DMF RW-1019 Quick start guide

DIVERSIFIED METAL FABRICATORS, INC.
DMF  665 Pylant Street  Atlanta, Georgia 30306
Parts [phone] Parts Fax [phone] [e-mail]
Service Department [phone] [e-mail]
Phone [phone]  Fax [phone] [e-mail]
http://www.dmfatlanta.com
Parts & Service Manual
RW-1019/1212
Chipper Railgear
May 2020
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. CHIPPER RAILGEAR
© 2020 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. 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 (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
[phone]
[phone] Fax
[phone] Parts
http://www.dmfatlanta.com
[e-mail]
Ship to:
668 Drewry St. NE
Atlanta, GA 30306

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER
RAILGEAR
© 2020 DMF, Inc. All Rights Reserved.
TABLE OF CONTENTS
SECTION 1.0 GENERAL INFORMATION
1.1 General Description, Weights & Capacities ...............1-2
1.2 Chipper Railgear ...................................................1-3
SECTION 2.0 OPERATIONS
2.1 Before You Operate the Railgear .............................2-2
2.2 Highway Operation ...............................................2-3
2.3 Getting On the Rail ...............................................2-4
2.4 Getting Off the Rail ...............................................2-6
SECTION 3.0 ROUTINE MAINTENANCE
3.1 Inspection and Maintenance ...................................3-2
3.2 Fluids and Lubrication ...........................................3-4
3.3 Wheel Wear Gauge ...............................................3-5
3.4 Derailment ...........................................................3-7
SECTION 4.0 RAILGEAR INSTALLATION
4.1 Pre-Install ............................................................4-2
4.2 Initial Instructions ................................................4-6
4.3 General Information ..............................................4-7
4.4 Installation of Chipper Railgear ...............................4-8
4.5 Alignment and Rail Test Procedures ........................4-14
SECTION 5.0 RAILGEAR OPTIONS
5.1 Rail Sweeps .........................................................5-2
5.2 Rail Brakes ..........................................................5-6
SECTION 6.0 HYDRAULIC SYSTEM
6.1 General Information ..............................................6-2
6.2 Hydraulic & Electrical Schematics ............................6-6
6.3 Hydraulic and Electrical Component Drawings ..........6-12
SECTION 7.0 REAR RAILGEAR PARTS
7.1 Before Ordering Parts ............................................7-2
7.2 Assembly Drawings ...............................................7-3
7.3 Axle Drawings ......................................................7-6

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER
RAILGEAR
© 2020 DMF, Inc. All Rights Reserved.
LIST OF FIGURES/TABLES
Figure 1.2.1 RW-1019 Chipper Railgear Components ........................1-3
Figure 1.2.2 RW-1212 Chipper Railgear Components ........................1-4
Figure 4.3 RW-1019 Chipper Railgear Major Components ...............4-7
Figure 4.4.1.A Tower Assembly Alignment w/ Axle ..............................4-8
Figure 4.4.1.B Selecting a Common Alignment Reference Point .............4-9
Figure 4.4.1.C Stowed & Deployed Measurements RW-1019 .................4-10
Figure 4.4.1.D Stowed & Deployed Measurements RW-1212 .................4-10
Figure 4.4.1.E Tower Assembly Alignment ..........................................4-11
Figure 4.4.1.F Axle Rod Pin, Axle Lugs & Cylinder Interface ..................4-12
Figure 4.4.1.G Axle Lug Weldment ....................................................4-12
Figure 4.4.1.H Alignment of Second Axle ............................................4-13
Figure 4.5.1 Railgear Alignment Single Axle .....................................4-15
Figure 4.5.2 Railgear Alignment Dual Axles .....................................4-16
Figure 5.2.1 Rail Brake Adjustment ................................................5-6
Table 4.1.6 Manufacturer Equivalent Welding Rod ...........................4-5

