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DIVERSIFIED METAL FABRICATORS, INC.

RW-1016

3-1

SECTION 3.0

OUTINE

AINTENANCE

3.1

INSPECTION AND MAINTENANCE ................................................................... 3-2

3.1.1

Daily Maintenance ........................................................................................... 3-2

3.1.2

Weekly Maintenance ........................................................................................ 3-2

3.1.3

Bi-Annual Maintenance or as required................................................................ 3-2

3.1.4

Annual Maintenance or as required ................................................................... 3-2

3.2

FLUIDS AND LUBRICATION ............................................................................ 3-3

3.2.1

Grease Fitting Locations ................................................................................... 3-4

3.3

RAIL WHEEL WEAR GAUGE ............................................................................. 3-5

3.4

TROUBLESHOOTING ....................................................................................... 3-7

3.5

DERAILMENT .................................................................................................. 3-8

Summary of Contents for RW-1016

Page 1: ...partment 404 879 7882 service dmfatlanta com Phone 404 875 1512 Fax 404 875 4835 info dmfatlanta com http www dmfatlanta com Parts Service Manual RW 1016 February 2019 SERIAL NUMBER FRONT ____________...

Page 2: ...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...

Page 3: ...railment 3 8 SECTION 4 0 RAILGEAR INSTALLATION 4 1 Before You Begin 4 3 4 2 Wheel Modification Kit Installation 4 7 4 3 Mounting Kit Installation 4 9 4 4 Railgear Installation 4 10 4 5 Alignment 4 12...

Page 5: ...GENERAL INFORMATION 1 1 GENERAL DESCRIPTION WEIGHTS CAPACITIES 1 2 1 1 1 Features and Description 1 2 1 1 2 Weights and Capacities 1 3 1 2 CURRENTLY SUPPORTED CHASSIS 1 4 1 2 1 GM 1 4 1 2 2 Ford 1 4 1...

Page 6: ...bearings that maximize service life and minimize maintenance Unlike most of our larger models RW 1016 does not lift the steer axle off the rail All vehicle tires remain in contact with the rail RW 10...

Page 7: ...and chassis make model Table 1 1 below summarizes weights typical of installations using RW 1016 Railgear Item Typical Weight lbs Front Railgear Steel Railwheels 285 Front Mounting Kit 20 Rear Railgea...

Page 8: ...completed vehicle must not exceed any GAWR or GVWR with 150 lbs in every seat per 49 CFR 567 4 Unless indicated otherwise all models below include Only single rear wheel variants Dual rear wheel model...

Page 9: ...onents of RW 1016 Railgear assemblies Appearances of some components may vary depending on chassis make model year as well as selected Railgear options These item descriptions will be used throughout...

Page 11: ...2 2 1 2 Highway Speeds 2 2 2 1 3 Pinoff Systems and Locations 2 2 2 1 4 Railgear Controls 2 3 2 1 5 Daily Inspection 2 3 2 2 HIGHWAY OPERATION 2 4 2 3 GETTING ON THE RAIL 2 4 2 3 1 Getting Onto the Tr...

Page 12: ...gles In many installations the guide wheels extend slightly beyond the corners of the front bumper To avoid equipment and property damage operators should be familiar with the modified clearances and...

Page 13: ...he base unit when the system is turned on by the master power switch There is no power switch on the remote it will power off after several minutes of activity to extend battery life Pushing any butto...

Page 14: ...to line up the front guide wheels with the rail 2 Ensure that the front Railgear pinoff is disengaged if equipped 3 Ensure that the vehicle tires are pointed straight ahead 4 Use the wireless remote...

Page 15: ...transmission in park with the parking brake set 3 Disengage both the front and rear Railgear pinoffs if equipped 4 Lift both sets of Railgear there is no preference for removal order 5 Re engage ALL...

Page 16: ...andle in the cab or another safe storage area 2 Ensure that Railgear is clear from obstructions 3 Disengage both front and rear Railgear pinoffs if equipped 4 Turn the vehicle key to the ignition posi...

