DMF RW-1630 Quick start guide

DIVERSIFIED METAL FABRICATORS, INC.
DMF 665 Pylant Street Atlanta, Georgia 30306
Parts [phone]Parts Fax [phone][email protected]
Service Department [phone][e-mail]
Phone [phone] Fax [phone][e-mail]
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
© 2017 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.
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
[phone]
[phone] Fax
[phone] Parts
http://www.dmfatlanta.com
[email protected]
Ship to:
668 Drewry St. NE
Atlanta, GA 30306

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
© 2017 DMF, Inc. All Rights Reserved.
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
© 2017 DMF, Inc. All Rights Reserved.
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
© 2017 DMF, Inc. All Rights Reserved.
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
© 2017 DMF, Inc. All Rights Reserved. 1-1
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
1-2 © 2017 DMF, Inc. All Rights Reserved.
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
© 2017 DMF, Inc. All Rights Reserved. 1-3
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
1-4 © 2017 DMF, Inc. All Rights Reserved.
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
© 2017 DMF, Inc. All Rights Reserved. 1-5
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.

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
© 2017 DMF, Inc. All Rights Reserved. 2-1
SECTION 2.0 OPERATIONS
2.1BEFORE YOU OPERATE THE RAILGEAR............................................................ 2-2
2.1.1Familiarize Yourself with the Railgear............................................................. 2-2
2.1.2Daily Inspection.......................................................................................... 2-2
2.2ANTI-LOCK BRAKE SYSTEM (ABS)................................................................... 2-3
2.2.1Trucks Equipped with ABS............................................................................ 2-3
2.2.2Rail Operation of Trucks with ABS ................................................................. 2-3
2.3HIGHWAY OPERATION.................................................................................... 2-4
2.4GETTING ON THE RAIL.................................................................................... 2-4
2.4.1Getting onto the Rail ................................................................................... 2-4
2.4.2Lower Rear Guide Wheels............................................................................. 2-4
2.4.3Lower Front Guide Wheels............................................................................ 2-4
2.4.4On the Tracks............................................................................................. 2-5
2.5GETTING OFF THE RAIL................................................................................... 2-5
2.5.1Removing Truck from Track.......................................................................... 2-5

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
2-2 © 2017 DMF, Inc. All Rights Reserved.
2.1 BEFORE YOU OPERATE THE RAILGEAR
2.1.1 Familiarize Yourself with the Railgear
Clearances & Approach Angles
The installation of Railgear typically reduces the ground clearance & approach angle in the front
and back. In some installations, the guide wheels extend slightly beyond the corners of the
front bumper. Operators should familiarize themselves with the modified clearance & approach
angles.
Pin-off Systems and Locations
Walk around vehicle and identify the location and type of pin-off system(s) that are installed on
this particular vehicle. Please note that front and rear Railgear may have different types of pin-
off systems (i.e. front may be manual, while rear may be cable pin-offs). See section 5.0 for
more information on pin-offs.
DMF offers the following Pin-off options:
Manual Pin-Offs
Cable Remote Pin-Offs
Air Remote Pin-Offs
NOTE:
DMF’s Rear Cylinders are equipped with integral locking valves, however, pin-offs are still
required in both the rail and highway positions.
Operation Controls
Locate and familiarize yourself with the front and rear Railgear operating controls
Locate Power Take-Off (PTO) toggle/switch control and indicator light, typically found on
the dashboard
If your truck is equipped with Railgear brakes, locate the brake switch on the dashboard
of the truck
Identify the type of steering lock used on your truck
2.1.2 Daily Inspection
Before operating your Railgear-equipped vehicle, whether for highway or rail use, it is
imperative that you perform a daily inspection – see Section 3.1.1 for Daily Inspection List. If
any items found during your inspection do not conform to requirements, it is your responsibility
to take corrective action before any use of the vehicle.

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
© 2017 DMF, Inc. All Rights Reserved. 2-3
2.2 ANTI-LOCK BRAKE SYSTEM (ABS)
2.2.1 Trucks Equipped with ABS
All medium and heavy duty trucks manufactured after March 1, 1998, and equipped with air
brakes, are required by federal law to also include ABS. The system is designed to prevent
wheel lock-up during braking.
The ABS consists of wheel speed sensors, an “ECU” (electronic control unit) and all wiring and
airlines that link the ABS component to the brakes and the truck’s electrical system.
During braking, the sensors will detect if one or more of the wheels are locking and
automatically engage the ABS. The ECU then signals the system to apply and release brake
pressure as much as 15 times per second, allowing the wheel(s) to turn just enough to
maintain optimum traction.
Vehicles equipped with WABCO or Allied-Bendix ABS have an amber dash-mounted warning /
diagnostic lamp. During normal road operation, the lamp will come ON when the truck engine is
started and, depending on the type of system, will go OFF after about 3 seconds or when the
truck reaches a speed of approximately 5-7 mph. A self-diagnostic check of the ABS is
conducted during this time. If the lamp stays on, or comes on any other time during road
operation, a possible malfunction is indicated, which will shut off only the part of the system at
fault. The affected wheel(s) will revert back to conventional braking. For complete information
and instructions relative to the ABS system, please refer to the truck’s operation manual.
2.2.2 Rail Operation of Trucks with ABS
When the Railgear is in the rail position, the front truck tires are lifted off the ground. This may
produce an ABS fault and cause the ABS light to illuminate. In this condition, the brakes will
still function but the ABS system will not. If the amber ABS dash light remains on during rail
operation, the truck engine must be turned off and restarted after returning to highway
operation. This will clear the ABS light after a few seconds. If the amber light remains on during
road operation, the truck’s brake system may have an active fault and should be checked out.
Please refer to the truck’s operation manual.

