parts & service manual rw-1019/1212 chipper railgear · align the rear railgear of the chipper...

DIVERSIFIED METAL FABRICATORS, INC.

DMF 665 Pylant Street Atlanta, Georgia 30306

Parts (404) 607-1684 Parts Fax (404) 879-7888 [email protected] Service Department (404) 879-7882 [email protected]

Phone (404) 875-1512 Fax (404) 875-4835 [email protected] http://www.dmfatlanta.com

Parts & Service Manual RW-1019/1212 Chipper Railgear

August 2017 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

© 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. If you find anything missing, incorrect or unclear in this manual, please contact us. We are always trying to improve our manuals. Manuals, service bulletins and general information are available on our website listed below. We reserve the right to update our manuals without notice. You can download a current manual at our website (http://www.dmfatlanta.com). Thank you for choosing DMF Railgear. We make every effort to provide quality, safe and rugged products for the railroad. We hope you'll find our gear to be satisfactory in every way. We take product support very seriously, so if you have any questions, please contact us. Contact: Diversified Metal Fabricators 665 Pylant St. NE Atlanta, GA 30306 (404) 875-1512 (404) 875-4835 Fax (404) 607-1684 Parts http://www.dmfatlanta.com [email protected] Ship to: 668 Drewry St. NE Atlanta, GA 30306



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 ......... 6-10

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



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

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR `

© 2017 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


1-2 © 2017 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 `


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.



Figure 1.2.2 RW-1212 Chipper Railgear Components



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


2-2 © 2017 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.



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.



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.



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.



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.



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



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



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.



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



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.



3.4 DERAILMENT The following are instructions for derailment inspection recommended by Diversified Metal Fabricators. In some circumstances, government or corporate regulations may require additional inspections to be performed. The operator must be aware of any inspection requirements that pertain to the Railgear and must abide by all local and national laws regarding Railgear maintenance and safety. In the case of a minor derailment, the cause of the derailment should be determined and corrective steps taken. The vehicle should be inspected to determine if repairs or adjustments are required. This inspection should include, but should not be limited to, the following:

• Visually inspect Railgear for hydraulic leaks. • Ensure all lines and hoses are still secured and out of the way of any moving parts. • Ensure all hydraulic hose connections and fittings are securely in place and not broken. • Verify that all threaded fasteners are secure, and that cotter pins are not broken. • Visually inspect the wheels to ensure that the tread and flange are not severely

damaged. • Spin all rail wheels, noting any bearing noise, resistance, and end play.

Any items noted should be repaired using Section 4, to ensure they are repaired to initial install standards. In case of a major derailment, a complete inspection should be performed, including but not limited to the following:

• Perform all inspection items as listed above in the Minor Derailment Section. • Inspect all frame brackets, core structures, and subframe to ensure they are not bent,

cracked, or broken. • Inspect and test rail brake system if applicable, see Section 5. • Ensure all welds are intact and show no signs of cracking or breaking. • Ensure all mounting hardware and brackets are securely fastened and are not bent,

cracked or damaged in any way. • A full alignment check should be performed if multiple axles are being used. • Wheels should be removed and the bore, bearing, races, and insulation, if applicable

should be inspected for any damage. For further wheel details, see Sections 7 for appropriate wheel and axle assembly drawings.

• 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.



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SECTION 4.0 RAILGEAR INSTALLATION 4.1 PRE-INSTALL .................................................................................................. 4-2

4.1.1 Safety Statements ........................................................................................ 4-2 4.1.2 Installation Order .......................................................................................... 4-2 4.1.3 Required Tools & Materials ............................................................................. 4-2 4.1.4 Fluids and Lubrication .................................................................................... 4-2 4.1.5 Bolt Torque Specifications .............................................................................. 4-3 4.1.6 Welding Information ...................................................................................... 4-5

4.2 INITIAL INSTRUCTIONS ................................................................................. 4-6

4.2.1 Work Area ................................................................................................... 4-6 4.2.2 Chipper Trailer Condition ............................................................................... 4-6

4.3 GENERAL INFORMATION ................................................................................ 4-7

4.4 INSTALLATION OF CHIPPER RAILGEAR .......................................................... 4-8

4.4.1 Chipper Railgear Installation ........................................................................... 4-8

4.5 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



4.1 PRE-INSTALL

NOTE: The proper installation of this equipment is solely the responsibility of the installer. When in doubt, contact DMF for assistance.