Page 17: ...NSPECTION AND MAINTENANCE 3 2 3 1 1 Daily Maintenance 3 2 3 1 2 Weekly Maintenance 3 2 3 1 3 Bi Annual Maintenance or as required 3 2 3 1 4 Annual Maintenance or as required 3 2 3 2 FLUIDS AND LUBRICA...

Page 18: ...rect tire pressures Inspect tires for abnormal wear including inboard sidewalls 3 1 2 Weekly Maintenance In addition to the daily maintenance outlined above Lubricate front rear pin off assemblies if...

Page 19: ...er units Grease Fittings o Factory Standard Citgo Syndurance Premium Synthetic 460 2 o Warm Climates Mystik JT 6 Hi Temp Multi Purpose Grease 2 Wheel bearing hub units Rail wheel bearing units are com...

Page 20: ...72 0 0 837 5 9 7 6 5 37 21 33 2 7 21 47 6 5 37 21 1 5 52 1 6 6 2 1 6 1 5 0 3 927 1 5 75811 21 287 5 1 5 75811 21 11 5 6 6 2 1 6863 16 21 3 927 3 1 5 6 53 6 0 72 5 1 6 81 66 63 0 5 9 5 1 180 5 7 7 7 33...

Page 21: ...WEAR GAUGE A metal wheel wear gauge DMF part number 800115 is available to aid in inspecting worn wheels The drawing on the next page illustrates how to use the gauge and also lists specifications for...

Page 22: ......

Page 23: ...wheel bearing unit if necessary Vehicle tracking to one side wandering Misalignment Overload or load imbalance Un Even Rail Wheel Load Vehicle Load Excessive Wheel Wear Check Alignment see Section 4 5...

Page 24: ...lace and not broken Verify that all threaded fasteners are secure and that cotter pins are not broken Visually inspect wheels to ensure that tread and flange are not severely damaged Spin all 4 rail w...

Page 25: ...tion 4 9 4 4 RAILGEAR INSTALLATION 4 10 4 4 1 Railgear Assemblies Identification and Orientation 4 10 4 4 2 Railgear Assembly Installation 4 10 4 5 ALIGNMENT 4 12 4 5 1 General Information 4 12 4 5 1...

Page 27: ...inspect the following areas Alignment Truck axles should be square with truck frame DMF recommends that a reputable alignment shop check this particularly on used or damaged vehicles 0 degree thrust a...

Page 28: ...s wire loom and electrical tape The following equipment and tools are not required but may ease installation Transmission Jack Motorcycle Lift Pallet Jack or Forklift Overhead Crane Work Lights Wheel...

Page 29: ...m the Cervis base unit before welding on vehicle or attached railgear components Dual Shield Wire spec AWS E71T 1 Low Hydrogen spec AWS E 7018 Low Hydrogen Electrodes AWS E 7018 Manufacturer Equivalen...

Page 30: ......

Page 31: ...hicles usually require the installation of steering stops These prevent the wheels and tires on vehicles with narrowed track widths from contacting the frame brake lines or suspension components durin...

Page 32: ...ip Please refer to the model specific information in Section 6 7 and provide this information to the dealer when having TPMS recalibration work performed 4 2 5 Speedometer Recalibration Common work tr...

Page 33: ...ry hitch In rare circumstances particularly very low or heavily loaded vehicles additional suspension components may be required to obtain sufficient ground and hitch clearance Please contact DMF for...

Page 34: ...contact between the Railgear truck components and the mounting brackets 4 Lift the Railgear until the bottom of the adjustment plates is 9 1 2 off of level ground Fine tune height to align holes in m...

Page 35: ...completed see 8 M101603 M101604 and manual sections 4 5 4 6 Identify the front and rear Railgear assemblies 1 Maneuver the railgear assemblies into position at the proper end of the vehicle oriented...

