allow for an unusually thick set of spacers As with spacers this can be on one or both axles 4 3 1 Safety Statement Brake lines and ABS Sensor Wires usually need to be tied back in order to clear the new wheels Zip ties and springs are useful for this purpose Ensure that Brake ABS wires and lines do not come in contact with the wheel tire or suspension in any position Make sure there is sufficient slack to allow the line to reach in any suspension position Refer to Section 5 5 Chassis Wheel Modifications to determine which of the following applies to your installation 4 3 2 Wheel Adapters Some vehicles will use wheel adapters to allow the use of a stock 19 5 rim These adapters will bolt to the vehicle hub and the rim will then bolt to the adapter 4 3 3 Spacers required spacers are easily installed by slipping them on the studs before installing a wheel tire Care should be taken to prevent thin spacers from binding and being bent or crushed Refer to 5 5 Chassis Wheel Modifications to determine if and where spacers are required IF YOUR KIT CAME WITH WHEEL SPACERS USE THEM If you don t you can damage brake lines ABS Sensor wires ti
114. mp grounds solenoid connections terminal strip connections and the terminal strip ground Failure to adequately protect the electrical components can lead to corrosion and system malfunction The manufacturer does not warranty the installation of a third party installer This is the installer s responsibility 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 4 0 INSTALLATI ON 4 6 Install Hydraulic System Refer to 5 3 Hydraulic System 4 6 1 Route Hydraulic Hoses Use supplied hydraulic hoses Take care to use the indicated lengths where shown Route all hydraulic hoses according to the Hydraulic Schematic Observe the following guidelines Route all hoses away from the drive train exhaust and any moving parts Ensure that hoses do not interfere with the Railgear Hoses can be routed inside the frame Support and restrain hoses with wire ties or wire clips Hoses should be marked and capped before routing through the frame to prevent collecting debris 4 6 2 Install Emergency Hand Pump e Install pump behind bumper or in truck bed tool box or cargo area Be careful to allow easy access to the Emergency Pump e Ensure hand pump selector switch can be easily reached while operating hand pump 4 6 3 Prime Emergency Hand Pump The emergency hand pump must be primed and tested after initial installation It must be re primed and tested after any components of the h
115. nstallation sheet for your specific chassis located in 5 1 Installation Guides Study this sheet before proceeding through the general instructions 4 1 4 Receiving General Supplied Parts Checklist PARTS QTY Manual Front RW 1015 Unit Rear RW 1015 Unit Hydraulic Power Unit and Bracket Wiring Harness Assembly In Cab Switch Box 1 Wheel Modification Kit if required see appendix for details Varies Wheels Adapters Spacers Lug nuts Steering Wheel Stops Assembly Steering Wheel Lock Assembly 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 1 5 Required Tools amp Materials Aside from general shop tools and safety equipment the following tools will be required Arc or MIG Welder Surge Protector Protects ECM from damage while welding Cutting Torch Hand Grinder Frame Drill Air Saw Test Rail 4 Steel Tubing 3x2x36 or actual rail ATF Fluid DEXRON I I I Electrical Terminal Insulation Spray on or Brush on Wire ties wire loom and electrical tape Additionally the following tools are recommended Transmission Motorcycle Lift Pallet Jack or Forklift Overhead Crane Work Lights Work Area Wheel Dolly 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 2 Cha