WARNING: Railgear alignment is crucial to ensure safe and reliable operation. Do not attempt to tow chipper on rail until these steps have been completed. See Section 4.5 for detailed instructions.

4.1.1 Safety Statements

• Always block up Railgear before getting underneath chipper. • Always use jack stands when jacking up the trailer. • Use personal protective equipment and clothing.

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.

4.1.3 Required Tools & Materials

Required: • General shop tools and safety equipment • Arc or MIG Welder • Surge Protector (Protects ECM from damage during welding) • Cutting Torch • Hand Grinder • Frame Drill • Air Saw • Angle Finder

Recommended:

• Transmission Jack, Motorcycle Lift, Pallet Jack or Forklift • Overhead Crane • Work Lights • Wheel Dolly

4.1.4 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



4.1.5 Bolt Torque Specifications

See the following page for recommended torque specifications.



4.1.6 Welding Information

• Dual Shield Wire spec. AWS E71T-1 • Low Hydrogen spec. AWS E-7018

Low Hydrogen Electrodes (AWS E-7018)

Manufacturer Equivalent Rod Air Products AP-7018, 7018IP

Airco 7018C, 7018-A1 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



4.2 INITIAL INSTRUCTIONS

4.2.1 Work Area

The Railgear installation area should meet the minimum requirements listed below. Doing so will help to complete the install in a safe, accurate and timely manner.

• Floor: Should be level to provide good measurements for Railgear installation. • Lighting: The work area should be adequately lite. • Space: There should be enough room to maneuver the Railgear components into

position and to safely work around other equipment.

4.2.2 Chipper Trailer Condition

Before installation, the following trailer items should be inspected: • Tires: Tires must be in good condition and inflated to manufacturer’s recommended

pressure. • Alignment: Railgear axle(s) must be square with trailer hitch. If multiple axles are being

used they must also be squared with one another. • 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.



4.3 GENERAL INFORMATION The Chipper Railgear has been designed for use on many makes and models of towable chippers. 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.

• Axle Assembly: The axle is provided fully assembled w/ rail wheels and brakes, if ordered. The axle is welded to the Tower Assembly during installation.

• Tower Assembly: Left and right side assemblies are provided with the hydraulic cylinders. This assembly will be welded to the mounting plate during installation.

• Mounting Plate: Welded to the tower assembly and bolted to the trailer frame once the Railgear height has been established.

• Pin Offs: Secures the Railgear in place when both stowed and deployed. Prevents the Railgear from drooping over long periods of time and from moving in case of a hydraulic failure.

• Locking Valves: Safety feature to prevent movement of Railgear cylinders when stationary and in cases of hydraulic failures. This is only a backup safety measure however, pin offs should always be engaged in both rail and highway positions.

• Hydraulic Power Unit: Provides hydraulic power for operating the Railgear and Railgear brakes when supplied.

• Brake Toggle Switch: Switch mounted on chipper used to turn on the hydraulic Railgear brakes for use on rail only.

MOUNTING PLATE

AXLE ASSEMBLY

TOWER ASSEMBLY

PINOFF

Figure 4.3 – RW-1019 Chipper Railgear Major Components

Prior to installation, review the components provided and understand how the Railgear operates. Check for sufficient clearances to prevent interference with Railgear and other parts of the trailer. This includes operation of the Railgear and chipper both on rail and on highway use.



4.4 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. This procedure is up to the installer and has not been detailed in this manual.

4.4.1 Chipper Railgear Installation

1. Ensure there is sufficient frame space to install both Chipper Tower assemblies. The Cylinders and Guide Tube assembly were designed to mount parallel to the axle centerline. See Figure 4.4.1.A.