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
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© 2020 DMF, Inc. All Rights Reserved. 1-1
SECTION 1.0 GENERAL INFORMATION
1.1 GENERAL DESCRIPTION, WEIGHTS & CAPACITIES ......................................... 1-2
1.1.1 Weights and Capacities .................................................................................... 1-2
1.1.2 Installation ..................................................................................................... 1-2
1.1.3 Options.......................................................................................................... 1-2
1.1.4 Brakes ........................................................................................................... 1-2
1.2 CHIPPER RAILGEAR ....................................................................................... 1-3
1.2.1 RW-1019 Chipper Railgear Components ............................................................. 1-3
1.2.2 RW-1212 Chipper Railgear Components ............................................................. 1-3

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
1-2 © 2020 DMF, Inc. All Rights Reserved.
1.1 GENERAL DESCRIPTION, WEIGHTS & CAPACITIES
DMF’s Chipper Railgear is designed for tow behind chippers. The Railgear completely lifts the
chipper tires above rail when deployed. This allows for various tracked chippers to be used on
the same gauge rail.
Two version of the Chipper Railgear are offered. The first version, RW-1019 Chipper Railgear
uses a RW-1019 standard 10” wheel and axle assembly. The gear is actuated by two hydraulic
cylinders per axle. RW-1019 Chipper Railgear is standard for most applications and tailored for
lighter chippers. The second version, RW-1212 Chipper Railgear uses a RW-1212 standard 12”
wheel and axle assembly. This gear uses four hydraulic cylinders per axle. The RW-1212
Chipper Railgear is used only in applications where the chipper is too heavy for standard RW-
1019 Chipper Railgear.
1.1.1 Weights and Capacities
Chipper Railgear Capacity per Railgear Axle @ 20 MPH:
 RW-1019 Chipper Railgear: ~8,200 lbs.
 RW-1212 Chipper Railgear: ~12,300 lbs.
Chipper Railgear installed weights per axle, no brakes:
 RW-1019 Chipper Railgear: ~300 lbs.
 RW-1212 Chipper Railgear: ~540 lbs.
1.1.2 Installation
The DMF Chipper Railgear assemblies were designed to minimize the mounting space needed
with minimal modifications to the trailer. The Chipper Railgear is mounted just behind the rear
axle where space is available. The Railgear can be ordered with a second axle, for mounting to
the front of the frame. Spacing should be considered to balance the chipper when the Railgear
is deployed. It should be noted that chippers requiring a second axle must be towed with a
drawbar.
1.1.3 Options
There are multiple options available when ordering a set of Chipper Railgear. The most
commonly ordered options include rail wheel brakes for aided stopping on rail, insulated wheels
to prevent crossing signal actuation and rail sweeps to clear the rail of potentially damaging
materials.
1.1.4 Brakes
NOTE:
Primary braking effort is provided from the towing vehicle when operating on rail. The rail
wheel brake system is intended to assist the vehicle. If the existing vehicle brakes are not
maintained in good working order, the rail wheel brakes are not capable of independently
stopping the vehicle in reasonably short distances.
The optional brakes are hydraulically actuated from the supplied Railgear power unit. When
enabled, the chipper brakes are applied when the brakes are applied in the tow vehicle. A
timer is used to limit the run time of the pump to prevent overuse.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
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© 2020 DMF, Inc. All Rights Reserved. 1-3
1.2 CHIPPER RAILGEAR
NOTE:
The orientation of brakes can be installed vertically or horizontally to improve brake clearances.
1.2.1 RW-1019 Chipper Railgear Components
Figure 1.2.1 identifies the key components of the RW-1019 Chipper Railgear. Appearances will
vary depending on the selected Railgear options. These item descriptions will be used
throughout this manual.
Figure 1.2.1 RW-1019 Chipper Railgear Components
1.2.2 RW-1212 Chipper Railgear Components
Figure 1.2.2 identifies the key components of the RW-1212 Chipper Railgear. Appearances will
vary depending on the selected Railgear options. These item descriptions will be used
throughout this manual.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
1-4 © 2020 DMF, Inc. All Rights Reserved.
Figure 1.2.2 RW-1212 Chipper Railgear Components