Page 36: ...is necessary to align them to the vehicle Accurate railgear alignment is crucial to safe operation and long component life 4 5 1 When to Check Alignment Initial installation Once per year or more freq...

Page 37: ...HKLFOHV DV PDQXIDFWXUHUV PD XVH GLIIHUHQW WUDFN ZLGWKV DW WKH IURQW DQG UHDU WUXFN D OHV RUN VORZO DQG PDNH VPDOO DGMXVWPHQWV I ODWHUDOO DGMXVWPHQW UDQJH LV LQVXIILFLHQW DGMXVW VKLPV EHWZHHQ UDLOJHDU...

Page 38: ...DS BEFORE OPERATING THE VEHICLE ON RAIL 4 6 2 When to check Rail Wheel Load Initial installation Once per year or more frequently as conditions dictate If you have changed the empty weight of your tru...

Page 39: ...the rail wheel flange is not touching the ground Ensure that none of the rail wheel flanges are riding right up against the rail as this may affect weight settings 3 Place the jack under the Railgear...

Page 40: ...HEEL LOAD ADJUSTMENT NOTES SEE MANUAL SECTION 4 6 FOR ADDITIONAL DETAILS ON RAIL WHEEL LOAD ADJUSTMENT RAIL WHEEL LOADS SHOULD BE ADJUSTED WITH THE VEHICLE NEAR SERIVCE WEIGHT AND FULL OF FUEL BALLAST...

Page 41: ...s and brackets to provide adequate clearance to hot exhaust components o Any factory heat shields protecting vital components should be retained modify as necessary o Use smooth transitions in pipe se...

Page 42: ...1 Weld Out Final Adjustments WARNING Select components of RW 1016 Railgear assemblies have been hot dip galvanized DMF recommends grinding off the galvanized coating to raw steel where welding is requ...

Page 43: ...n vehicle or attached railgear components Repaint any ground or welded areas to prevent corrosion FRAC MACH 03 01 17 BREAK SHARP EDGES 03 X 45 MAX 2A AND 2B M101606 REV DRAWING NUMBER TITLE DATE APPD...

Page 44: ...event of an emergency the steering wheel can be forcibly turned and the Velcro fasteners will separate 1 Clean the top of the steering column and wheel with rubbing alcohol and a clean cloth 2 Allow t...

Page 45: ...RW 1016 2017 DMF Inc All Rights Reserved 4 21 4 9 2 Install Operation and Safety Decals Install the provided operation and safety decals where shown on the following pages Surfaces should be clean of...

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Page 49: ...the pin offs work in both the rail and highway positions if equipped Follow Section 2 4 to verify emergency pump function Load test vehicle to GVWR and verify Railgear function 4 10 3 Road Test Befor...

Page 51: ...nit 5 2 5 1 2 Locating Hydraulic Components 5 2 5 1 3 Hydraulic Hose Installation 5 2 5 1 4 Hydraulic Fitting Installation 5 2 5 1 5 Emergency Hand Pump 5 7 5 2 ELECTRICAL SYSTEM 5 8 5 2 1 Locating El...

Page 52: ...d to the weld on pump bracket front or rear Inside the cab installer designed Under hood installer designed avoid heat sources Inside a tool box installer designed Suggested Locking Valve Manifold Loc...

Page 53: ...R8 CHASSIS SPECIFIC PUMP MOUNTING KITS NOT SHOWN 701055 2017 FORD FRONT MOUNT KIT GAS ENGINE ONLY 701060 BATTERY TRAY PUMP KIT 14 GM GAS ENGEING ONLY 1 3 2 LOCKING VALVE MANIFOLD BOLTED TO REAR CROSS...

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Page 57: ...raulic pump longer hoses to connect the two may need to be fabricated and wiring on the selector switch extended Verify the handle for the hand pump is stowed in a location where it will be readily ac...

Page 58: ...be routed inside the frame o Support and restrain wires with wire ties or wire clips as necessary All electrical terminations should be protected with liquid electrical tape or other means Heat shrin...