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
2-4 © 2017 DMF, Inc. All Rights Reserved.
2.3 HIGHWAY OPERATION
Before operating a Railgear-equipped vehicle on the highway:
1. Verify Railgear is in highway position
2. Verify pins are properly and fully inserted in both front and rear Railgear (even if the
Railgear on your truck is equipped with a locking valve system, you MUST verify that the
pins are correctly inserted)
3. Steering wheel lock has been removed (if applicable)
4. Verify that Railgear brakes have been disengaged (if applicable)
5. Verify PTO has been disengaged and that the indicator light is OFF
2.4 GETTING ON THE RAIL
2.4.1 Getting onto the Rail
1. At the track crossing, drive past the track, then back the vehicle onto the rails. Engaging
the rear Railgear first will allow your vehicle to side-shift and align itself to the rail, making
it easier to engage the front Railgear.
2. Engage the truck’s parking brake to prevent the truck from rolling.
2.4.2 Lower Rear Guide Wheels
3. If the Railgear has brakes, turn brake switch on.
4. Engage the PTO, leave the truck running and the transmission in neutral gear.
5. Remove the safety pin-off pins (4 pins: 2 front and 2 rear, on both driver and passenger
sides). If pins are too tight to be easily removed, verify that Railgear is fully raised by
briefly pulling (bumping) the valve handle towards you.
6. Push valve handles to lower wheels and engage rail.
7. To assist with alignment of the wheels to the rail, you can also use the valve handles
independently to lower one side at a time to engage the rail, at which point you can then
lower the opposite side. This will cause your vehicle to side-shift and align itself with the
rail.
8. When both wheels are in rail position and properly engaging rail, replace safety pin-off pins.
2.4.3 Lower Front Guide Wheels
9. If necessary, drive the truck into position to line up the front guide-wheels with the rail.
10.Ensure that the PTO is engaged (this was engaged during the lowering of the rear Railgear).
11.Ensure front safety pin-off pins are removed.
12.Check and make sure that the front guide wheels line up with the rail.
13.Push valve handle to lower wheels and engage rail.
14.Engage the steering wheel lock (if applicable).
15.If you do not require the use of the PTO for additional equipment, it can now be disengaged.
16.Disengage the truck’s parking brake when you are ready to proceed.
NOTE:
The front guide wheel assembly is an over-center design and does not require safety
pin-off pins engaged in rail mode.

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
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2.4.4 On the Tracks
Do not exceed posted track speed limit, and at no time exceed 30 MPH while on track.
Be aware that some Railgear is insulated, and will not operate the crossing gate circuits.
You are responsible for knowing if your Railgear equipped vehicle has 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 slide tires or guide wheels on the tracks as this will cause premature wear.
Do not exceed the maximum rated capacity of the equipment.
On newer trucks with Anti-Lock braking systems, the amber ‘ABS’ dash light may remain on
with the front wheels elevated. This will not affect rear truck braking or rail wheel braking.
2.5 GETTING OFF THE RAIL
2.5.1 Removing Truck from Track
1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the truck parking brakes and engage the PTO.
3. Leave the truck running and the transmission in neutral gear.
4. Lift both sets of Railgear (there is no preference for removal order).
5. Engage all 4 safety pin-off pins in highway position (passenger and driver side, for both
front and rear Railgear).
6. Disengage the switch that controls the Railgear brakes (if applicable).
7. Disengage the steering wheel lock (if applicable).
8. Disengage the PTO and the parking brakes.
9. Make sure surrounding area is free and clear of any obstacles and vehicles before pulling off
of the rail and onto the road.
10.If the amber ABS dash light remains on during rail operation, the truck engine must be
turned off and restarted after returning to highway operation. This will clear and ABS light
after a few seconds. If the amber light remains on during road operation, the truck’s brake
system may have an active fault and should be checked out. Please refer to the truck’s
operation manual.