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
© 2020 DMF, Inc. All Rights Reserved. 2-1
SECTION 2.0 OPERATIONS
2.1 BEFORE YOU OPERATE THE RAILGEAR ........................................................... 2-2
2.1.1 Familiarization of Railgear ................................................................................ 2-2
2.2 HIGHWAY OPERATION ................................................................................... 2-3
2.3 GETTING ON THE RAIL ................................................................................... 2-4
2.3.1 Getting Onto the Tracks ................................................................................... 2-4
2.3.2 Lowering Guide Wheels – Single Axle ................................................................ 2-4
2.3.3 Lowering Guide Wheels – Dual Axles ................................................................. 2-4
2.3.4 On the Tracks ................................................................................................. 2-5
2.4 GETTING OFF THE RAIL .................................................................................. 2-6
2.4.1 Single Axle ..................................................................................................... 2-6
2.4.2 Dual Axles ..................................................................................................... 2-6

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
2-2 © 2020 DMF, Inc. All Rights Reserved
2.1 BEFORE YOU OPERATE THE RAILGEAR
2.1.1 Familiarization of Railgear
Clearances & Approach Angles
Installation of Railgear typically reduces ground clearance, with the rail wheels resting below
the frame of the chipper. This must be taken into consideration by the operator when
maneuvering on-road and positioning for Railgear deployment. To avoid equipment and
property damage, operators should be familiar with the modified clearances and working
envelope before towing.
Pin Off Systems and Locations
Walk around the chipper and identify the location and type of Railgear pin off system installed.
Locking valves are provided for each cylinder. Pin Offs are installed on both sides of the
Railgear assembly. It is required that the Pin Offs are used when the Railgear is in both the
highway and rail positions.
Operation Controls
 Locate and be familiar with the location of the Railgear operating controls.
 Locate the Hydraulic Power Unit, its power source and power switch on the trailer.
 If the truck is equipped with Railgear brakes, locate the brake switch. This switch
should only be enabled on rail to avoid continuously running the hydraulic Power Unit.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
© 2020 DMF, Inc. All Rights Reserved. 2-3
2.2 HIGHWAY OPERATION
Before towing a Railgear-equipped chipper on the highway ensure the following:
1. Verify Railgear is in highway position.
2. Verify that the pin offs for both sides of the axle(s) are properly engaged.
3. Verify that Railgear brakes have been disengaged and the switch has been turned off, if
applicable.
4. Verify PTO has been disengaged and that the indicator light is OFF.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
2-4 © 2020 DMF, Inc. All Rights Reserved
2.3 GETTING ON THE RAIL
NOTE:
The hydraulic power unit is turned on by pushing a momentary switch mounted next to
each spool valve. Release the switch when not in use to avoid overheating the power
unit.
2.3.1 Getting Onto the Tracks
1. If at any time the chipper is unhitched from the tow vehicle the wheels/tires must be
secured in place to prevent it from moving. The Railgear brakes will NOT hold the chipper
in place.
2. At the track crossing, drive past the track and back the vehicle and trailer onto the rails.
Align the rear Railgear of the chipper over the tracks.
3. Engage the truck’s parking brake to prevent the truck from rolling.
4. Leave the truck running and the transmission in neutral gear.
2.3.2 Lowering Guide Wheels – Single Axle
1. Disengage the Railgear pin offs on each side of the chipper. If a pin off is difficult to
disengage, momentarily raise the Railgear to remove load from the pin off.
2. Hold the pump power button and use the valve to lower the guide wheels. The flanges of
the wheels should be to the inboard sides of the railheads. It may be necessary to adjust
truck position slightly.
3. Release the power button when finished using the hydraulics.
4. When both wheels are down and properly engaging the rail, re-engage the Railgear pin offs.