116. nstallation sheets are found in 5 1 If you are reading this to learn more about our Railgear you ll want to start with the section on Specifying a Truck Operations and then look through the remaining material 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 manual at our website listed above 2015 DMF Inc All Rights Reserved 00 02 RW 1015 Preface doc DIVERSIFIED METAL FABRICATORS INC RW 1015 1 0 GENERAL INFORMATION 1 0 GENERAL I NFORMATI ON 1 0 General I nformation 1 1 General Description 1 2 Currently Approved Chassis 1 2 1 Chevy GM 1 2 2 Ford 1 2 3 Ram 1 3 Specification Considerations 1 3 1 Rail Gage Wheel Track 1 3 2 Body Requirements 1 3 3 Rail Clearance 1 3 4 Equipment 1 3 5 Railgear Weight 1 3 6 Railgear Options 1 4 Questions Installers Should Ask 1 5 Chassis Spec Sheets 1 1 General Description DMF RW 1015 Railgear is designed for vehicles in the 8 000 to 12 000 GVWR range It is applicable to many Pick up Trucks Cab amp Chassis and SUV s in this range It is not intended for vehicles with dual rear wheels RW 1015 Railgear does not provide braking or drive power Unlike most of our larger models RW 1015 does not lift the steering axle All vehicle tires are in contact with the rail Many vehicles require alternate wheels and tire
117. ntended to deploy the Railgear 2 4 1 To Stow Railgear with Emergency Hand Pump Ensure that Railgear is clear Remove rail position pins if equipped Hold Emergency Pump Switch UP to select the front Railgear Pump Emergency Hand Pump until Front Railgear is in highway position Insert Front Highway Position Pins if equipped Hold Emergency Hand Pump Switch Down to select the rear Railgear Pump Emergency Hand Pump until Rear Railgear is in highway position Insert Rear Highway Position Pins if equipped M Refer to the 5 3 1 Hydraulic System Diagram Safety Notes e When raising gear and holding the pins careful of pinch points e Do not drive vehicle at normal highway speeds if Railgear is not restrained by the safety pins or chained up e f Railgear is chained up and not fully in highway position be aware of your ground clearance 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICATORS I RW 1015 2 0 Operations This page intentionally left blank 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 0 MAINTENANCE amp INSPECTION 3 0 Maintenance amp Inspection 3 Recommended Maintenance amp Inspection Frequency 1 1 Daily Maintenance 1 2 Weekly Maintenance 1 3 Bi Annual Maintenance or as required 1 4 Annual Maintenance or as required 3 Lubricant amp Fluids Sp
118. on fixed payload and are not ranges within which to set rail wheel loads on an empty vehicle Min rail wheel Target rail wheel Max rail wheel load each load each load each Front Railgear 500 62525 900 Rear Railgear 500 525 25 900 Table 3 4 4 A Target rail wheel loads 3 4 5 Adjusting Rail Wheel Load NOTE DO NOT CHANGE SUSPENSION PRELOAD FROM FACTORY SETTINGS ORDER TO SET INITIAL RAIL WHEEL LOADS RAIL WHEEL LOAD ADJ USTMENTS SHOULD BE PERFORMED BY INSERTING REMOVING SPACERS BETWEEN THE MOUNTING BRACKET AND TRUCK FRAME Rail wheel loads can be adjusted by changing the position of the Railgear mounting plates using the provided slots and by adding or removing spacers from between the truck frame and the Railgear Once those adjustments are as close as possible to the desired rail wheel load small adjustments less than 5016 can also be made by adjusting the preload on the rubber suspension bushings Do not use preload adjustment to compensate for large deviations in rail wheel loads Over compression of the suspension bushings eliminates the suspension function provided by this system places greater stress on the Railgear and creates a rough ride when on rail The suspension bushings are factory preloaded to a 2 height when in highway position Keep adjustments to within 1 8 of the factory setting for each suspension bushing Front Adjustments 1 Adjust mounting plates up o
