DMF RW-1630 Kurzanleitung

DIVERSIFIED METAL FABRICATORS, INC.

DMF 665 Pylant Street Atlanta, Georgia 30306

Parts (404) 607-1684Parts Fax (404) 879-7888[email protected]

Service Department (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-1630

RW-1630/50*

November 2017

SERIAL NUMBER (FRONT) ________________________

SERIAL NUMBER (REAR) ________________________

NOTE:

Please refer to the serial numbers when ordering parts or

inquiring about warranty items.

* This manual applies to both DMF’s RW-1630 Railgear, and DMF’s higher capacity

RW-1630/50 Railgear, including all configurations (standard, behind cab, and under cab)

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

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. 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.

For purposes of this manual, we will refer to RW-1630 when discussing either RW-1630 or

RW1630/50, and we will explicitly call out any differences when appropriate.

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 (http://www.dmfatlanta.com).

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.

Contact:

Diversified Metal Fabricators

665 Pylant St. NE

Atlanta, GA 30306

(404) 875-1512

(404) 875-4835 Fax

(404) 607-1684 Parts

http://www.dmfatlanta.com

[email protected]

Ship to:

668 Drewry St. NE

Atlanta, GA 30306

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

TABLE OF CONTENTS

SECTION 1.0 GENERAL INFORMATION

1.1 General Description............................................. 1-2

1.2 Front Railgear .................................................... 1-3

1.3 Rear Railgear ..................................................... 1-5

SECTION 2.0 OPERATIONS

2.1 Before You Operate the Railgear ........................... 2-2

2.2 Anti-Lock Brake System (ABS).............................. 2-3

2.3 Highway Operation.............................................. 2-4

2.4 Getting on the Rail.............................................. 2-4

2.5 Getting off the Rail.............................................. 2-5

SECTION 3.0 ROUTINE MAINTENANCE

3.1 Inspection and Maintenance ................................. 3-2

3.2 Lubrication Specification ...................................... 3-3

3.3 Wheel Wear Gauge.............................................. 3-5

3.4 Troubleshooting.................................................. 3-7

3.4 Derailment......................................................... 3-8

SECTION 4.0 RAILGEAR INSTALLATION

4.1 Pre-Install.......................................................... 4-3

4.2 Initial Instructions............................................... 4-5

4.3 Installation of Rear Railgear ................................. 4-7

4.4 Varying Front Railgear Configurations .................... 4-13

4.5 Traditional Long Arm Assembly Installation............. 4-14

4.6 Cargo Arm Front Assembly Installations ................. 4-21

4.7 Completing Front Installation................................ 4-23

4.8 Under Cab Front Unit Installation .......................... 4-26

4.9 Behind Cab Front Unit Installation ......................... 4-30

4.10 Overall Alignment Procedure............................... 4-32

4.11 Rail Test .......................................................... 4-34

4.12 Final Weld-Out.................................................. 4-34

4.13 Install Decals.................................................... 4-36

4.14 Velcro Steering Wheel Lock................................. 4-37

4.15 Installation Review Checklist............................... 4-38

SECTION 5.0 RAILGEAR OPTIONS

5.1 Rail Sweeps ....................................................... 5-2

5.2 Pin-Off Options................................................... 5-3

5.3 Brakes .............................................................. 5-7

5.4 Two-Piece Wheels ............................................... 5-14

5.5 Stub Axle Shunts ................................................ 5-16

SECTION 6.0 HYDRAULIC SYSTEM

6.1 Hydraulic System................................................ 6-2

6.2 Valve Assemblies and Hydraulic Schematic ............. 6-4

6.3 Rear Hydraulic Cylinder Drawings.......................... 6-5

6.4 Front Hydraulic Cylinder Drawings......................... 6-9

6.5 Cylinder Assembly Procedures .............................. 6-11

6.6 Fitting Installation............................................... 6-12

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