5. If the Railgear is equipped with auxiliary rail brakes, turn the brake switch on.
6. Follow owner’s manual to operate tow vehicle’s Railgear.
2.3.3 Lowering Guide Wheels – Dual Axles
NOTE:
If the chipper is equipped with at second axle it must be towed on rail using a draw bar.
1. Disengage the Railgear pin offs on each side of the chipper for both axles. If a pin off is
difficult to disengage, momentarily raise the Railgear to remove load from the pin off.
2. Push and hold the pump power button and use the valve to lower the rear rail wheels only.
The flanges of the wheels should be to the inboard sides of the railheads. It may be
necessary to adjust the truck position slightly.
3. Release the power button when finished using the hydraulics.
4. When the rear Railgear is deployed, re-engage the Railgear pin offs for that axle only.
5. Follow the owner’s manual to deploy the tow vehicle’s Railgear on rail.
6. Chock the chipper rear Railgear wheels to keep it stationary.
7. Push and hold the pump power button and deploy the front Railgear enough to lift the
weight of the chipper off the trailer hitch. Release the power button. Detach the trailer
from the tow vehicle.
8. Ensure all safety chains and electrical connections are disconnected between the chipper
and tow vehicle.
9. Drive the tow vehicle forward and install the draw bar.
10. Reverse the tow vehicle and use the draw bar to reattach to the chipper.
11. Ensure all electrical connections and safety chains are secured.
12. Fully deploy the front Railgear and engage the pin offs.
13. Remove the chocks from the rear Railgear axle.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
© 2020 DMF, Inc. All Rights Reserved. 2-5
14. If the Railgear is equipped with auxiliary rail brakes, turn the brake switch on.
2.3.4 On the Tracks
 Do not exceed posted track speed limit, and at no time exceed 20 MPH while on the track.
 Be aware that some Railgear is insulated, and will not operate the crossing gate circuits. It
is the operator’s responsible to know if the Railgear equipped vehicle and trailer have
insulated or non-insulated wheels. To assist in identifying insulated rail wheels, a grooved
ring is machined around the inside of the front and rear driver’s side wheels.
 All railroad rules and safety guidelines should be observed.
 Reduce speed while in reverse and/or at all crossings, curves, branch lines, switches and
frogs. No more than a slow walking pace is recommended.
 Traction is reduced on the track, especially in wet conditions.
 Braking distance is increased on the track, especially in wet conditions.
 Do not exceed the maximum rated capacity of the equipment.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
2-6 © 2020 DMF, Inc. All Rights Reserved
2.4 GETTING OFF THE RAIL
NOTE:
The hydraulic power unit is turned on by pushing a momentary switch mounted next to
each spool valve. Release the switch when not in use to avoid overheating the power
unit.
2.4.1 Single Axle
1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the parking brake, leave the truck running and the transmission in neutral.
3. Follow the necessary steps outlined in the provided operations manual for stowing the tow
vehicle’s Railgear.
4. Disengage the Railgear pin offs on both sides of the trailer.
5. Push and hold the pump power button and use the spool valve to lift the Railgear
6. Release the power button when the hydraulics are not in use.
7. Re-engage all pin offs for safe travel on the highway.
8. Turn off the switch controlling the Railgear brakes, if applicable.
9. Make sure the surrounding area is free and clear of any obstacles and vehicles before
disengaging the parking brake and pulling onto the road.
2.4.2 Dual Axles
1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the parking brake, leave the truck running and the transmission in neutral.
3. Chock the rear Railgear wheels.
4. Disengage the pin offs on both axles.
5. Remove the draw bar and secure it in an appropriate location.
6. Back the tow vehicle up to hitch to the chipper.
7. Stow and pin off the front Railgear and remove the wheel chocks.
8. Fully stow the rear Railgear and pin off.
9. Follow the necessary steps in the provided operations manual for stowing the tow vehicle’s
Railgear.
10. Always release the power button when the hydraulics are not in use.
11. Disengage the switch controlling the Railgear brakes, if applicable.
12. Make sure the surrounding area is free and clear of any obstacles and vehicles before
disengaging the parking brake and pulling onto the road.