119. r down as required using the provided slots If the provided adjustment is not sufficient to achieve the target rail wheel load spacers can be added between Railgear and frame 2 Adjust the preload of the suspension bushings Rear Adjustments 1 Add or remove spacers between Railgear and frame 2 Adjust the preload of the suspension bushings When adjusting suspension bushing e Tighten nut to decrease rail wheel load e Loosen nut to increase rail wheel load Refer to section 5 1 for the mounting details of your specific chassis There will be interaction between wheel loads when any adjustments are made Typically increasing or decreasing the load on one rail wheel will cause a similar change in load on the diagonal rail wheel and have the opposite effect on the loads of the remaining two rail wheels Make small adjustments and re check rail wheel loads after each adjustment 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE RAIL WHEEL LOADS MUST REMAIN WITHIN 500 9005 UNDER ANY LOADING CONDITION EMPTY OR FULLY LOADED RAIL WHEEL LOADS MUST REMAIN WITHIN 50165 LEFT TO RIGHT ON AN AXLE IMPROPER RAIL WHEEL LOADING CAN CAUSE DERAILMENT 3 4 6 After Setting Rail Wheel Loads After making any changes to rail wheel loads during initial installation or maintenance continue to section 3 5 to check your Railgear alignment and adjust as
120. racket to the axle tube See Section 5 1 for inboard outboard locations e Weld the plate washers on the slotted frame mounting plates on the front and rear to fix the alignment of the unit e the rear weld the 3 hole mounting plate on the top and bottom to secure rear bracket in place e Weld the bottom of rear bracket side plate to the rear bracket along front and rear facing edges to secure side plates from sliding in and out e Ensure all shims are fully welded on both the front and rear Railgear 4 12 Install Decals e Label the reservoir RAILGEAR RESERVI OR DEXRON ATF III ONLY e Label the vehicles according to the diagram on the back of the decal sheet See decal drawings in section 5 1 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 13 Inspection amp Function Test 4 13 1 General Inspection Check that all fasteners are tight Check that all hoses and wire are routed properly Verify that the area is clear Verify that all electrical terminations are insulated and protected 4 13 2 Function Test Verify the battery is charged and hydraulic fluid is full Verify the power indication on the power switch in the cab Verify the function of the front and rear pin offs Verify rear switches bumper amp in cab actuate the rear Railgear and front switches bumper amp in cab actuate front Railgear and that the switches are
121. rating With Petroleum Based Fluids At Pressures Below 4000 PSI Or Minimum Component Rating PARTS GENERALLY ENCOMPASSED BY THIS PROCEDURE Purchased Fittings With SAE JIC 37 Degree Flared Ends PROCEDURE A Inspect fitting components to ensure that mating parts are free of burrs nicks scratches or any foreign material B Align tube flare against nose of fitting body and screw on the nut finger tight clamping the tube flare between the fitting nose and the nut C Tighten the nut the indicated Flats From Finger Tight F F F T listed in the chart below Use a second wrench to hold the hose in proper alignment while tightening to avoid twisting the lay line One flat on a hex is equal to 1 6th of a full turn Tolerance on tightening is plus or minus 1 4 flat 1 24 of full turn SAE 37 Flare Fittings 7 16 20 9 16 18 3 4 16 1 1 16 12 1 5 16 12 1 5 8 12 1 7 8 12 Swivel Nut Tube or Hose Connection Connection F F F T F F F T AT DATE DESCRIPTION TOLERANCES TITLE PRODUCTION PROCEEDURE 005 JIC FITTING INSTALLATION TOLERANCES UNLESS SPECIFIED _ COMMON SENSE PREVAILS DIVERSIFIED METAL FABRICATORS INC 404 875 1512 om 008 ANGULAR T DRAWN BY APPD BY DATE DRAWING NUMBER REV BREAK SHARP EDGES TITLE Cylinder Assembly PURPOSE To Establish Production Methods For The Assembly Of Cylinders COMMON USAGE All Models PARTS GENERALLY ENC
122. res and or suspension parts 4 3 4 Studs Current DMF kits use factory studs 4 3 5 Install Steering Stops Cautions STEERING WHEEL STOPS MUST BE VERIFIED BEFORE A VEHICLE IS OPERATED ON THE HIGHWAY CHECK THIS ON EVERY VEHICLE Incorrectly installed Steering Stops can cause serious tire damage and create a hazard for anyone operating the vehicle e INSTALL STEERING STOPS BEFORE MOVING THE VEHICLE If you don t you can cause serious tire damage and create a hazard for anyone operating the vehicle Installation e Install Stops Refer to 5 5 Chassis Wheel Modifications for the details on your specific steering stops e Verify