TOWER ASSEMBLY ALIGNED W/ AXLE

FIGURE 4.4.1.A– Tower Assembly Alignment w/ Axle

2. Chock the trailer tires in place so the trailer does not move during installation.

NOTE:

When fully deployed the Railgear is designed to lift the chipper tires off the ground. It is recommended at this point to secure the chipper to a tow vehicle to keep it from moving.

3. All measurements should be from a common location to square the Railgear with the trailer hitch. This may be difficult so an alternative is to find a common point relative to the front hitch on both sides of the frame. See Figure 4.4.1.B.



COMMON LOCATION

TO ALIGN AND SQUARE RAILGEAR TO TRAILER HITCH

TRAILER HITCHON BOTH SIDES ABOUT

USE COMMON LOCATION

DO NOT USE TRAILER AXLE AS REFERENCE POINT

Figure 4.4.1.B – Selecting a Common Alignment Reference Point

4. Measure the height of the trailer frame. Determine the height needed to lift the trailer above rail when pinned off. In most cases 3” above rail is required but this may vary based on application. 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.



3" GROUNDCLEARANCE

10" ROLLINGDIAMETER

Figure 4.4.1.C - Stowed & Deployed Measurements RW-1019

3" GROUNDCLEARANCE

12" ROLLINGDIAMETER

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.



6. Measure from the Tower Assembly to the reference point, see Figure 4.4.1.E. 7. Clamp the other Mounting Plate and Tower Assembly on to the opposing side of the

trailer frame. Use the measurements taken from the reference point to position these components and clamp in place. See Figure 4.4.1.E.

Figure 4.4.1.E – Tower Assembly Alignment

8. Use the mounting plate as a template to drill holes in the chipper frame. Bolt the

Mounting Plates to the frame and tack weld the Tower Assemblies to the plates. 9. Ensure the Tower Assemblies are square with the reference point. Adjust as necessary

and fully weld into place. 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.

B

B

TOWER ASSEMBLIESLOCATION TO SQUARE UP MEASURE FROM COMMON RAILGEAR TOWER

ASSEMBLY

B

B



AXLE LUG

RW-1212 CHIPPER RAILGEAR

AXLE LUGS

RW-1019 CHIPPER RAILGEAR

TO TOWER ASSEMBLYUSED TO SECURE AXLE LIGS LOWER CYLINDER ROD PIN

TOWERASSEMBLY

Figure 4.4.1.F - Axle Rod Pin, Axle Lugs & Cylinder Interface

NOTE:

Figure 4.4.1.F shows both tower assemblies in the deployed position for clarity only. Follow installation instructions as detailed in this section.

11. Pin off both Tower Assemblies to keep them in the stowed position. 12. Carefully move the axle into place below the Tower Assemblies. Center the axle about

the frame and tower assemblies. The brakes may be oriented vertically or horizontally to address clearance issues.

13. Raise the axle into place using a jack or a recommended lifting device as listed in Section 4.1.3. Verify that the axle is centered and square to the reference points, see Figure 4.5.1. Tack weld each lug in place and add the cotter pins. Reference Figure 4.4.1.G.

TACK IN PLACE

REMOVE CYLINDER ROD PIN BEFORE FULLY WELDING

Figure 4.4.1.G – Axle Lug Weldment

14. At this point the hydraulic and electrical systems should be installed. Run the Railgear

cylinders in both directions to ensure there are no clearance issues. 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.



Figure 4.4.1.H – Alignment of Second Axle

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.



4.5 ALIGNMENT AND RAIL TEST PROCEDURES With the Railgear fully assembled on the chipper it is necessary to do a final alignment and rail test. When performing the alignment procedure, record the final alignment measurements on the tear sheet provided at the end of the section.

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. The Railgear must be absolutely square to the trailer hitch to prevent towing issues. The following measurements are to be taken with the Railgear fully deployed and the chipper properly supported and secured in place. All pin offs must be in use. If available hitch the chipper to a suitable tow vehicle.

NOTE:

When the Railgear is deployed the chipper axle(s) will be completely lifted off rail and will have no affect with travel on rail. This is why it is not acceptable to measure from the axle(s) to align the Railgear.