SECTION 7.0 REAR RAILGEAR PARTS

7.1 Before Ordering Parts – Rear Railgear.................... 7-2

7.2 Rear Parts Detail Drawing .................................... 7-4

7.3 RW-1630 Pin-Off Orientation ................................ 7-5

7.4 Link Dimensions ................................................. 7-6

7.5 Extra-Short Links................................................ 7-7

7.6 Short Links ........................................................ 7-8

7.7 Long Links ......................................................... 7-9

7.8 RW-1630 Wheel & Rear Axle Assembly (Detail) ....... 7-10

7.9 RW-1630 Stub Axle Assembly, Rear, Double

Insulated........................................................... 7-11

7.10 RW-1650 Wheel & Rear Axle Assembly (Detail) .... 7-12

7.11 RW-1650 Stub Axle Assembly, Rear, Double

Insulated......................................................... 7-13

7.12 Rear Mounting Bracket – 12” .............................. 7-14

7.13 Rear Mounting Bracket – 10-3/4” ........................ 7-15

SECTION 8.0 FRONT RAILGEAR PARTS

8.1 Before Ordering Parts – Front Railgear................... 8-2

8.2 Front Parts Detail Drawing.................................... 8-3

8.3 Long Arm Variations............................................ 8-4

8.4 RW-1630 Wheel & Front Axle Assembly.................. 8-5

8.5 RW-1630 Stub Axle Assembly, Front, Double

Insulated .......................................................... 8-6

8.6 RW-1630 Under Cab Front Railgear Assembly ......... 8-7

8.7 RW-1650 Behind Cab Front Railgear Assembly ........ 8-8

8.8 RW-1630 Mounting Tube Variations....................... 8-9

8.9 RW-1630 Spring Hanger Variations........................ 8-10

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

LIST OF FIGURES/TABLES

Figure 1.2.1 Front Railgear Components ..................................... 1-3

Figure 1.3.1 Rear Railgear Components ...................................... 1-5

Figure 3.2 Railgear Grease Locations ....................................... 3-4

Figure 3.3 Rail Wheel Wear Gauge........................................... 3-6

Figure 4.1.4 Bolt Torque Specifications ....................................... 4-4

Figure 4.2.4 Installation Rails.................................................... 4-6

Figure 4.3.2 Diagram of Key Rear Components............................ 4-8

Figure 4.3.4 Location and Clearance of Rear Railgear.................... 4-9

Figure 4.3.7 Squaring Rear Railgear........................................... 4-11

Figure 4.3.9 Rear Mounting Plate Installation............................... 4-12

Figure 4.3.10 Tack Welding of Rear Spacer ................................... 4-12

Figure 4.5.2 Diagram of Key Front Components ........................... 4-14

Figure 4.5.3 Bolted Joint Cross Section....................................... 4-15

Figure 4.5.4.A Below Frame Rail Bridge Kit..................................... 4-16

Figure 4.5.4.B Between Frame Rail Bridge Kit................................. 4-17

Figure 4.5.5 Front Railgear Mounting Dimensions......................... 4-18

Figure 4.5.7 Front Railgear Clearance......................................... 4-20

Figure 4.6.2 Diagram of Key Cargo Arm Components & Front

Mounting Dimensions ............................................. 4-21

Figure 4.7.1.A Recommended Tack Location for Standard Front

Axle..................................................................... 4-24

Figure 4.7.1.B Recommended Tack Location for Front Stub Axle........ 4-24

Figure 4.7.1.C Front Tire Clearance Above Rail................................ 4-25

Figure 4.8.6 Remote Air Pin-Off Installation – Under Cab............... 4-29

Figure 4.9.3 Behind Cab Installation Height................................. 4-31

Figure 4.10.1 Overall Alignment Procedure and Final Weight

Adjustment........................................................... 4-33

Figure 4.12.A Standard Front Railgear Final Weld-out ..................... 4-34

Figure 4.12.B Front Stub Axle Final Weld-out................................. 4-35

Figure 4.12.C Rear Mounting Plate Weld-off................................... 4-35

Figure 4.12.D Rear Spacer Welding .............................................. 4-36

Figure 5.1.A Rail Sweeps .......................................................... 5-2

Figure 5.1.B Rail Sweep Position................................................ 5-2

Figure 5.2.A Manual Pin-Off....................................................... 5-4

