Parts & Service Manual RW-1019B - dmfatlanta.com

1 DIVERSIFIED METAL FABRICATORS, INC. DMF 665 Pylant Street Atlanta, Georgia 30306 Parts (404) 607-1684 Parts Fax (404) 879-7888 Service Department (404) 879-7882 Phone (404) 875-1512 Fax (404) 875-4835 Parts & Service Manual RW-1019B March 2017 SERIAL NUMBER (FRONT) _____ SERIAL NUMBER (REAR) _____ NOTE: Please refer to the serial numbers when ordering Parts or inquiring about warranty items. DIVERSIFIED METAL FABRICATORS, INC. RW-1019B 2017 DMF, Inc. All Rights Reserved. Message from DMF No matter what your job function is, Operation, Installation, Maintenance, or Repair, it is your responsibility to familiarize yourself with the entire Manual .

2 Once you have read the entire Manual , there are some specific sections that you will want to pay special attention to, depending on your role. If you find anything missing, incorrect or unclear in this Manual , please contact us. We are always trying to improve our manuals. Manuals, Service bulletins and general information are available on our website listed below. We reserve the right to update our manuals without notice. You can download a current Manual at our website ( ). 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.

3 We take product support very seriously, so if you have any questions, please contact us. Contact: Diversified Metal Fabricators 665 Pylant St. NE Atlanta, GA 30306 (404) 875-1512 (404) 875-4835 Fax (404) 607-1684 Parts Ship to: 668 Drewry St. NE Atlanta, GA 30306 DIVERSIFIED METAL FABRICATORS, INC. RW-1019B 2017 DMF, Inc. All Rights Reserved. TABLE OF CONTENTS SECTION GENERAL INFORMATION General Description, Weights & Capacities .. 1-2 Currently Approved Chassis .. 1-4 Front Railgear Key Components .. 1-5 Rear Railgear Key Components .. 1-6 SECTION OPERATIONS Before You Operate the Railgear .. 2-2 Anti-Lock Brake System (ABS), Traction Control.

4 2-2 Highway Operation .. 2-3 Getting On the 2-3 Getting Off the Rail .. 2-4 SECTION ROUTINE MAINTENANCE Inspection and Maintenance .. 3-2 Fluids and Lubrication .. 3-3 Wheel Wear Gauge .. 3-6 Troubleshooting .. 3-8 Derailment .. 3-9 SECTION RAILGEAR INSTALLATION Pre-Install .. 4-3 Initial Instructions .. 4-6 Installation of Rear Railgear .. 4-8 Exhaust Modification .. 4-15 Installation of Front Railgear .. 4-19 Installation of Front Axle Lock .. 4-28 Hydraulic & Electrical Installation .. 4-35 Alignment, Weight Adjustment, & Rail Test .. 4-36 Install Provided Accessories .. 4-41 Installation Review Checklist.

5 4-46 SECTION RAILGEAR OPTIONS Rail Sweeps .. 5-2 Rail Brakes .. 5-5 Pin Offs .. 5-8 SECTION HYDRAULIC SYSTEM General Information .. 6-2 Brake Line Routing .. 6-6 Hydraulic and Electrical Schematics .. 6-7 Hydraulic and Electrical Component Drawings .. 6-10 SECTION REAR RAILGEAR Parts Before Ordering Parts .. 7-2 Rear Core Assembly Diagrams .. 7-3 Mounting Kit Diagrams .. 7-5 H-Bracket Kit Diagrams .. 7-8 Rear Axle Diagrams .. 7-10 SECTION FRONT RAILGEAR Parts Before Ordering Parts .. 8-2 Front Assembly Diagrams .. 8-3 Front Axle Diagrams .. 8-7 Axle Lock Kit Diagrams .. 8-9 DIVERSIFIED METAL FABRICATORS, INC.