4.5.1 Railgear Alignment – Single Axle

Refer to Figure 4.5.1 for the alignment of chipper Railgear with a single axle. • A & B: Diagonal measurement from the hitch to the axle. The measurements should be

equal to within ¼”. • C & D: Length measurement from the flange face of the Railgear to the chipper frame.

The measurements should be equal to within 1/8”. If adjustments are required grind the axle loose from the mounting lugs and reposition to meet the above requirements. Tack weld the lugs and recheck the measurements. When the measurements are within the tolerances listed, record them in the alignment tear sheet included at the end of this section.



A = B WITHIN 1/4"C = D WITHIN 1/8"

D

C

Figure 4.5.1 – Railgear Alignment Single Axle

4.5.2 Railgear Alignment – Dual Axles

Refer to Figure 4.5.2 for the alignment of chipper Railgear with dual axles. • A & B: Diagonal measurement from the hitch to the rear axle. The measurements

should be equal to within 1/4”. • C & D: Length measurement from the flange face of the rear Railgear to the chipper

frame. The measurements should be equal to within 1/8”. • E & F: Length measurement from front Railgear to rear Railgear. Values should be equal

to within 1/8”. • G & H: Diagonal measurements from front Railgear axle to rear Railgear axle. The

measurements should be equal to within 1/4”. If adjustments are required grind the axle loose from the mounting lugs and reposition to meet the above requirements. 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.



A = B WITHIN 1/4"C = D WITHIN 1/8"E = F WITHIN 1/8"G = H WITHIN 1/4"

E

C

F

D

Figure 4.5.2 – Railgear Alignment Dual Axles

A

B

G

H

REV

DA

TED

ESC

RIPT

ION

BYA

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WITH

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:___

____

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____

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ME

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____

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AR

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____

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4.5.3 Rail Test

After aligning the Railgear and welding the components in place, attach the chipper to a suitable tow vehicle and put it on a segment of test track following the procedures found in Section 2. Note if a second axle has been installed a tow bar is required between the tow vehicle and the chipper. Run the following tests:

• Run the trailer forwards and backwards on rail. • Check for proper clearance between the trailer tires and the rail. • If available, run the trailer through curves and switches. • If applicable verify that the Railgear brakes operate smoothly. • Verify alignment by observing the wear pattern on the rail wheels and the behavior of

the trailer.

4.5.4 Final Weld-out

After the Railgear has been aligned and tested satisfactorily on rail, it is necessary to fully weld all lug blocks.

4.5.5 Installation Review Checklist

The following checklist is intended to assist the installer in re-checking and verifying aspects of the installation that are often overlooked or forgotten.

Check tire pressures. Double check all welds and fasteners. Tie strap all hydraulic hoses, air hoses, and electrical

wires away from moving parts. Ensure that all hydraulic hoses have sufficient radius at bends.

Raise the Railgear to highway position and check that it is possible to pin off both sides. Rail test the trailer to check for braking. Check that rail wheels with brakes do not lock-up

or slide. Adjust the Railgear height as required to completely lift all tires off rail when all pin offs are

in place. 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.



SECTION 5.0 RAILGEAR OPTIONS 5.1 RAIL SWEEPS ................................................................................................. 5-2

5.1.1 Rail Sweep Adjustment .................................................................................. 5-2 5.1.2 Rail Sweep Parts ........................................................................................... 5-2

5.2 RAIL BRAKES ................................................................................................. 5-6

5.2.1 Brake Adjustment ......................................................................................... 5-6 5.2.2 Brake Parts .................................................................................................. 5-6



5.1 RAIL SWEEPS

5.1.1 Rail Sweep Adjustment

Rail sweeps are available as an option for Chipper Railgear. Installation and adjustment of rail sweeps are done with the Railgear in the deployed position. The bottom of the rubber rail sweep should lightly brush the rail surface. Adjust up or down as necessary.

• Axles with brakes: Rail sweeps are typically shipped loose. • Axles without brakes: Weld-on rail sweeps are shipped loose and should be welded to

the axle by the installer.

5.1.2 Rail Sweep Parts

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.

RW-1

019

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BY:

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( 0.