that the steering stops limit the wheels or tires from any contact with frame sway bar wheelhouse suspension etc DMF recommends at least 1 8 clearance from any fixed obstruction to the wheel or tire in any suspension position e To check clearance in the normal suspension position jack the vehicle under the axle suspension or upright until the tire clears the ground e To check clearance the drooped position jack the vehicle under the frame cross member or body jack point until the tire clears the ground Check the steering clearance on both sides Many suspensions are not entirely symmetrical Ford Twin 1 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 4 0 INSTALLATION 4 3 6 Wheelhouse Body Modifications Occas
123. res to a cold pressure of 85 psi Remove Stock Wheels amp Tires a Liftthe vehicle and properly support using jack stands b Remove the stock wheels and tires retaining the stock lug nuts for reuse Install Steering Stops as shown in Figure 2 Remove Lower Brake Housing Bolt from each side Install Steering Stops as shown re using the stock bolt Actuate steering to its extents in both directions and verify that the Steering Stops are contacting stop surfaces gt 3 5 14 STUDS LOWER BRAKE HOUSING BOLT 19 5 RIM M20 SPLIT FLANGE NUT Figure 2 Wheel Adapter Details 2012 DMF Inc All Rights Reserved Page 2 of 4 5 Install Adapters 19 5 Wheels amp Tires as shown Figure 2 a Remove and discard the factory lug retaining clips b Mount the Wheel Adapters using the stock lug nuts Torque as specified in Figure 1 c Mount the 19 5 rims with 19 5 tires to the Wheel Adapter using the provided M20 Split Flange Nuts Torque as specified in Figure 1 6 Clearance Check s a Verify that neither the rims nor tires contact any frame or suspension components in any combination of steering positions and axle droop jounce conditions Verify that all brake ABS sensor and other wires or hoses are clear in all steering and suspension positions Restrain if necessary NOTE The following steps must be performed at a dealer as modification of these settings requires a software update specifi
124. s to properly track the rail DMF provides Wheel Modification Kits for use on standard gage rail where necessary for supported chassis These kits can include rims wheel adapters wheel spacers steering stops steering wheel locks and wheel hardware The Railgear is hydraulically actuated and is over center when in the rail position This prevents a hydraulic leak from allowing the gear to collapse the highway position the Railgear prevented from falling from the highway position as a result of a hydraulic leak by hydraulic locking valves The system includes a hand pump to allow the gear to be put in highway position in the case of hydraulic failure RW 1015 Railgear incorporates rubber suspensions to provide a smooth ride and rail guidance over uneven track surfaces We offer both steel and rubber treaded guide wheels 2015 DMF Inc All Rights Reserved 01 00 RW 1015 General Info doc DIVERSIFIED METAL FABRICATORS INC RW 1015 1 0 GENERAL INFORMATION Figure 1 1 A 09 FORD F350 SRW w RW 1015 Installed 1 2 Currently Approved Chassis 1 2 1 Chevy GM 08 13 C2500HD Pick up preferred to C2500 08 13 C2500HD box delete 08 13 C3500 Single Rear Wheel Models only 08 12 C2500 Suburban 1 2 2 Ford 08 12 F2 350 Pick up Single Rear Wheel Models only 08 712 F350 Box Delete Single Rear Wheel Models only 1 2 3 Ram 11 12 2500 3500 4x4 Pick up Single Rear Wheel Models only 11 12 2500 3500 4 4 Box Delete S
