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DMF RW-1016 Parts & Service Manual

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DIVERSIFIED METAL FABRICATORS, INC.
SERIAL NUMBER (FRONT)
SERIAL NUMBER (REAR)
Please refer to the serial numbers when ordering parts or
Parts (404) 607-1684 Parts Fax (404) 879-7888 parts@dmfatlanta.com
Service Department (404) 879-7882 service@dmfatlanta.com
Phone (404) 875-1512  Fax (404) 875-4835 info@dmfatlanta.com
Parts & Service Manual
RW-1016
February 2019
inquiring about warranty items.
DMF  665 Pylant Street  Atlanta, Georgia 30306
http://www.dmfatlanta.com
________________________
________________________
NOTE:

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Summary of Contents for DMF RW-1016

  • Page 1 NOTE: Please refer to the serial numbers when ordering parts or inquiring about warranty items. DMF  665 Pylant Street  Atlanta, Georgia 30306 Parts (404) 607-1684 Parts Fax (404) 879-7888 parts@dmfatlanta.com Service Department (404) 879-7882 service@dmfatlanta.com Phone (404) 875-1512  Fax (404) 875-4835 info@dmfatlanta.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    SECTION 6.0 RAILGEAR PARTS 6.1 Before Ordering Parts ..........6-2 6.2 Railgear Mounting Kits ...........6-3 6.3 Railgear Core Assemblies ........6-13 6.4 Suspension Assemblies, Bearings, & Wheels.....6-17 6.4 Optional Components ..........6-25 6.4 Chassis/Wheel Modification Kits ......6-9 © 2017 DMF, Inc. All Rights Reserved.
  • Page 4 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved.
  • Page 5 Weights and Capacities ..................1-3 CURRENTLY SUPPORTED CHASSIS ..............1-4 1.2.1 GM ........................ 1-4 1.2.2 Ford ......................1-4 1.2.3 Ram ......................1-4 RAILGEAR COMPONENTS AND TERMINOLOGY ..........1-5 1.3.1 Key Railgear Components ................1-5 © 2017 DMF, Inc. All Rights Reserved.

  • Page 6: General Description, Weights & Capacities

    Unlike most of our larger models, RW-1016 does not lift the steer axle off the rail. All vehicle tires remain in contact with the rail. RW-1016 does not provide braking or drive power, and relies on the vehicle tires for those functions.

  • Page 7: Weights And Capacities

    Capacity: 500-1,000 lb. per railwheel @ 40 MPH. Typical Railgear Weights: Exact weights vary based on many factors, including options and chassis make/model. Table 1.1 below summarizes weights typical of installations using RW-1016 Railgear. Item Typical Weight (lbs.) Front Railgear (Steel Railwheels)

  • Page 8: Currently Supported Chassis

    Only pickup or box delete variants. Chassis cab models are not typically supported. The list below includes basic guidelines regarding chassis suitability, but is not exhaustive. See DMF Technical Reference Bulletin TRB009 for additional details. Please contact DMF for assistance or questions with chassis and option selection for your project. 1.2.1 GM ...

  • Page 9: Railgear Components And Terminology

    1.3 RAILGEAR COMPONENTS AND TERMINOLOGY 1.3.1 Key Railgear Components Figure 1.3.1 identifies key components of RW-1016 Railgear assemblies. Appearances of some components may vary depending on chassis make/model/year, as well as selected Railgear options. These item descriptions will be used throughout this manual.
  • Page 10 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved.
  • Page 11 Lower Rear Guide Wheels ................2-4 2.3.3 Lower Front Guide Wheels................2-4 2.3.4 On the Tracks ....................2-4 GETTING OFF THE RAIL .................. 2-5 2.4.1 Removing Truck from Track ................2-5 EMERGENCY HAND PUMP OPERATION ............2-6 © 2017 DMF, Inc. All Rights Reserved.