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Page 61: ...PISTON 2 ID 8 605041 1 ROD SEAL POLYPAK 1 ID 1 8 W 9 605042 1 ROD WIPER AN 959 940 1 ID 1 8 10 605044 1 BACK UP RING 224 11 605043 1 O RING 224 12 605040 2 PISTON SEAL POLYPAK 1 625 ID 3 16 W 2 BORE 1...

Page 62: ...5 9 7 6 5 37 21 33 7 0 12 3 57 180 5 47 6 5 37 21 2 1 9 9 2 21 0 0 25 77 1 25 9 9 2 1 3 3 3 5 5 1 8 5 5 6 53 6 0 1 0 52 5 6 6 685 1 6 7 5 6 72 5 1 6 5 0 81 66 63 5 27 5 7 0 5 9 5 1 180 5 7 7 7 33 5 1...

Page 63: ...embly Standard Gauge Steel Wheels 6 14 6 3 2 Rear Core Assembly Standard Gauge Steel Wheels 6 15 6 4 SUSPENSION ASSEMBLIES BEARINGS WHEELS 6 17 6 4 1 Suspension Assembly Side A Steel Wheels 6 18 6 4 2...

Page 64: ...out cylinder o Driver side on front assemblies Passenger side on rear assemblies SIDE B with cylinder o Passenger side on front assemblies Driver side on rear assemblies 6 1 3 Custom Applications If y...

Page 66: ...USH TUBE 11 GM PICKUP RW 1016 5 605020 2 HHCS 1 2 13 X 5 GR8 6 500691 6 FLAT WASHER 1 2 GR8 7 605599 1 CARRIAGE BOLT 1 2 13 X 4 1 2 GRADE 8 8 703057 1 MOUNTING SHIM SET RW 1016 703058 2 MOUNTING SHIM...

Page 67: ...K WASHER 3 4 GR8 10 703057 1 MOUNTING SHIM SET RW 1016 703058 2 MOUNTING SHIM 375 RW 1016 703059 2 MOUNTING SHIM 25 RW 1016 703060 2 MOUNTING SHIM 125 RW 1016 703061 2 MOUNTING SHIM 0625 RW 1016 60534...

Page 68: ...Y APP ITEM NO PART NUMBER QTY DESCRIPTION 1 701059 1 BATTERY TRAY PUMP BRACKET 14 GM GAS ONLY RW 1016 2 605196 1 HHCS 3 8 16 X 2 GR8 3 605121 3 HHCS 3 8 16 X 1 1 4 GR8 4 12566 2 LOCK WASHER 3 8 GR8 5...

Page 69: ...12 211 7 216 25 5 1 226 1 3 67 1 3 527 7 1 1 5 0 176 7 7 1 1 36 72 6 85 7 1 72 5 6 3 66 1 5 6 2 1 9 9 1 5 5 1 8 1 2 1 9 9 25 17 7 21 25 6 1 1 21 5 9 7 6 5 37 21 33 3803 63 5 6 83 7 3803 02 1 2 1 9 9...

Page 70: ...D IN 703057 TAM 2017 FORD F 250 350 FRONT ITEM NO PART NUMBER QTY DESCRIPTION 1 703102 1 DS FRONT BRAKCET 17 FORD PICKUP 4X4 RW 1016 2 703103 1 PS FRONT BRAKCET 17 FORD PICKUP 4X4 RW 1016 3 605573 4 H...

Page 71: ...OVE AND REPLACE THE TWO LOWER BOLTS IN THE AUX SPRING PAD F 250 INSTALL THE 1 PROVIDED BOLTS IN THE TWO LOWER THREADED FRAME HOLES FROM INBOARD SIDE INSTALL SHORT CRUSH TUBES 2 SIDE ON BOLTS HANG REAR...