Figure 5.2.B Front Remote Pin-Off.............................................. 5-5

Figure 5.2.C Rear Remote Pin-Off............................................... 5-6

Figure 5.3.1 Cobra Air Brake Location......................................... 5-7

Figure 5.3.2 Front Air Brake Installation...................................... 5-8

Figure 5.3.3 Rear Air Brake Installation ...................................... 5-8

Figure 5.3.5.A Cobra Air Brake Control System Assembly................. 5-10

Figure 5.3.5.B Air Brake Control Kit for Behind Cab ........................ 5-11

Figure 5.3.6 Brake Inspection and Alignment............................... 5-12

Figure 5.3.8 Cobra Air Brake Assembly....................................... 5-13

Figure 5.4 RW-1630/50 Insulated 2-Pc. Wheel Assembly............ 5-15

Figure 5.5 Stub Axle Shunt Wiring........................................... 5-17

Table 3.4.1 Troubleshooting On-Track Problems.......................... 3-7

Table 4.1.5 Manufacturer Equivalent Welding Rod ....................... 4-5

Table 4.3.3 Location of Rear Railgear ........................................ 4-9

Table 4.3.5 Shimming Chart .................................................... 4-10

Table 4.8.1.A Cylindrical Tank Spacing – Under Cab ....................... 4-26

Table 4.8.1.B Squared Tank Spacing – Under Cab.......................... 4-26

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

SECTION 1.0 GENERAL INFORMATION

1.1GENERAL DESCRIPTION................................................................................. 1-2

1.2FRONT RAILGEAR........................................................................................... 1-3

1.2.1Standard Front Railgear Components............................................................... 1-3

1.2.2Behind Cab Front Railgear Components............................................................ 1-4

1.2.3Under Cab Front Railgear Components............................................................. 1-4

1.3REAR RAILGEAR ............................................................................................. 1-5

1.3.1Rear Railgear Components (Including RW-1630 and RW-1650) ........................... 1-5

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

1.1 GENERAL DESCRIPTION

DMF’s RW-1630 Railgear is our original and very successful Railgear for large trucks. The front

guide wheel assembly attaches to the frame and front axle and lifts the front truck tires off the

track, thus utilizing the vehicle’s front suspension. This design supports the vehicle as it was

intended and helps the truck navigate curves smoothly and damps out the effects of track

irregularities. The rear assembly attaches directly to the truck frame behind the rear

axle/tandem spring hangers. It deploys with an articulating dual scissor action that allows the

rear Railgear to be moved both vertically and horizontally. This mechanism provides the “side

shift” action which has made DMF gear so well known in the industry. It gives operators a

greater margin for aligning the vehicle to the track, which speeds and simplifies the process of

getting the vehicle on rail.

DMF RW-1630 Railgear is designed for vehicles with GVWR’s 33,000 lbs and above. For greater

capacity you can upgrade to our RW-1650 rear gear. It can boost your Railgear weight capacity

by supplying a larger axle, bigger bearings, and special hardened rail wheels. The front

Railgear and all other components remain the same as standard RW-1630. In addition to the

high-capacity axle upgrade available with our RW-1650 Railgear, we also offer additional

options for extreme conditions or tight curvature situations. See Sections 1.2 and 1.3 for

specific configuration information.

For purposes of this manual, we will refer to RW-1630 when discussing either RW-1630 or

RW1630/50, and we will explicitly call out any differences when appropriate.

Materials:

All structural members and brackets are constructed of carbon steel. The 16” guide wheels for

DMF RW-1630 Railgear are machined from hardened steel castings and are fitted to high

strength alloy steel axles with heavy-duty tapered roller bearings.

Installation:

Both DMF front and rear guide wheel units bolt to the truck frame using only hand tools found

in any shop. They are designed to minimize the amount of space required and in many cases fit

within the existing boundaries of the vehicle. The front units, however, sometimes require a

bolt-on frame extension to complete the installation. Rear RW-1630 Railgear mounts below the

top of frame and directly behind the rear axle spring hangers.