  • Page 12: Before You Operate The Railgear

    Section 3.1.3. Operators should have access to a torque wrench. 2.1.3 Pinoff Systems and Locations NOTE: ALL RW-1016 Railgear assemblies feature cylinders that are equipped with external locking valves to prevent the Railgear from falling the in the event of a hydraulic system failure.

  • Page 13: Railgear Controls

    RW-1016 2.1.4 Railgear Controls RW-1016 Railgear is typically controlled using a wireless handheld remote. The remote should be stored in a safe, easily accessible location inside the cab. A master power switch inside the cab must be turned on to supply power to the hydraulic pump and wireless receiver.

  • Page 14: Highway Operation

     Operator is responsible for determining safe speed.  All four guide wheels on RW-1016 Railgear are typically insulated and will not operate  crossing gate circuits. Optional switchable shunt systems can be installed to selectively control when the vehicle will be detected on rail.

  • Page 15: Getting Off The Rail

    6. Turn off the railgear system power when not in use to prevent unintended movement. 7. Stow the Velcro steering wheel lock. 8. Make sure surrounding area is free and clear of any obstacles and vehicles before pulling off of the rail and onto the road. © 2017 DMF, Inc. All Rights Reserved.

  • Page 16: Emergency Hand Pump

    Do not drive vehicle at normal highway speeds if Railgear is not adequately restrained.  If Railgear is chained up and not fully in highway position, be aware of your ground clearance! FOR HYDRAULIC SYSTEM DIAGRAMS, PLEASE SEE SECTION 5.3. © 2017 DMF, Inc. All Rights Reserved...
  • Page 17 Bi-Annual Maintenance or as required..............3-2 3.1.4 Annual Maintenance or as required ..............3-2 FLUIDS AND LUBRICATION ................3-3 3.2.1 Grease Fitting Locations ................... 3-4 RAIL WHEEL WEAR GAUGE ................3-5 TROUBLESHOOTING ..................3-7 DERAILMENT ....................3-8 © 2017 DMF, Inc. All Rights Reserved.

  • Page 18: Inspection And Maintenance

    Verify the operation of the emergency hand pump. If pump does not operate, check that the pump is properly primed (see Section 5.1).  Check Railgear alignment (see Section 4.5).  Check Railgear wheel loads (see Section 4.6).  Replace handheld wireless remote batteries (QTY 3 AAA) © 2017 DMF, Inc. All Rights Reserved.

  • Page 19: Fluids And Lubrication

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 FLUIDS AND LUBRICATION  Hydraulic Oil: Dexron III ATF (DMF supplied electric/hydraulic power units)  Grease Fittings: Factory Standard: Citgo Syndurance Premium Synthetic 460 #2 Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose Grease #2  Wheel bearing hub units: Rail wheel bearing units are completely sealed. No lubrication or adjustment is necessary.

  • Page 21: Rail Wheel Wear Gauge

    RW-1016 RAIL 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.

  • Page 23: Troubleshooting

    Check Alignment and Adjust Alignment, Wheel Wear Replace Worn Wheels Insufficient traction or Rail Wheel Load set See Section 4.6 Set Rail Wheel Load braking too high Tires worn Inspect Tires Replace tires © 2017 DMF, Inc. All Rights Reserved.

  • Page 24: Derailment

    Inspect studs on wheel bearing units for damaged threads or missing lugs. Replace as necessary. Any items noted should be repaired using Section 4.0, to ensure they are repaired to initial install standards. Please contact DMF for any assistance you may require. © 2017 DMF, Inc. All Rights Reserved.
  • Page 25 Weld-Out & Final Adjustments ................ 4-18 INSTALL PROVIDED ACCESSORIES............... 4-20 4.9.1 Velcro Steering Wheel Lock ................4-20 4.9.2 Install Operation and Safety Decals ..............4-21 4.10 INSTALLATION REVIEW ................4-25 4.10.1 General Inspection..................4-25 © 2017 DMF, Inc. All Rights Reserved.
  • Page 26 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 4.10.2 Railgear Function Test ................4-25 4.10.3 Road Test ....................4-25 4.10.4 Before Customer Delivery ................4-25 © 2017 DMF, Inc. All Rights Reserved.