030

X 45

° M

AX

)

± 1/

16"

± .0

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+ .0

15

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32"

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63

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2A A

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2B

125

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AX

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± 1/

16"

± .0

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+ .0

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± 1/

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T, L

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P RU

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DET

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9: R

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RAIL

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SSY,

AXL

E SE

T, W

ELD

-ON



5.2 RAIL BRAKES

WARNING: The rail wheel brake system is intended to assist the tow vehicle brakes when on rail. The brakes on the chipper are applied for a 30 second interval when the vehicle brakes are applied. Rail wheel brakes alone are insufficient to stop the vehicle in a reasonable distance.

5.2.1 Brake Adjustment

It may be periodically necessary to adjust the rail brakes to compensate for pad and wheel wear. See the figure below for brake adjustment procedures.

TO ADJUST, REMOVE ROD ENDPIN AND THREAD ADAPTER TO DESIRED LENGTH, TIGHTENJAM NUT TO CYLINDER BODY, REINSERT ROD END PIN

ADJUST TO MAX. ALLOWED 1/4")(REPLACE SHOE IF UNABLE TOADJUST TO 1/16"

1/8" MIN. SHOETHICKNESS

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.

FRA

C, O

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AC

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TARY

INFO

RMA

TION

OF

DIV

ERSI

FIED

1270

0RE

V:

DRA

WIN

G N

UMBE

R:

TITLE

:

DRA

WN

BY:

11/2

8/95

RW-1

019

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NT

HYD

. BRA

KE A

SSY.

(1-1

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CES

(UN

LESS

SPE

CIF

IED

):

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ND

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RW-1

019

.X .XX

.XXX

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LL S

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NG

ULA

R:SU

RF F

INIS

H:TH

REA

DS:

± 1/

32"

±1/1

6"±

.063

± .0

30±

.005

+ .0

15±

1°12

5 M

ICRO

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F (4

04)8

75-1

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3

5

CO

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2

8

9

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9

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TED

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ION

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PP

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TO

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LID

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ED N

OTE

S; R

EMO

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127

10 E

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2476

; 127

50 Q

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0 Q

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ITEM

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PART

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DES

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N

112

710

1H

YDRA

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KE C

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; RW

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9/12

122

1274

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IC B

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SID

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123

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ASS

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/ ST

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RW

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24

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, RW

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9/12

125

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62

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LOC

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0 H

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01

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019/

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ITTIN

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8 (A

LEM

ITE 1

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B)11

1247

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1/2

-13

X 1-

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, GR8

1212

481

4LO

CK

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, 1/2

", G

R8

1312

750

REF

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RAUL

IC B

RAKE

AXL

E SA

DD

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0" W

HEE

L

RW-1

212

11/2

8/95

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212

HYD

RAUL

IC B

RAKE

ASS

EMBL

YFR

AC

, MA

CH:

MRV

BREA

K SH

ARP

ED

GES

.03

X 45

° MA

X2A

AN

D 2

B

1270

2RE

V:

DRA

WIN

G N

UMBE

R:

TOLE

RAN

CES

(UN

LESS

SPE

CIF

IED

):

APP

D B

Y:D

RAW

N B

Y:

THIS

DRA

WIN

G C

ON

TAIN

S C

ON

FIDEN

TIAL

PRO

PRIE

TARY

INFO

RMA

TION

OF

DIV

ERSI

FIED

FRA

C, O

THER

:

TSH

MET

AL

FABR

ICA

TORS

, IN

C (D

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. CO

PYRI

GHT

DM

F, A

LL R

IGHT

S RE

SERV

ED.

J

TITLE

:

DA

TE:

.X .XX

.XXX

DRI

LL S

IZES

:A

NG

ULA

R:SU

RF F

INIS

H:TH

REA

DS:

± 1/

32"

±1/1

6"±

.063

± .0

30±

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+ .0

15±

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ICRO

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F (4

04)8

75-1

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REV

DA

TED

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ION

BYA

PP

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7M

IGRA

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TO

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LID

WO

RKS

BJF

ITEM

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PART

N

UMBE

RQ

TY.