Brakes: NOTE:

The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail

mode. As the vehicle rear tires are in contact with the railhead, the primary braking effort is

derived from the rubber tires. Rail wheel brakes alone are insufficient to stop the vehicle in a

reasonable distance.

The optional RW-1630 rail brakes are of the air actuated external Cobra shoe type. The rail

brakes use a truck style air chamber to supply the clamping force. Supply pressure comes from

the vehicle’s air system. A pressure protection valve separates the Railgear and the truck’s air

systems, preventing a failure in the rail brake system from adversely affecting truck braking.

The rail brakes are applied simultaneously with the truck brakes when the operator presses the

brake pedal. There is also a dashboard-mounted switch that permits the operator to enable or

disable the rail braking system.

Options:

There are several options available for RW-1630 Railgear. The most commonly ordered options

include rail wheel brakes for improved stopping on rail, insulated wheels to prevent crossing

signal actuation, rail sweeps to clear the rail of potentially damaging materials, and remote pin-

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

offs for ease of operation. Other less common options are non-standard track gauges, slotted

links for improved hi-rail performance at crossings, and two-piece wheels for extreme

conditions.

1.2 FRONT RAILGEAR

DMF’s Heavy Duty Front Railgear is available in 3 different variations. The standard front

Railgear uses a 1630 axle (see section 1.2.1), the Behind Cab variation uses an extra heavy

duty 1650 axle and wheels (see section 1.2.2), and the Under Cab variation uses the 1630 axle

(see section 1.2.3).

1.2.1 Standard Front Railgear Components

Figure 1.2.1 shows the individual parts of the installed front Railgear. These item descriptions

will be used throughout this installation manual. DMF Railgear assemblies are also referred to

as guide wheels, Rail wheels, or hi-rail gear.

Front Railgear attached to front vehicle springs and front bumper, with 16” guide wheels

GVWR Range: 33,000 lbs. and above

Approx. Installed Weight (Front): 1385 lbs.

Capacity: 40,000 pounds per Railgear axle @ 20 MPH

For parts drawings, see Section 8.0, and for installation instructions, see Section 4.0.

Figure 1.2.1 Front Railgear Components

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

1.2.2 Behind Cab Front Railgear Components

DMF Behind Cab Front Railgear uses the RW-1650 axle and wheels.

Front Railgear mounted to truck frame behind the vehicle cab, with 16” guide wheels

GVWR Range: 33,000 lbs. and above, for heavy load applications

Approx. Installed Weight (Front): 1800 lbs.

Capacity: 70,000 pounds per Railgear axle @ 20 MPH

For parts drawings, see Section 8.0, and for installation instructions, see Section 4.0.

1.2.3 Under Cab Front Railgear Components

DMF Under Cab Front Railgear uses the RW-1630 axle and wheels.

Front Railgear mounted to truck frame underneath the vehicle cab, with 16” guide wheels

GVWR Range: 33,000 lbs. and above

Approx. Installed Weight (Front): 1700 lbs.

Capacity: 40,000 pounds per Railgear axle @ 20 MPH

For parts drawings, see Section 8.0, and for installation instructions, see Section 4.0.

DIVERSIFIED METAL FABRICATORS, INC. RW-1630

1.3 REAR RAILGEAR

1.3.1 Rear Railgear Components (Including RW-1630 and RW-1650)

DMF offers two different variations of Rear Railgear, RW-1630 and RW-1650. The components

are the same, other than the axles and wheels, which have different weight capacities.

RW-1630

GVWR Range: 33,000 lbs. and above

Approx. Installed Weight (Rear): 1185 lbs.

Capacity: 40,000 pounds per Railgear axle @ 20 MPH

RW-1650

GVWR Range: 33,000 lbs. and above, for heavy load applications

Approx. Installed Weight (Rear): 1385 lbs.

Capacity: 70,000 pounds per Railgear axle @ 20 MPH

Figure 1.3.1 shows the individual parts of the installed rear Railgear with the rail wheels in the

rail position. These item descriptions will be used throughout this installation manual.

Figure 1.3.1 Rear Railgear Components

For parts drawings, see Section 7.0, and for installation instructions, see Section 4.0.

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