  • Page 27: Before You Begin

    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.

  • Page 28: Required Tools & Materials

    Railgear was manufactured for. One set of simulated rails is required for each end of the vehicle. Build simulated rails from heavy wall steel tubing. Recommended dimensions are shown below in Figure 4.1.6 Figure 4.1.6 Simulated Rails © 2017 DMF, Inc. All Rights Reserved.

  • Page 29: Welding Information

    RW-1016 4.1.7 Welding Information ****WARNING**** Select components of RW-1016 Railgear assemblies have been hot dip galvanized. DMF recommends grinding off the galvanized coating to raw steel where welding is required. For vehicles with installed wireless Railgear controls, remove all electrical and antenna connections from the Cervis base unit before welding on vehicle or attached railgear components.

  • Page 31: Wheel Modification Kit Installation

    Most vehicles require installation of alternate wheels and tires to properly align the vehicle’s track width to the rails. DMF offers Wheel Modification Kits for many popular chassis models for use on standard gage rail. Specific components and part numbers vary by application, but most wheel modification kits include appropriate wheel adapters and rims, steering stops, and TPMS sensors.

  • Page 32: Tire Pressure Monitoring Systems (Tpms)

    Speedometer re-calibration is usually done at the same time as the TPMS re-calibration. See Section 6.7 for information specific to your chassis. FOR DETAILED PARTS DIAGRAMS OF MODEL-SPECIFIC WHEEL MODIFICATION KITS SEE SECTION 6.7 © 2017 DMF, Inc. All Rights Reserved.

  • Page 33: Mounting Kit Installation

    MOUNTING KIT INSTALLATION 4.3.1 General Information Your RW-1016 Railgear was shipped with front and rear mounting kits specific to your vehicle and the hardware necessary to install them. Before you begin your installation, please note:  Your Railgear shipment includes many parts designed for your particular chassis year/make/model and selected options.

  • Page 34: Railgear Installation

    4.4.1 Railgear Assemblies – Identification and Orientation RW-1016 Railgear assemblies share many components between the front and rear assemblies and are visually similar. Make sure the correct Railgear assembly is installed on the proper end of the vehicle and facing the proper direction. See drawing M101602 on the following page for identification and orientation of Railgear assemblies.
  • Page 35 M101603, M101604 and manual sections 4.5-4.6). .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE: DRAWING NUMBER:...

  • Page 36: Alignment

     After a derailment. 4.5.2 Checking and Adjusting Alignment DMF recommends a “String Line” method to properly align the railgear to the vehicle axles. See drawing M101603 on the following page for recommended setup details, adjustment points, and tolerances. When performing the alignment procedure, record final alignment measurements on the loose copy of Drawing M101603, and provide it to the customer with all documentation.

  • Page 38: Rail Wheel Loads

    Proper adjustment of rail wheel loads will ensure that the completed vehicle operates safely, and offers good ride quality and component life. RW-1016 Railgear features an independent suspension system at all 4 wheels. The rail wheel loads at each corner can be independently adjusted.

  • Page 39: Checking & Adjusting Rail Wheel Loads

    8. When the paper begins to slip out from under the wheel note the gauge pressure. 9. If using the DMF 501749 jack, the reading on the gauge in PSI is equivalent to the rail wheel load on the adjacent wheel.
  • Page 40 RW-1016 ± .030 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED SUPPORT JACK DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:...