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© 2017 DMF, Inc. All Rights Reserved. 3-1
SECTION 3.0 ROUTINE MAINTENANCE
3.1Inspection and Maintenance ........................................................................... 3-2
3.1.1Daily......................................................................................................... 3-2
3.1.2Weekly...................................................................................................... 3-2
3.1.3Bi-annually ................................................................................................ 3-3
3.1.4Annual Maintenance or as required................................................................ 3-3
3.2Lubrication Specification................................................................................. 3-3
3.3Wheel Wear Gauge.......................................................................................... 3-5
3.4Troubleshooting.............................................................................................. 3-7
3.4.1Troubleshooting On-track Problems ............................................................... 3-7
3.5Derailment...................................................................................................... 3-8

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
3-2 © 2017 DMF, Inc. All Rights Reserved.
3.1 Inspection and Maintenance
If your Railgear vehicle is high-use or operated under extreme conditions, such as material
handlers or weed-spraying vehicles, or such as operating in mountainous regions or extreme
temperatures, the levels of inspections listed below may need to be performed more frequently
than stated.
The following are instructions for routine inspections recommended by Diversified Metal
Fabricators. In some circumstances, government or corporate regulations may require
additional inspections be performed. Please ensure that you are aware of any inspection
requirements that pertain to your Railgear and that you abide by all local and national laws
regarding Railgear maintenance and safety.
3.1.1 Daily
Visually inspect for hydraulic fluid leaks.
Check and make sure that all threaded fasteners are secured. NOTE: All hex nuts are either
nylon insert or slotted hex nuts with cotter pins.
Check and make sure all tie straps that secure hoses from moving parts and exhaust
systems are in place. Replace if cracked or worn.
Inspect wheel flanges for excessive wear (see Section 3.3 for wear gauge), primarily noting
differences in wear between wheels on the same axle or diagonally. If an abnormal pattern
is noted, check Railgear alignment (see alignment procedure in Section 4.10).
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 you feel
there is too much movement in and out, or if the wheel does not rotate freely, a detailed
inspection should be performed. See Sections 7.0 & 8.0 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 Section 7.0 & 8.0 for
appropriate axle assembly drawings.
If your vehicle is equipped with DMF “two piece” wheels, check the bolt torque indicators
(the tabs around each bolt) to ensure that they have not moved. If torque indicators are
missing or damaged, please contact DMF for replacements. If torque indicators have
moved, you must check bolt torque – see Section 5.4 for additional information.
3.1.2 Weekly
Perform standard daily inspection points as listed above, and then check the following:
Grease and lubricate all grease fittings on front and rear Railgear and guide wheel
assemblies.
NOTE:
There are six (6) locations on front assembly and fourteen (14) locations on rear
assembly. Stub axles will have an addition (2) grease fittings in the axle sleeve on the
front axle. See Drawing in Section 3.2 for details.
Check level of hydraulic oil and all other fluids.
Check air pressure in tires and inflate to proper inflation pressure (if necessary).
Inspect brakes and adjust if necessary. Refer to Section 5.3.6 & 5.3.7.
Brake Testing
- Operate the vehicle on a test track. With the “on/off” toggle valve “on” and the ball
valve(s) open, check that:
(1) When the vehicle brake pedal is depressed, the guide wheel brakes clamp the Rail
wheel enough to begin slowing its rotation, but not enough to totally lock the Rail

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
© 2017 DMF, Inc. All Rights Reserved. 3-3
Wheel. The Rail Wheels should not be allowed to lock up since that will cause a flat
spot on the wheel due to the sliding action on the rail.
(2) The brakes properly release when the brake pedal is released.
-If brakes do not function properly, contact a Service Representative at DMF.
3.1.3 Bi-annually
Perform standard daily and weekly inspection points as listed above, and then check the
following:
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
recommended grease without removing and/or re-packing the bearings.
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 traction and adjust as appropriate (see Section 4.10).
Rail test for proper braking and adjust as appropriate (see Section 5.3).
Check Railgear alignment (see Section 4.10)
3.1.4 Annual Maintenance or as required
In addition to the items listed in 3.1.1 Daily Maintenance, 3.1.2 Weekly Maintenance and 3.1.3
Bi-annual Maintenance; perform the following:
Disassemble, inspect, repack and reassemble Rail Wheel Bearings as shown in Sections
7.0 & 8.0.
3.2 Lubrication Specification
Hydraulic Oil:
ASTM D6158 HM (Unax RX-46 Hydraulic Oil, Shell Tellus EE 46 or equal)
OR
Some customers operate on Dexron III ATF
Wheel Bearing Grease / Grease Fittings:
Factory Standard: Citgo Syndurance Premium Synthetic 460 #2
Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose Grease #2 (or equivalent)

DIVERSIFIED METAL FABRICATORS, INC. RW-1630
© 2017 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 as well as tolerance on wheel
back-to-back spacing.