125. ssis Prep 4 2 1 Vehicle Condition The vehicle s suspension and frame should be in good condition If the vehicle s stock wheels and tires are to be used they should be inspected and properly inflated 4 2 2 Alignment It is important for rail wheel alignment that the rear axle of the vehicle is square to the truck frame It is recommended that all even new vehicles be laser aligned before Railgear installation Some alignment equipment can t accept a truck after the installation of Railgear The vehicle should be aligned for a zero thrust angle Factory alignment specifications are set to account for the crown of the road and can affect rail tracking 4 2 3 Mount and Balance Tires If your vehicle requires a wheel modification kit refer to 5 5 you should have the tires mounted before installation The early stages of install can be done without the modified wheels but they must be installed before Rail Wheel Loads are set Tire should be properly inflated Rims should be mounted using a torque wrench and not air tools 4 2 4 Tire Pressure Monitoring 5 The TREAD act has made TPMS mandatory on passenger vehicles under 10k GVWR Typically this is done with an RF transmitter located in the tire or the valve stem If the wheels are replaced as a part of the upfit these systems must be installed and calibrated to the higher pressure appropriate for these tires typically 225 70R19 5 or 245 70R19 5 at 85psi The re calibration is usu
126. stall and Align Rear Gear 4 7 2 Set Initial Rail Wheel Load amp Rear Bracket Height 4 7 3 Install Hydraulic Lines 4 7 4 Align Rear Gear 4 7 5 Set Rail Wheel Load 4 7 6 Set Rail Sweeps 4 7 7 Exhaust Modifications 4 8 Install Front Railgear 4 8 1 Remove Front Bumper 4 8 2 Install Front Gear 4 8 3 Hook up Hydraulics 4 8 4 Align Front Railgear to Rear Railgear 4 8 5 Set Rail Wheel Load 4 8 6 Bumper Installation Modification 4 8 7 Set Rail Sweeps 4 9 Verify amp Adjust Rail Wheel Load amp Alignment 4 10 Rail Test 4 11 Final Weld out 4 12 Install Decals 4 13 Inspection amp Function Test 4 13 1 General Inspection 4 13 2 Function Test 4 14 Road Test 4 15 Final Inspection 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 1 Pre Install 4 1 1 Safety Statements e Always block up gear before getting underneath e Always use jack stands when jacking up vehicle e Use personal protective equipment and clothing 4 1 2 Installation Order We have presented the installation information in the order that we have found work best Your shop tools personnel or other factors may dictate a different order of operations This is acceptable as long as the Inspection Rail Test Road Test and Final Inspection are performed at the end You should pay attention to the warnings in the Chassis Modifications and Wheel Modification Kits sections 4 1 3 Installation Sheets Refer to the i
127. t Diagram Method 2 FRONT GUAGE LEAD GUAGE TRAIL REAR FRONT REAR GUAGE 2 Fh 1 1 lt MEASURED CALC D SET TOE IN GUAGE FRONT GUAGE TRAIL 53158 1 FRONT GUAGE LEAD 5375 FRONT 178 REAR GUAGE TRAIL 53 4 REAR GUAGE LEAD 53 REAR a 2 VERIFY DIAGONALS FRONT DIAGONAL Di 4 FRONT DIAGONAL 02 1 Di D2 0 5 8 x 2 REAR DIAGONAL 01 E 4003 REAR DIAGONAL De Di De 0 5 3 ALIGN REAR AXLE RAIL WHL TO AXLE PS VARIES RAIL WHL TO AXLE DS Xe VARIES XI Xe 0 5 DIAGONAL D3 VARIES DIAGONAL D4 VARIES XI Xe 0 8 n 3 ALIGN GEAR REAR GEAR RAILGEAR WHEELBASE WB1 VARIES 4 RAILGEAR WHEELBASE WB2 VARIES y WBe 0 18 DIAGONAL DS VARIES veacce DIAGONAL D6 VARIES RAILGEAR ALIGNMENT SG xe 0 354 Figure 3 5 8 A Alignment Diagram Method 2 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRIC
128. tracted position Jack up slightly and place a piece of paper between the rail wheel and track Lower the rail wheel back onto the track Jack the rail wheel up very slowly while pulling on the paper Figure 3 4 3 A When the paper begins to slip out from under the wheel note the gauge pressure If using the DMF 501749 jack the reading on the gauge in PSI is equivalent to the rail wheel load on the adjacent wheel 10 Repeat this procedure for the remaining rail wheels and note the measured loads 11 After any adjustments are made repeat this procedure for each wheel PW NOTE WHEN CHECKING AND ADJ USTI RAIL WHEEL LOADS BOTH FRONT AND REAR RAILGEAR MUST BE IN THE RAIL POSITION 2015 DMF Inc All Rights Reserved 03_00 RW 1015 Maintenance doc DIVERSIFIED METAL FABRICATORS INC RW 1015 3 0 MAINTENANCE 3 4 4 Target Rail Wheel Loads Rail wheel loads should be set with the vehicle in an operational configuration If rail wheel loads are set on a bare truck and later equipment is added rail wheel loads may exceed allowable limits Likewise if rail wheel weights are set for a heavily loaded truck and equipment is later removed the rail wheel weights may fall below allowable limits Rail wheel loads should be maintained at the target rail wheel loads listed in table 3 4 3 A Minimum and maximum values are given as limits on individual rail wheel loads when the vehicle is carrying a n
