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DMF RW-1019 Parts & Service Manual

Chipper railgear
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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-1019/1212
Chipper Railgear
May 2020
inquiring about warranty items.
DMF  665 Pylant Street  Atlanta, Georgia 30306
http://www.dmfatlanta.com
________________________
________________________
NOTE:

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  • 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

    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 © 2020 DMF, Inc. All Rights Reserved.
  • Page 4 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 &...
  • Page 5 Weights and Capacities ..................1-2 1.1.2 Installation ..................... 1-2 1.1.3 Options......................1-2 1.1.4 Brakes ......................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 © 2020 DMF, Inc. All Rights Reserved.

  • Page 6: General Description, Weights & Capacities

    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.

  • Page 7: Chipper Railgear

    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.
  • Page 8 DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR Figure 1.2.2 RW-1212 Chipper Railgear Components © 2020 DMF, Inc. All Rights Reserved.
  • Page 9 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 GETTING OFF THE RAIL .................. 2-6 2.4.1 Single Axle ..................... 2-6 2.4.2 Dual Axles ..................... 2-6 © 2020 DMF, Inc. All Rights Reserved.

  • Page 10: Before You Operate The Railgear

    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. © 2020 DMF, Inc. All Rights Reserved...

  • Page 11: Highway Operation

    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. © 2020 DMF, Inc. All Rights Reserved.

  • Page 12: Getting On The Rail

    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. © 2020 DMF, Inc. All Rights Reserved...

  • Page 13: On The Tracks

    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.  © 2020 DMF, Inc. All Rights Reserved.

  • Page 14: Getting Off The Rail

    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. © 2020 DMF, Inc. All Rights Reserved...
  • Page 15 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 FLUIDS AND LUBRICATION ................3-4 WHEEL WEAR GAUGE ..................3-5 DERAILMENT ....................3-7 © 2020 DMF, Inc. All Rights Reserved.

  • Page 16: Inspection And Maintenance

    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. Contact a Service Representative at DMF if additional assistance is needed. 3.1.3 Bi-Annual Maintenance or as Required ...

  • Page 17: Annual Maintenance Or As Required

    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. © 2020 DMF, Inc. All Rights Reserved.

  • Page 18: Fluids And Lubrication

    DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR FLUIDS AND LUBRICATION  Hydraulic Oil: Dexron III ATF for DMF supplied electric/hydraulic power units  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...

  • Page 19: Wheel Wear Gauge

    CHIPPER RAILGEAR 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.

  • Page 21: Derailment

    Ensure axle threads are not stripped or damaged. Any items noted should be repaired using Section 4, to ensure they are repaired to initial install standards. Please contact DMF for any assistance you may require. © 2020 DMF, Inc. All Rights Reserved.
  • Page 22 ALIGNMENT AND RAIL TEST PROCEDURES ........... 4-14 4.5.1 Railgear Alignment – Single Axle..............4-14 4.5.2 Railgear Alignment – Dual Axles ..............4-15 4.5.3 Rail Test ...................... 4-18 4.5.4 Final Weld-out ....................4-18 4.5.5 Installation Review Checklist ................4-18 © 2020 DMF, Inc. All Rights Reserved.

  • Page 23: Pre-Install

    4.1.2 Installation Order This manual presents the installation information in the order that DMF finds to work best. The installer’s shop, tools, personnel or other factors may dictate a different order. This is acceptable as long as the Overall Alignment, Rail Test, Road Test, and Final Inspection are performed at the end.

  • Page 24: Bolt Torque Specifications

    DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR 4.1.5 Bolt Torque Specifications See the following page for recommended torque specifications. © 2020 DMF, Inc. All Rights Reserved.

  • Page 26: Welding Information

    Arcos Ductilend 70 Air Products 170-LA, SW-47,616 Chemtron 170-LA, SW-47,616 Hobart 718, 718-SR Marquette 7018 McKay Co 7018 Reid-Avery 7018 Uniblaze 7018 Westinghouse Wiz-18 Lincoln Jetweld LH-70 Table 4.1.6 Manufacturer Equivalent Welding Rod © 2020 DMF, Inc. All Rights Reserved.

  • Page 27: Initial Instructions

    Frame: Inspect to ensure that there is no damage and has not been bent. NOTE: Deploying Railgear lifts the trailer tires completely off rail. Ensure the trailer will remain stationary during this operation. © 2020 DMF, Inc. All Rights Reserved.

  • Page 28: General Information

    Therefor minor modifications to the trailer or Railgear may be required for proper installation. The Railgear provided consists of the listed major components below, which are also shown in Figure 4.3. This figure shows the standard RW-1019 Chipper Railgear. ...