DES

CRI

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112

710

1H

YDRA

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; RW

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122

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52

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RAUL

IC B

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E BR

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9/12

123

1273

51

HYD

. BRA

KE L

EVER

ARM

ASS

EMBL

Y W

/ ST

OP,

RW

-121

24

1243

41

HYD

RAUL

IC B

RAKE

SH

OE,

CO

BRA

CUT

OFF

, RW

-101

9/12

125

1243

62

HYD

RAUL

IC B

RAKE

SH

OE

MO

UNTIN

G B

LOC

K, R

W-1

019/

1212

681

8452

1A

IR B

RAKE

SH

OE

PIN

712

424

1PI

N W

ELD

MEN

T, 1

019/

1212

/142

0 H

YDRA

ULIC

BRA

KE S

HO

E8

1276

01

HYD

RAUL

IC B

RAKE

S C

YLIN

DER

RO

D P

IN, R

W-1

019/

1212

981

8456

3C

OTT

ER P

IN, 1

/8" X

1-1

/2"

1081

8105

2G

REA

SE F

ITTIN

G, 1

/4"-2

8 (A

LEM

ITE 1

641-

B)11

1247

94

HH

CS,

1/2

-13

X 1-

1/4"

, GR8

1212

481

4LO

CK

WA

SHER

, 1/2

", G

R8

1312

755

REF

RW-1

212

HYD

RAUL

IC B

RAKE

AXL

E SA

DD

LE

11

1

12

4

CO

AT

W/

AN

TI-SI

EZE

5 2

8

9

3

7

9

10

6

13

CO

AT

W/

AN

TI-SI

EZE

13 12 11 10 9 8 7

1

14 1523456

SEE

DETA

IL A

5 6 4 3

10

2 79

DETA

IL A

: IN

TERN

AL

CO

MPO

NEN

TS(F

ITTIN

GS

#14

& #

15 H

IDDE

N F

OR

CLA

RITY

)ASS

EMBL

Y PR

OC

EDUR

E:En

sure

all p

arts

are

cle

an a

nd fr

ee o

f bur

rs a

nd sh

arp

edge

s.1.

Lubr

icat

e ro

d, g

land

, and

all s

eals

light

ly w

ith b

lue

asse

mbl

y go

o.2.

Inst

all w

iper

(#5)

, rod

seal

(#6)

, bac

kup

ring

(#4)

, and

o-ri

ng (#

3) in

gla

nd (#

2) in

3.

orie

ntat

ions

show

n in

Det

ail A

.In

stal

l ext

erna

l sna

p rin

g (#

7) a

nd sp

ring

(#9)

ont

o ro

d (#

8).

4.Pl

ace

rod

into

bod

y (#

1) w

ith th

read

ed e

nd fa

cing

upw

ard

s.5.

Slid

e gl

and

ass

embl

y ov

er ro

d, c

ompr

ess s

prin

g, a

nd se

cure

with

inte

rnal

snap

ring

(#10

).6.

Inst

all ja

mb

nut (

#11

) ont

o ro

d e

xten

sion

(#12

). C

oat e

xpos

ed th

read

s with

ant

iziez

e.

7.Th

read

ext

ensio

n co

mpl

etle

y in

to ro

d, a

nd ti

ghte

n ja

mb

nut.

Inst

all g

reas

e fit

ting

(#13

), bl

eed

val

ve (#

14),

and

hyd

raul

ic fi

tting

(#15

). O

bser

ve

8.or

ient

atio

n sh

own.

TEST

PRO

CED

URE:

DUR

ING

TES

T PR

OC

EDUR

E, D

O N

OT

ALL

OW

RO

D T

O R

EAC

H FU

LL E

XTEN

SIO

N.

MA

X RO

D

1.EX

TEN

SIO

N S

HOUL

D B

E PH

YSIC

ALL

Y RE

STRA

INED

TO

3/4

" OR

LESS

.C

onne

ct h

ydra

ulic

pow

er u

nit;

set p

ress

ure

relie

f to

2,00

0 ps

i.2.

Ope

n bl

eed

val

ve, c

ycle

cyl

ind

er to

pur

ge a

ir, a

nd c

lose

ble

ed v

alve

.3.