129. ure to set the spindle bolts horizontally Axle brackets will be fully welded during the Final Alignment step 4 8 5 Set Rail Wheel Load Set Rail Wheel Load per 3 4 Rail Wheel Load 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS I NC RW 1015 4 0 INSTALLATI ON 4 8 6 Bumper Installation Modification Refer to 5 1 Installation guides on modifying and installing the bumper Pickups and Suburban s typically only require modification to the front bumper and mounting forward to clear the Railgear 4 8 7 Set Rail Sweeps The angle of the rail sweeps should be set to allow the sweep rubber to contact the rail when adjusted to the top of the slots This allows adjustment when the rubber wears 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 9 Verify amp Adjust Rail Wheel Load amp Alignment e Verify and adjust the Rail Wheel Load Refer to Sections 3 4 amp 3 5 Verify and adjust the alignment 4 10 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 3 5 Alignment 4 11 Final Weld out See drawings in Section 5 1 for additional details and welding locations e Fully weld each leg of each axle b
130. ve the vehicle on the road You should have the vehicle serviced as soon as possible 2 2 2 Reduced Turning Radius Vehicles with Wheel Modification Kits typically have reduced steering angles Operators should familiarize themselves with the turning limitations of their vehicle Any noise occurring when the wheel is turned to the limit may indicate a problem with your steering stops Have them checked as soon as possible 2 2 3 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 The operator should familiarize themselves with the modified clearance amp approach angles 2 2 4 Highway Speeds Vehicles with Wheel Modification Kits should not exceed the wheel or tire ratings Current wheel kits provided by DMF are rated for 70 or 65 mph The operator is responsible for maintaining lug nut torque Lug nut torque must be checked according to section 3 3 Wheel Modification Kit Inspection amp Maintenance Operators should have or have access to a torque wrench 2015 DMF Inc All Rights Reserved 02 00 RW 1015 Operations doc DIVERSIFIED METAL FABRICATORS INC RW 1015 2 0 Operations 2 3 Operation on the Rail 2 3 1 1 2 3 4 UF 10 11 Getting the Rail At the track crossing drive past the track and then back t
131. ydraulic system are removed or replaced Failure to do so may render the hand pump inoperable The following procedure is one method of priming that DMF has found to be quick and effective Loosen the hose connected to emergency hand pump inlet port port 1 as shown in figure 4 6 3 A slightly such that air can bleed from the line Activate the hydraulic pump and cycle the Railgear cylinders There is sufficient back pressure in the tank return line to force air out of the hand pump inlet line When oil begins to escape from the connection stop activation of the cylinders and re tighten Check operation of the emergency hand pump You may have to cycle the hand pump several times before the pump will work throughout its full range PUSH TO PRESSURIZE D TO T PORT Emergency hand pump assembly Figure 4 6 3 A 2015 DMF Inc All Rights Reserved 04 00 RW 1015 Installation doc DIVERSIFIED METAL FABRICATORS INC RW 1015 4 0 INSTALLATION 4 7 Install Rear Railgear Safety Statements If the gear is in the highway position and not pinned off you haven t installed the pin offs yet it can drop if any of the fittings are opened or leaky The gear is heavy enough to hurt you badly Block up the gear before you crawl under it Refer to 5 1 Installation Guides 4 7 1 Install and Align Rear Gear The rear Railgear may be installed as a unit if suitable lifting equipment is available Using a forklift pallet jack or floor jack

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