  • Page 29: Installation Of Chipper Railgear

    INSTALLATION OF CHIPPER RAILGEAR NOTE: The following section describes a typical installation of RW-1019 Chipper Railgear mounted directly to the frame of the chipper. The gear may be installed on a fabricated cross member if frame space is not available. In this case modification to the mount between the Tower Assemblies and the Axle would be required.
  • Page 30 Determine this location with respect to the Tower Assembly and the Mounting Plate. Take into consideration axle droop and rail wheel diameter. Figure 4.4.1.C & 4.4.1.D shows the basic overall dimensions of Railgear in both deployed and stowed positions. © 2020 DMF, Inc. All Rights Reserved.
  • Page 31 DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR 10" ROLLING 3" GROUND DIAMETER CLEARANCE Figure 4.4.1.C - Stowed & Deployed Measurements RW-1019 3" GROUND 12" ROLLING CLEARANCE DIAMETER Figure 4.4.1.D – Stowed & Deployed Measurements RW-1212 5. Clamp the Mounting Plate and Tower Assembly to the trailer frame at the previously determined location.
  • Page 32 10. Insert the lower Cylinder Rod Pin through the Axle Lugs and rod end of the cylinder as shown in Figure 4.4.1.F for both sides. For RW-1019 Railgear the larger Axle Lug is placed inside the base of the Tower Assembly.
  • Page 33 15. Follow these steps if a second axle is required. Ensure the second axle is squared to the other axle. Adjust as needed, see Figure 4.4.1.H. 4-12 © 2020 DMF, Inc. All Rights Reserved.
  • Page 34 16. Run all Railgear up and down to makes sure it can be pinned off in both positions and as a final clearance check. 17. Secure all hoses away from moving parts and pinch points. © 2020 DMF, Inc. All Rights Reserved. 4-13...

  • Page 35: Alignment And Rail Test Procedures

    NOTE: DMF recommends these procedures to be performed after the hydraulic and electrical systems have been installed. A fully functional hydraulic system will make it possible to repeatedly lift and lower the Railgear to check and verify adjustments.

  • Page 36: Railgear Alignment - Dual Axles

    Tack weld the lugs and recheck the measurements. When the measurements are within the tolerances listed, record them on the alignment tear sheet included at the end of this section. © 2020 DMF, Inc. All Rights Reserved. 4-15...
  • Page 37 DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR A = B WITHIN 1/4" C = D WITHIN 1/8" E = F WITHIN 1/8" G = H WITHIN 1/4" Figure 4.5.2 – Railgear Alignment Dual Axles 4-16 © 2020 DMF, Inc. All Rights Reserved.
  • Page 38 ± .030 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. COMPLETE RAIL TEST PROCEDURE OUTLINED IN MANUAL. ANGULAR: ± 1° DRAWN BY: APPD BY:...

  • Page 39: Rail Test

    Verify the Railgear does not interfere with the chipper operation.  Re-check alignment of the Railgear to the trailer hitch.  Touch-up the black acrylic enamel paint on the Railgear.  Check hydraulic oil level and top off if needed. 4-18 © 2020 DMF, Inc. All Rights Reserved.
  • Page 40 SECTION 5.0 R AILGEAR PTIONS RAIL SWEEPS ....................5-2 5.1.1 Rail Sweep Adjustment ..................5-2 5.1.2 Rail Sweep Parts ..................... 5-2 RAIL BRAKES ....................5-6 5.2.1 Brake Adjustment ................... 5-6 5.2.2 Brake Parts ....................5-6 © 2020 DMF, Inc. All Rights Reserved.

  • Page 41: Rail Sweeps

    The rubber rail sweeps should be replaced when they are worn to a point where satisfactory adjustment is no longer possible. Bent or broken rails sweeps should be repaired or replaced as necessary. See parts diagrams on following pages. © 2020 DMF, Inc. All Rights Reserved.
  • Page 42 RAILSWEEP BRACKET (DRIVER'S SIDE) (10HD) 5/13/13 REDRAWN IN SOLIDWORKS, REMOVED NOTE 1/25/96 ADDED MOUNTING HARDWARE TO B.O.M. DATE DESCRIPTION TOLERANCES: TITLE: (UNLESS SPECIFIED) RW-1019 RAILSWEEP ASSEMBLY RW-1019 FRAC, MACH: ± 1/32" FRAC, OTHER: ± 1/16" ± .063 ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512 .XXX ±...
  • Page 43 ITEM NO. PART NUMBER QTY. DESCRIPTION 10042 RW-1019 RAILSWEEP MOUNTING BRACKET, WELD ON 818503 RAILSWEEP RUBBER BELTING DETAIL 106241 FLAT WASHER, 3/8" 12566 3/8" LOCK WASHER, GRADE 8 12475 HHCS, 3/8-16 X 1", GR5 106243 HEX NUT, 3/8-16 DATE DESCRIPTION...
  • Page 44 ± .005 818503 RAILSWEEP RUBBER BELTING DETAIL THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. 818508 FLAT WASHER, 3/8, GR8 ANGULAR: ± 1° DRAWN BY: APPD BY:...