  • Page 41: Exhaust Modification

    2017+ Ford F-2/350 w/ 6.7L Diesel Engine This section outlines best practices for exhaust modification on 2017 model year and newer F- 250 and F-350 trucks with a 6.7L diesel engine for use with RW-1016 rear Railgear. Please see Ford SVE Bulletin Q-253 (https://www.fleet.ford.com/truckbbas/topics/qvmp.html) for...

  • Page 42: Rail Test, Weld-Out, & Final Adjustment

    4.8.1 Weld-Out & Final Adjustments ****WARNING**** Select components of RW-1016 Railgear assemblies have been hot dip galvanized. DMF recommends grinding off the galvanized coating to raw steel where welding is required. For vehicles with installed wireless Railgear controls, remove all electrical and antenna connections from the Cervis base unit before welding on vehicle or attached railgear components.
  • Page 43 WELD-OUT NOTES: • Select components of RW-1016 Railgear assemblies have been hot dip DROOP LIMITER ADJUSTMENT (OPTIONAL): galvanized. DMF recommends grinding off the galvanized coating to SMALLER GAP BETWEEN BOLT HEAD AND FINGER WITH raw steel where welding is required.

  • Page 44: Install Provided Accessories

    4.9.1 Velcro Steering Wheel Lock The DMF steering wheel lock consists of two 2” wide adhesive backed “hook” strips and a 4” wide piece of “loop” fabric. A piece of adhesive backed hook is placed on the steering wheel column and a second piece placed on the top flat of the steering wheel hub. The 4” wide piece of loop fabric can then be applied to bridge the gap between column and wheel preventing the front tires from accidentally being turned while on the rail.

  • Page 45: Install Operation And Safety Decals

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 4.9.2 Install Operation and Safety Decals Install the provided operation and safety decals where shown on the following pages. Surfaces should be clean of oil and dirt before application. © 2017 DMF, Inc. All Rights Reserved. 4-21...

  • Page 49: Installation Review

    Verify that the emergency pump handle is safely stowed.  Include this manual in the vehicle for operator reference.  Include this checklist and a completed alignment sheet in the vehicle for the customer’s records. © 2017 DMF, Inc. All Rights Reserved. 4-25...
  • Page 50 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. 4-26 © 2017 DMF, Inc. All Rights Reserved.
  • Page 51 ELECTRICAL SYSTEM ..................5-8 5.2.1 Locating Electrical Components ................. 5-8 5.2.2 Routing Wires ....................5-8 5.2.3 Electrical Insulation ..................5-8 HYDRAULIC & ELECTRICAL SCHEMATICS ............5-9 HYDRAULIC & ELECTRICAL COMPONENT DRAWINGS ........5-11 © 2017 DMF, Inc. All Rights Reserved.

  • Page 52: Hydraulic System

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 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 ...
  • Page 53 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 11257 1/4"-20 NYLOCK NUT; GR8 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:...

  • Page 57: Emergency Hand Pump

    It must be re-primed and tested after any components of the hydraulic system are removed or replaced. Failure to do so may render the hand pump inoperable. The following procedure is one method of priming that DMF has found to be quick and effective.

  • Page 58: Electrical System

    Failure to adequately protect the electrical components can lead to corrosion and system malfunction. The manufacturer does not warranty the installation of a third party installer. This is the installer’s responsibility. © 2017 DMF, Inc. All Rights Reserved.
  • Page 61 ITEM PART QTY. DESCRIPTION NUMBER 701023 WELDMENT, CYL. BARREL, 2" BORE, RW-1016 701028 ROD WELDMENT; RW-1016 818105 GREASE FITTING, 1/4"-28 (ALEMITE 1641-B) 501789 DETAIL, CYL GLAND, 2" BORE x 1" ROD, RW-1013 605038 5/8"-18 NYLOCK NUT; GR8 605047 1/8 MPT X 04 JIC 90 DEG LONG 501786 DETAIL, PISTON 2"...