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© 2020 DMF, Inc. All Rights Reserved. 3-1
SECTION 3.0 ROUTINE MAINTENANCE
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 ................................................................... 3-3
3.2 FLUIDS AND LUBRICATION ............................................................................ 3-4
3.3 WHEEL WEAR GAUGE ..................................................................................... 3-5
3.4 DERAILMENT .................................................................................................. 3-7

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
3-2 © 2020 DMF, Inc. All Rights Reserved.
3.1 INSPECTION AND MAINTENANCE
To assure safe and reliable operation, Diversified Metal Fabricators recommends the following
inspection and maintenance guidelines detailed below.
Government or corporate regulations may require additional inspections not covered below. The
operator is responsible for being aware of any additional recurring inspections that pertain to
the Railgear, and to have them completed accordingly.
Vehicles operated in the following severe-duty conditions may need more frequent inspection
and maintenance than suggested below:
 Extreme hot or cold temperatures
 Operation on steep grades
 Extended exposure to road salt
 High mileage use on track
3.1.1 Daily Maintenance
 Visually inspect for hydraulic fluid leaks.
 Check and make sure that all threaded fasteners are secured.
 Visually inspect protective hose/wire wraps, and securing straps, near moving parts.
Replace if cracked or worn.
 Inspect wheel flanges for excessive wear, primarily noting differences in wear between
wheels on the same axle or diagonally, which may indicate and alignment issue.
 Inspect wheel “end-play”: Placing one hand at the 9 o’clock position and your other
hand at the 3 o’clock position firmly grab the wheel and push and pull it a few times.
There should be no discernable movement in and out, and the wheel should rotate
freely. If there is too much movement in and out, or if the wheel does not rotate freely,
a detailed inspection should be performed. See Section 7 for appropriate axle assembly
drawings.
 Throughout the day, inspect wheel temperature. If extremely hot, this could indicate
bearing adjustment is too tight. For adjustment information, see Sections 7 for
appropriate axle assembly drawings.
3.1.2 Weekly Maintenance
 Perform standard daily inspection points as previously listed.
 Apply grease to inner tubes of tower assembly as needed.
 Check level of hydraulic oil.
 Check air pressure in tires and correct if necessary.
 Inspect brakes and adjust if necessary. Refer to Section 5.2.
 Test rail brakes on a test track.
o With the Railgear brake switch “on”, verify that pressing vehicle brake pedal,
causes the rail brakes to slow, but not lock up the rail wheels.
o Locking up the wheels on rail can lead to “flat spotting” of wheels. Rail brakes
should properly release when the vehicle brake pedal is released.
o Contact a Service Representative at DMF if additional assistance is needed.
3.1.3 Bi-Annual Maintenance or as Required
 Perform standard daily and weekly inspection points as listed previously.
 Remove the hubcaps from the rail wheels and inspect for deterioration or loss of wheel
bearing grease. Unless there is a problem, the cavity may be topped off with the

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
© 2020 DMF, Inc. All Rights Reserved. 3-3
recommended grease without removing and/or re-packing the bearings, see Section 3.2.
If parts appear worn or damaged, replace and repack as shown in Sections 7.
 Clean the hubcap and mating surfaces and apply a bead of silicone gasket and re-attach
securely.
 Clean the strainer / filter in the hydraulic power unit tank.
 Rail test for proper braking and adjust as appropriate, see Section 5.2.
 Check Railgear alignment if multiple axles are in use.
3.1.4 Annual Maintenance or as Required
 Perform standard daily, weekly, and bi-annual inspection points as listed above. In
addition:
 Disassemble, inspect, repack and reassemble Rail Wheel Bearings as shown in Section 7.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
3-4 © 2020 DMF, Inc. All Rights Reserved.
3.2 FLUIDS AND LUBRICATION
 Hydraulic Oil: Dexron III ATF for DMF supplied electric/hydraulic power units
 Wheel Bearing Grease / Grease Fittings:
o Factory Standard: Citgo Syndurance Premium Synthetic 460 #2
o Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose Grease #2, or equivalent

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
© 2020 DMF, Inc. All Rights Reserved. 3-5
3.3 WHEEL 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 minimum wall thickness on the wheel tread and tolerance on wheel
back-to-back spacing.