Page 72: ...RW 1016 3 703082 2 BOTTOM PLATE FT BRKT 08 16 FORD F 2 350 RW 1016 4 605259 4 HHCS 1 2 13 X 1 3 4 GR8 5 113014 4 1 2 13 NYLOCK NUT GR8 6 500691 4 FLAT WASHER 1 2 GR8 7 703057 1 MOUNTING SHIM SET RW 10...

Page 73: ...1 5 5 12 1 8 1 7 0 7 0 12 3 57 180 5 47 6 5 37 21 36 5 5 5 0 5 7 25 36 5 5 5 0 5 7 25 5 5 5 7 5266 5 25 5 7 63 5 25 5 64 85 6 5 6 5 1 2 187 5 6 5 2 6 5 5 02817 1 6 0 6 7 5 02817 1 6 0 5 02817 1 6 0 5...

Page 74: ...M 0625 RW 1016 605341 8 FLAT WASHER 7 16 GR8 605276 4 HHCS 1 2 13 X 2 1 4 GR8 113014 4 1 2 13 NYLOCK NUT GR8 NOTES PASSENGER SIDE FRAME BRACKET INSTALLATION SHOWN DRIVERS SIDE SIMILAR 5 8 FLAT WASHER...

Page 75: ...05276 4 HHCS 1 2 13 X 2 1 4 GR8 113014 4 1 2 13 NYLOCK NUT GR8 NOTES MOST FACTORY EXHAUST SYSTEMS DO NOT REQUIRE MODIFICATION FIT BRACKETS SNUG AGAINST BOTTOM OF FRAME BEFORE MARKING DRILLING HOLES PA...

Page 76: ...ies share many components between the front and rear assemblies The following terminologies are used to describe many shared parts and assemblies SIDE A without cylinder o Drivers side on front assemb...

Page 77: ...RW 1016 7 704083 1 GALVANIZED SWING FRAME ADJUSTABLE STD GAUGE RW 1016 8 704040 1 TRUNNION EAR WELDMENT RW 1016 9 702130 1 SUSPENSION ASSY SIDE B STW NTN RW 1016 10 702129 1 SUSPENSION ASSY SIDE A STW...

Page 78: ...NT SIDE A RW 1016 7 704083 1 GALVANIZED SWING FRAME ADJUSTABLE STD GAUGE RW 1016 8 704040 1 TRUNNION EAR WELDMENT RW 1016 9 702130 1 SUSPENSION ASSY SIDE B STW NTN RW 1016 10 702129 1 SUSPENSION ASSY...

Page 80: ...ar assemblies share many components between the front and rear assemblies The following terminologies are used to describe many shared parts and assemblies SIDE A without cylinder o Driver side on fro...

Page 81: ...6 5 6 5 8 7 5 0 187 6 5 723 7 2 7 5217 3 1 3 1 3 7 17 527 7 21 2 5 3 6863 16 21 8670 17 2 7 5 0 187 81 7 635 1 3 7 5 7 0 5 1 635 1 5 1 5 1 28 6 2 7 6 5 5 7 5 2 1 6 28 5 6 5 1 8 5 5 6 53 6 0 1 0 52 5 6...

Page 82: ...6 5 6 5 8 7 5 0 187 81 7 0 187 6 5 723 7 2 7 5217 3 1 3 1 3 7 17 527 7 21 2 5 3 6863 16 21 8670 17 2 7 5 635 1 3 7 5 7 0 5 1 635 1 5 1 5 1 28 6 2 7 6 5 5 7 5 2 1 6 28 5 6 5 1 8 5 5 6 53 6 0 1 0 52 5 6...

Page 83: ...66 0 72548 6 6 2 1 127 6 817 2 25 17 7 21 5 9 7 6 5 37 21 33 7 0 12 3 57 180 5 47 6 5 37 21 81 1 2 187 5 7 67 75 25 171 3 8 7 171 3 8 7 5 1 8 66 63 1 1 5 1 37 5 25 3 8 7 2 6 5 5 6 0 00 66 63 1 2 7 16...

