DMF RW-1016, Parts & Service Manual

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DIVERSIFIED METAL FABRICATORS, INC. RW-1016
© 2017 DMF, Inc. All Rights Reserved. 4-3
4.1 BEFORE YOU BEGIN
****WARNING****
Satisfactory adjustment of the Railgear alignment and weight
settings are crucial to ensure safe and reliable operation. Do not
attempt to use vehicle on rail until these steps have been
completed. See Section 4.5 & 4.6 for detailed instructions.
4.1.1 Working Safely
 Never work under a suspended load. Use appropriate blocking and restraints to secure
loads before removing lifting equipment.
 Always use jack stands when jacking up vehicle.
 Use personal protective equipment and clothing.
 Be aware of flammable fluids and use caution with tools that may create sparks.
4.1.2 Work Area
The Railgear installation area should allow you to work safely, accurately and efficiently:
 Floor - The floor should be level in order to provide good measurements required to
check the alignment of the Railgear.
 Lighting - The work area should be well lit.
 Space - There should be enough space to maneuver the Railgear components into
position and to safely work around other equipment.
4.1.3 Truck Condition
Before installation, 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 angle (which may be different than the factory specification) is required for proper
Railgear operation.
 Frame & Suspension - On a new truck, these should be in good condition. On a used
truck, the frame should be inspected to ensure that it has not been damaged or bent.
The suspension bushings should also be examined for excessive wear and replaced if
necessary.
4.1.4 Recommended Installation Order
DMF recommends following the installation order below, which is how the manual is arranged.
Your workspace, tools, personnel or other factors may dictate a different order. As long as the
Alignment and Railwheel load adjustments, Rail Test, Road Test, and Installation Review
processes can be satisfactorily completed, installation order is not critical.
1. Wheel Modification Kit (Section 4.2).
2. Front & Rear Railgear Mounting Kits (Section 4.3).
3. Railgear Assemblies (Section 4.4).
4. Hydraulic and Electrical Systems (Section 5).
5. Alignment, Weight Adjustment (Section 4.5-4.6)
6. Exhaust Modification (Section 4.7)
7. Rail Test (Section 4.8).
8. Installation of miscellaneous Railgear accessories (Section 4.9).
9. Installation Review (Section 4.10)