DMF RW-1016, Parts & Service Manual

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DIVERSIFIED METAL FABRICATORS, INC. RW-1016
5-2 © 2017 DMF, Inc. All Rights Reserved.
5.1 HYDRAULIC SYSTEM
5.1.1 Hydraulic Power Unit
DMF supplies a 12V DC hydraulic power unit with RW-1016 Railgear with the following
specifications. The unit includes a pump, motor and reservoir.
 Flow: 1.25 GPM @ 2,000 psi
 Recommend Fluid: Dexron III Automatic Transmission Fluid
 Pressure Relief: Internal; factory set at 2,000 psi.
 Power: 150A circuit breaker required, 4 GA minimum welding cable connections.
 Ground : Dedicated ground to frame required; 4 GA welding cable minimum.
5.1.2 Locating Hydraulic Components
DMF has provided several options for mounting hydraulic components with RW-1016 Railgear.
In some cases, chassis specific kits are available to mount the hydraulic pump (see Section
6.2). Certain applications may require devising custom mounting solutions. The pump should
be protected from high heat and road spray. Access to the fluid fill port should be considered.
The pump solenoid should be protected from accidental contact with loose tools or cargo with
covers if necessary. See Drawing M101605 on the following pages for additional information.
Suggested Pump Mounting Locations
 Chassis specific mounting kit (some models, see Section 6.2).
 Bolted 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 Locations (1 front, 1 rear)
 Bolted to the rear cross brace.
 Bolted to the weld-on pump bracket.
 Bolted to the universal mounting plate included.
5.1.3 Hydraulic Hose Installation
DMF supplies hydraulic hoses appropriate for standard installations. Take care to use the
indicated hose lengths where shown on the hydraulic schematics. Observe the following
guidelines when routing houses:
 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.
 Allow slack in hoses where connected components may move while operating, such as
hydraulic cylinders.
 Neatly secure excess hose length as required.
5.1.4 Hydraulic Fitting Installation
DMF supplies hydraulic fittings appropriate for standard installations. Certain fittings may need
to be reoriented from what is shown in schematics for clearance or to optimize hose routing.
To reduce the risk of system leaks, refer to the guidelines on the following pages for
recommended installation practices of JIC, NPT and O-Ring hydraulic fittings.