  • Page 63: Railgear Parts

    Shunt Kit ..................... 6-27 6.5.3 Heavy Duty Cable Pinoff Assembly ..............6-28 CHASSIS/WHEEL MODIFICATION KITS ............6-29 6.6.1 2017+ Chevrolet 2/3500 ................6-31 6.6.2 2017+ Ford F-2/350 4x4 ................6-35 6.6.3 2014+ Ram 2/3500 ..................6-40 © 2017 DMF, Inc. All Rights Reserved.

  • Page 64: Before Ordering Parts

    Serial numbers uniquely identify your Railgear, as it was built to your specifications, and also allows DMF to help you maintain an order and repair history. DMF normally assigns serial numbers sequentially. The front railgear assembly typically has a lower serial number than the rear.

  • Page 65: Railgear Mounting Kits

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 RAILGEAR MOUNTING KITS © 2017 DMF, Inc. All Rights Reserved.
  • Page 66 703035 DS FRONT FRAME BRACKET; '11 GM PICKUP FRAME RAIL 113014 1/2"-13 NYLOCK NUT; GR8 703048 FRONT CRUSH TUBE, '11 GM PICKUP; RW-1016 605020 HHCS, 1/2-13 X 5", GR8 500691 FLAT WASHER, 1/2", GR8 605599 CARRIAGE BOLT; 1/2-13 X 4-1/2"; GRADE 8...
  • Page 67 703042 PS REAR FRAME BRACKET; '11 GM PICKUP 703043 DS REAR FRAME BRACKET; '11 GM PICKUP 703062 REAR BRACKET CROSS BRACE; '11 GM; RW-1016 MATCH DRILL 1/2" HOLE AND INSTALL 703049 BOLT PLATE WELDMENT; REAR BRACKET; '11 GM PICKUP 818466 HHCS, 1/2-13 X 1-1/2", GR8...
  • Page 68 PART QTY. DESCRIPTION NUMBER STEP 4: 701059 BATTERY TRAY PUMP BRACKET; '14 GM - GAS ONLY, RW-1016 605196 HHCS, 3/8-16 X 2", GR8 • SECURE FRONT BRACKET HOLE WITH 2" LONG BOLT AND NUT 605121 HHCS, 3/8-16 X 1-1/4", GR8 12566 LOCK WASHER, 3/8", GR8...
  • Page 70 ITEM PART 2017+ FORD F-250/350 FRONT QTY. DESCRIPTION NUMBER 703102 DS FRONT BRAKCET; '17 FORD PICKUP; 4X4; RW-1016 703103 PS FRONT BRAKCET; '17 FORD PICKUP; 4X4; RW-1016 605573 HHCS, 5/8-11 X 2-1/4", GR8 DRIVER SIDE BRACKET INSTALLATION 605276 HHCS, 1-2/13 X 2-1/4", GR8 605075 5/8"-11 NYLOCK NUT;...
  • Page 71 ITEM PART QTY. DESCRIPTION NUMBER STEP 2 703112 DS REAR BRAKCET; '17 FORD PICKUP; 4X4; RW-1016 703113 PS REAR BRAKCET; '17 FORD PICKUP; 4X4; RW-1016 STEP 4 703124 REAR BRACKET CROSS BRACE; '17 FORD PICKUP; RW-1016 703121 LONG CRUSH TUBE; REAR BRACKET; '17 FORD; RW-1016 703120 SHORT CRUSH TUBE;...
  • Page 72 NUMBER 2008-2016 FORD F-250/350 FRONT 703077 DS FRONT FRAME BRACKET; '08-16 FORD F-2/350; RW-1016 703076 PS FRONT FRAME BRACKET; '08-16 FORD F-2/350; 4X4; RW-1016 703082 BOTTOM PLATE; FT BRKT; '08-16 FORD F-2/350; RW-1016 605259 HHCS, 1/2-13 X 1-3/4", GR8 113014 1/2"-13 NYLOCK NUT;...
  • Page 74 ITEM PART 2011+ RAM 2500/3500 FRONT QTY. DESCRIPTION NUMBER 703085 PS FRONT FRAME BRACKET WELDMENT, '11 RAM PICKUP, RW-1016 703084 DS FRONT FRAME BRACKET WELDMENT, '11 RAM PICKUP, RW-1016 605569 HHCS, 1/2-13 X 4", GR8 500691 FLAT WASHER, 1/2", GR8 113014 1/2"-13 NYLOCK NUT;...