Page 84: ...58 6863 16 21 50 1 63 1 66 0 72548 6 6 2 1 5 9 7 6 5 37 21 33 7 0 12 3 57 180 5 47 6 5 37 21 81 1 2 187 5 7 67 75 25 171 3 8 7 171 3 8 7 5 1 8 66 63 1 1 5 1 37 5 25 3 8 7 2 6 5 5 6 0 00 66 63 1 2 7 16...

Page 85: ...121 2 HHCS 3 8 16 UNC x 1 1 4 GRADE 8 4 818508 4 FLAT WASHER 3 8 GR8 5 605077 2 3 8 16 NYLOCK NUT GR8 A X ANGULAR BREAK SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL...

Page 86: ...121 2 HHCS 3 8 16 UNC x 1 1 4 GRADE 8 4 818508 4 FLAT WASHER 3 8 GR8 5 605077 2 3 8 16 NYLOCK NUT GR8 A X ANGULAR BREAK SHARP EDGES 0 030 X 45 MAX 1 16 005 030 015 1 32 063 1 2A AND 2B 125 MICRO DRILL...

Page 89: ...167 7 21 127 6 5217 20321 176 6 2 1 5 5 167 7 21 6 0 5 7 5 7 1 3 1 9 5 7 7 6 1625 6 203 7 81 29 5 5 7 5 5 672 1 203 7 29 5 5 1 3 2 25 8 1 5 7 5 9 7 6 5 37 21 33 7 0 12 3 57 180 5 47 6 5 37 21 352 6 7...

Page 90: ...1 7 50 1 6 7 6367 03 5 1 7 50 1 6 817 6 7 5 7 5 6 53 6 0 72 5 1 6 81 66 63 5 9 5 1 180 5 7 7 7 33 5 1 7 6 5 1 217 16 21 17 35235 7 5 1 250 7 21 2 9 56 0 7 5 7256 1 0 23 5 7 0 5 76 5 6 59 7 0 5 6 817 7...

Page 91: ...BLE ACTUATION RW 1016 3 705012 1 PINOFF BASE PLATED RW 1016 4 305071 1 CABLE PINOFF MOUNTING TUBE MACHINING 1 STROKE 5 305070 1 CABLE PINOFF PIN EXTENSION SPRING SS 6 305069 1 CABLE PINOFF HANDLE ASSE...

Page 94: ...mmended Tires DMF does not typically include tires with wheel modification kits Recommended tire models and sizes are shown below Using different tire sizes than shown below can result in component in...

Page 95: ...n the steering wheel to its extents in both directions and verify the steering stops are contacting the stop surfaces It is usually necessary to have someone hold the steering wheel at full lock in bo...

Page 96: ...applicable State and Federal regulations b In particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance 10 Inspection Maintenance a...

Page 98: ...ot typically include tires with wheel modification kits Recommended tire models and sizes are shown below Using different tire sizes than shown below can result in component interference or poor perfo...

Page 99: ...vided M20 Split Flange Nuts torque as specified in Figure 1 4 Install Steering Stops a Remove the lower brake caliper bracket bolt from each side of the front steering knuckles b Install steering stop...

Page 101: ...may show this to be an adequate setting to comply with the FMVSS 138 requirements for TPMS telltale indicator illumination c Using FORScan Software Cold inflation pressures can be set to 85 psi using...

Page 103: ...ups NOT EQUIPPED with factory TPMS Figure 1 Installation Exploded Parts Diagram 509068 shown Recommended Tires DMF does not typically include tires with wheel modification kits Recommended tire models...

Page 104: ...g stops are contacting the stop surfaces It is usually necessary to have someone hold the steering wheel at full lock in both directions while looking for interference e Trim rear fender well liners i...

Page 105: ...ral regulations b In particular the regulations and test procedures outlined in FMVSS Standard 138 must be performed in order to ensure compliance 9 Inspection Maintenance a Visually inspect wheels ti...

Page 109: ...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 c...

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