6 RW-1019B 2017 DMF, Inc. All Rights Reserved. 8-1 SECTION FRONT RAILGEAR Parts BEFORE ORDERING Parts .. 8-2 FRONT ASSEMBLY DIAGRAMS .. 8-3 FRONT AXLE DIAGRAMS .. 8-7 AXLE LOCK KIT DIAGRAMS .. 8-9 DIVERSIFIED METAL FABRICATORS, INC. RW-1019B 2017 DMF, Inc. All Rights Reserved. LIST OF FIGURES/TABLES Figure Front Railgear Components .. 1-5 Figure Rear Railgear Components .. 1-6 Figure Installation Rails .. 4-7 Figure Rear Railgear Components - Ford .. 4-9 Figure Exhaust Modifications Ford .. 4-16 Figure Required Exhaust Clearances .. 4-16 Figure Required Hanger Relocation .. 4-17 Figure Exhaust Modifications Ram.

7 4-18 Figure Required Exhaust Clearances .. 4-18 Figure Front Primary Components Ford .. 4-19 Figure Crush Tube Location .. 4-20 Figure Hardware Locations .. 4-21 Figure Transmission Cooler Relocation .. 4-21 Figure Front Bumper Relocation .. 4-22 Figure Sample Front Bumper Trim .. 4-22 Figure Front Primary Components Ford 2017+ .. 4-23 Figure Crush Tube Location Ford 2017+ .. 4-24 Figure Hardware Location Ford 2017+ .. 4-25 Figure Front Primary Components Ram .. 4-26 Figure Bumper Bracket Modification Ram .. 4-26 Figure Front Railgear Installation Ram .. 4-27 Figure Front Bumper Trimmed Ram.

8 4-27 Figure Front Brake Line Relocation Ram .. 4-34 Figure Front Brake Line Relocation Ram .. 4-34 Figure Checking Rear Railgear for Square to Truck Axle .. 4-36 Figure Steering Wheel Lock Installation .. 4-41 Figure Steering Wheel Lock Installed .. 4-41 Figure Rear Rail Sweeps .. 5-2 Figure Front Rail Sweeps .. 5-2 Figure Rail Brake Adjustment .. 5-5 Figure Rear Pin Off Handle Routing .. 5-9 Figure Typical Front Pin Off Cable Mounting .. 5-14 Table Troubleshooting On-Track Problems .. 3-8 Table Manufacturer Equivalent Welding Rod .. 4-5 DIVERSIFIED METAL FABRICATORS, INC. RW-1019B ` 2017 DMF, Inc.

9 All Rights Reserved. 1-1 SECTION GENERAL INFORMATION GENERAL DESCRIPTION, WEIGHTS & CAPACITIES .. 1-2 Weights and Capacities .. 1-2 Materials .. 1-2 Installation .. 1-2 Options .. 1-2 Brakes .. 1-2 CURRENTLY APPROVED CHASSIS .. 1-4 Ram .. 1-4 Ford .. 1-4 FRONT RAILGEAR .. 1-5 Key Front Railgear Components .. 1-5 REAR RAILGEAR .. 1-6 Key Rear Railgear Components .. 1-6 Rear Railgear Body Clearances .. 1-6 DIVERSIFIED METAL FABRICATORS, INC. RW-1019B 1-2 2017 DMF, Inc. All Rights Reserved. GENERAL DESCRIPTION, WEIGHTS & CAPACITIES DMF s RW-1019B Railgear is designed for medium duty chassis in the 10,000 to 19,500 lb GVWR range.

10 In most applications, the rear Railgear accommodates factory rear-mounted fuel tanks. The front assembly attaches to the frame and lifts the front truck tires completely off the track. A front axle lock system prevents the truck suspension from sagging when elevated on rail. The rear assembly attaches to the truck frame before and after the rear axle spring hangers. The inner-dual rear tires remain in contact with the rails to provide traction for acceleration and braking. Weights and Capacities Typical Chassis GVWR Range: 10,000 to 19,500 lbs Capacity: 8,200 lbs. per Railgear Axle @ 20 MPH Weights: Front Railgear and Axle Lock System: ~550 lbs.