  • Page 75: 2014+ Ram 2500/3500

    QTY. DESCRIPTION NUMBER 703094 PS REAR FRAME BRACKET; '14 RAM 2500/ 3500 PICKUP 703109 REAR BRACKET CROSS BRACE, '14 RAM 2500, RW-1016 INSERT HANDLE BOLTS THROUGH 703093 DS REAR FRAME BRACKET, '14 RAM 2500/3500 PICKUP FRAME ACCESS HOLES 304099 HANDLE BOLT ASSEMBLY, 11-9/16 HANDLE, 1/2-13 X 2 BOLT, RW-1019B MATCH DRILL FRAME 1/2"...

  • Page 76: Railgear Core Assemblies

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 RAILGEAR CORE ASSEMBLIES RW-1016 Railgear assemblies share many components between the front and rear assemblies. The following terminologies are used to describe many shared parts and assemblies:  “SIDE A” (without cylinder) Drivers side on front assemblies Passenger side on rear assemblies ...
  • Page 77 1"-8 NYLOCK NUT .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. 605534 HHCS, 1-8 X 6", GR8 ANGULAR: ± 1° DRAWN BY: APPD BY:...
  • Page 78 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 605534 HHCS, 1-8 X 6", GR8 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE: DRAWING NUMBER:...
  • Page 79 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved. 6-16...

  • Page 80: Suspension Assemblies, Bearings, & Wheels

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 SUSPENSION ASSEMBLIES, BEARINGS, & WHEELS RW-1016 Railgear assemblies share many components between the front and rear assemblies. The following terminologies are used to describe many shared parts and assemblies:  “SIDE A” (without cylinder) Driver side on front assemblies; Passenger side on rear assemblies.
  • Page 85 ITEM NO. PART NUMBER QTY. DESCRIPTION 818503 RAILSWEEP RUBBER BELTING DETAIL 702160 RAILSWEEP BRACKET - TUBE LASER, SIDE A, RW-1016 605121 HHCS 3/8-16 UNC x 1-1/4", GRADE 8 818508 FLAT WASHER, 3/8", GR8 605077 3/8"-16 NYLOCK NUT; GR8 8/24/2018 BRACKET 702089 REPLACED BY 702160...
  • Page 86 ITEM NO. PART NUMBER QTY. DESCRIPTION 818503 RAILSWEEP RUBBER BELTING DETAIL 702161 RAILSWEEP BRACKET - TUBE LASER, SIDE B, RW-1016 605121 HHCS 3/8-16 UNC x 1-1/4", GRADE 8 818508 FLAT WASHER, 3/8", GR8 605077 3/8"-16 NYLOCK NUT; GR8 8/24/2018 BRACKET 702090 REPLACED BY 702161...
  • Page 87 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved. 6-24...

  • Page 88: Optional Components

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 OPTIONAL COMPONENTS © 2017 DMF, Inc. All Rights Reserved. 6-25...
  • Page 91 PART NUMBER QTY. DESCRIPTION 305077 CABLE PINOFF, BULKHEAD SWIVEL ENDS, 60" LENGTH, 1" TRAVEL 705013 PINOFF PIN, PLATED, FOR CABLE ACTUATION, RW-1016 705012 PINOFF BASE, PLATED, RW-1016 305071 CABLE PINOFF, MOUNTING TUBE, MACHINING, 1" STROKE 305070 CABLE PINOFF, PIN EXTENSION SPRING, SS 305069 CABLE PINOFF, HANDLE ASSEMBLY, 1"...