  • Page 45: Rail Brakes

    See the figure below for brake adjustment procedures. Figure 5.2.1 Rail Brake Adjustment 5.2.2 Brake Parts  See the figures on following pages for replacement brake actuation parts.  See Section 6 for hydraulic and electrical brake control components. © 2020 DMF, Inc. All Rights Reserved.
  • Page 46 ± .063 BORE) ± .030 .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: REV:...
  • Page 47 RW-1212 ± .030 .XXX ± .005 ANTI-SIEZE 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: REV: SURF FINISH:...
  • Page 48 ITEM PART QTY. DESCRIPTION NUMBER 12712 CYL BODY DETAIL 1019/1212 12763 GLAND DETAIL; GEN2 HYD. BRAKE CYLINDER; RW-1019/1212 12720 O-RING; #022; 90A DURO 12719 BACK UP RING, #022 605165 ROD WIPER, AN 959/940, .75" ID, 1/8" W 605545 ROD SEAL, STD POLYPAK, .75" ID, 1/8"W 12717 EXTERNAL SNAP RING;...

  • Page 49: General Information

    GENERAL INFORMATION ................6-2 6.1.1 System Pressures and Relief Settings ..............6-2 6.1.2 Using Hydraulic Power Unit Provided by DMF ............6-2 6.1.3 Fitting Installation ................... 6-3 HYDRAULIC & ELECTRICAL SCHEMATICS ............6-6 HYDRAULIC & ELECTRICAL COMPONENT DRAWINGS ........6-12...
  • Page 50 Front Railgear control Valve (when equipped): 1600 PSI 6.1.2 Using Hydraulic Power Unit Provided by DMF DMF typically provides an electric over hydraulic power unit (Monarch M-304) to power the Railgear and rail brakes, when equipped. The unit includes a pump, motor and reservoir. This unit must be located somewhere accessible on the chipper.
  • Page 60 ± .030 -MAX PRESSURE 1850 PSI .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 61 ITEM PART NO. DESCRIPTION C95030 COTTRELL HYDRAULIC CYLINDER, 12" STROKE, 2" TUBE, 1.5" ROD NOTE: MAX PRESSURE 1850 PSI 2" TUBE ID, 1.5" ROD OD #6 JIC O-RING 23.0 CLOSED 35.0 OPEN (12.0 STROKE) 6/20/16 #6 JIC O-RING WAS 3/8 NPT DATE DESCRIPTION TOLERANCES:...
  • Page 62 ADDED 1800 PSI, 700 PSI DATE DESCRIPTION TOLERANCES: TITLE: (UNLESS SPECIFIED) MANUAL, BRAKE VALVE MANIFOLD ASSY (F&R), FRAC, MACH: ± 1/32" HYDRAFORCE, RW-1019 FRAC, OTHER: ± 1/16" ± .063 ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512 .XXX ± .005 DRILL SIZES: + .015...
  • Page 63 ADDED 1800 PSI DATE DESCRIPTION TOLERANCES: TITLE: (UNLESS SPECIFIED) MANUAL, BRAKE VALVE MANIFOLD ASSY RW-1019 FRAC, MACH: ± 1/32" (F ONLY), HYDRAFORCE, RW-1019 FRAC, OTHER: ± 1/16" ± .063 ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512 .XXX ± .005 DRILL SIZES: + .015...
  • Page 64 MANIFOLD LABELED "HYDRAFORCE 7024840" MANIFOLD LABELED "DMF#701061" REQUIRES ORRIFICE NO ORRIFICE REQUIRED (INTEGRATED INTO MANIFOLD) ORIFICE ORIENTATION: BEVELED FACE INTO MANIFOLD; FLAT EDGE TOWARDS LOCKING VALVE ITEM NO. PART NUMBER QTY. DESCRIPTION ITEM NO. PART NUMBER QTY. DESCRIPTION 600612 1015 LOCKING VLV BODY ONLY (7024840)
  • Page 65 RW-1212 CHIPPER ± .030 .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: REV: SURF FINISH:...
  • Page 66 ± .063 RW-1019/1212 ± .030 .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: REV:...
  • Page 68 DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR SECTION 7.0 R AILGEAR ARTS BEFORE ORDERING PARTS ................7-2 ASSEMBLY DRAWINGS ................... 7-3 AXLE DRAWINGS .................... 7-6 © 2020 DMF, Inc. All Rights Reserved.

  • Page 69: Before Ordering Parts

    Other Considerations for Ordering Parts: This is a list of considerations to make before placing a parts order with DMF. There are many variations and customer requirements that we strive to accommodate, and as a result, the more information that can be provided when placing an order, the more likely that we will be able to help quickly and efficiently.
  • Page 70 RW-1019 ± .063 ± .030 .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: REV:...
  • Page 71 RW-1019 ± .063 ± .030 .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: REV:...
  • Page 72 ITEM PART QTY. DESCRIPTION NUMBER 12055 OUTER GUIDE TUBE WELDMENT, 1212 VERTICAL GEAR 12058 INNER GUIDE TUBE WELDMENT, 1212 VERTICAL GEAR 12060 HYDRAULIC CYLINDER, 1212 VERTICAL GEAR, 12" STROKE 09766 CHIPPER BASE END PIN 10563 COTTER PIN; 1/8" X 1.5" 12062 AXLE SADDLE, 1212 VERTICAL GEAR 12065...
  • Page 73 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE:...
  • Page 74 .XXX ± .005 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED DRILL SIZES: + .015 INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED. ANGULAR: ± 1° DRAWN BY: APPD BY: DATE:...
  • Page 75 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.

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