  • Page 92: Chassis/Wheel Modification Kits

    DIVERSIFIED METAL FABRICATORS, INC. RW-1016 CHASSIS/WHEEL MODIFICATION KITS © 2017 DMF, Inc. All Rights Reserved. 6-29...
  • Page 93 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved. 6-30...
  • Page 94 Figure 1 – Installation/Exploded Parts Diagram Recommended Tires DMF does not typically include tires with wheel modification kits. Recommended tire models and sizes are shown below. Using different tire sizes than shown below can result in component interference or poor performance on rail.
  • Page 95 The TPMS system will not operate properly until the new sensors are paired with the vehicle. b. Use factory tools and techniques to “re-learn” the new sensors to the vehicle. © 2017 DMF, Inc. All Rights Reserved. Page 2 of 4...
  • Page 96 Visually inspect wheels & tires both prior to and after use on rail (look for damage, loose hardware, etc.) b. Check the fastener torque 50 miles after wheel/tire change and every 2000 miles or 6 months. © 2017 DMF, Inc. All Rights Reserved. Page 3 of 4...
  • Page 97 Page left intentionally blank © 2017 DMF, Inc. All Rights Reserved. Page 4 of 4...
  • Page 98 Figure 1 – Installation/Exploded Parts Diagram Recommended Tires DMF does not typically include tires with wheel modification kits. Recommended tire models and sizes are shown below. Using different tire sizes than shown below can result in component interference or poor performance on rail.
  • Page 99 Verify that all brake, ABS sensor and other wires or hoses are clear in all steering and suspension positions. Restrain if necessary. © 2017 DMF, Inc. All Rights Reserved. Page 2 of 5...
  • Page 100 Figure 2 – Steering Stop Installation and Adjustment © 2017 DMF, Inc. All Rights Reserved. Page 3 of 5...
  • Page 101 Using FORScan Software: Cold inflation pressures can be set to 85 psi using freely available FORScan software and a supported OBDII interface adapter. Road testing by DMF has shown this this procedure typically complies with FMVSS requirements, but certifying compliance of the completed vehicle is the responsibility of the installer.
  • Page 102 Page left intentionally blank © 2017 DMF, Inc. All Rights Reserved. Page 5 of 5...
  • Page 103 Figure 1 - Installation/Exploded Parts Diagram (509068 shown) Recommended Tires DMF does not typically include tires with wheel modification kits. Recommended tire models and sizes are shown below. Using different tire sizes than shown below can result in component interference or poor performance on rail.
  • Page 104 The speedometer calibration is limited to stock tire sizes. As the tires we recommend are not a stock size for this vehicle, the stock LT265/60R20 tire setting should be selected as it is the most comparable in size. © 2017 DMF, Inc. All Rights Reserved. Page 2 of 5...
  • Page 105 Visually inspect wheels & tires both prior to and after use on rail (look for damage, loose hardware, etc.) b. Check the fastener torque 50 miles after wheel/tire change and every 2000 miles or 6 months. © 2017 DMF, Inc. All Rights Reserved. Page 3 of 5...
  • Page 106 Figure 2 – Steering Stop Details, Driver Side Figure 3 – Rear Fender Trim © 2017 DMF, Inc. All Rights Reserved. Page 4 of 5...
  • Page 107 Page left intentionally blank © 2017 DMF, Inc. All Rights Reserved. Page 5 of 5...
  • Page 108 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 This page intentionally left blank. © 2017 DMF, Inc. All Rights Reserved. 6-46...
  • Page 109 United States and Canada. DMF shall not be liable for other loss, damage, or expense directly or indirectly arising from the use of its products.
  • Page 110 DIVERSIFIED METAL FABRICATORS, INC. RW-1016 © 2017 DMF, Inc. All Rights Reserved.

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