With

rod

ext

ensio

n lim

ited

to 3

/4",

pres

sure

test

for 1

5 se

c. w

hile

insp

ectin

g fo

r lea

ks.

4.D

iscon

nect

pow

er u

nit a

nd c

ap h

ydra

ulic

fitti

ng.

5.

K K

REV

DA

TED

ESC

RIPT

ION

BYA

PP

K02

/01/

16M

IGRA

TED

TO

SO

LID

WO

RKS.

127

63 W

AS

1271

4, 6

0554

5 W

AS

1272

5, A

DD

ED

6051

65TA

M

ITEM

N

O.

PART

N

UMBE

RQ

TY.

DES

CRI

PTIO

N1

1271

21

CYL

BO

DY

DET

AIL

101

9/12

122

1276

31

GLA

ND

DET

AIL

; GEN

2 HY

D. B

RAKE

CYL

IND

ER; R

W-1

019/

1212

312

720

1O

-RIN

G; #

022;

90A

DUR

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1271

91

BAC

K UP

RIN

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#02

25

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ROD

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ER, A

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75" I

D, 1

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660

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, 1/8

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OM

PRES

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PRIN

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BRA

KE C

YLIN

DER

1012

718

1IN

TERN

AL

SNA

P RI

NG

; 1-3

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RE; #

118

1160

5071

1JA

MB

NUT

, 3/8

-24

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RAKE

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D E

XTEN

TION

1381

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ITTIN

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8 (A

LEM

ITE 1

641-

B)14

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019/

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HYD

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KE C

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)15

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ING

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0 D

EG B

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PT X

1/8

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AN

GUL

AR:

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ARP

ED

GES

( 0.

030

X 45

° MA

X )

± 1/

16"

± .0

05±

.030

+ .0

15

± 1/

32"

± .0

63

± 1°

2A A

ND

2B

125

MIC

RO

DRI

LL S

IZES

:

SURF

FIN

ISH:

THRE

AD

S:

.XXX

.XX

TOLE

RAN

CES

:

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C, M

AC

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(UN

LESS

SPE

CIF

IED

)

FRA

C, O

THER

:

11/2

8/95

1271

0M

RV

REV:

DRA

WIN

G N

UMBE

R:

TITLE

:

DA

TE:

APP

D B

Y:D

RAW

N B

Y:

DIV

ERSI

FIED

MET

AL

FABR

ICA

TORS

,INC

.(404

)875

-151

2

TSH

HYD

RAUL

IC B

RAKE

CYL

IND

ER; R

W-1

019/

1212

RW-1

019



Page intentionally left blank.



SECTION 6.0 HYDRAULIC & ELECTRICAL SYSTEMS

6.1 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

6.2 HYDRAULIC & ELECTRICAL SCHEMATICS ....................................................... 6-6

6.3 HYDRAULIC & ELECTRICAL COMPONENT DRAWINGS ................................... 6-12



6.1 GENERAL INFORMATION

6.1.1 System Pressures and Relief Settings

Various components within the Chipper Railgear require different pressure setting to operate safely and reliably. Relief valves are typically factory set and should not require adjustment. Adjusting relief valves above or below the values shown below may result in damage to components and/or unsafe operation.

• Railgear System Relief: 2000 PSI • Rear Brake Relief (when equipped): 1700 PSI • Front Brake Relief (when equipped): 700 PSI • Rear Railgear Control Valve: 1850 PSI • 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. The unit should be protected from road spray and moisture. Only operate with Dexron III hydraulic oil.

14"

FRA

C, M

AC

H:

PRP

BREA

K SH

ARP

ED

GES

.03

X 45

° MA

X

MET

AL

FABR

ICA

TORS

, IN

C (D

MF)

. CO

PYRI

GHT

DM

F, A

LL R

IGHT

S RE

SERV

ED.

0976

5RE

V:

DRA

WIN

G N

UMBE

R:

TITLE

:

DA

TE:

FRA

C, O

THER

:H

YDRA

ULIC

CYL

IND

ER, C

HIP

PER,

2" X

1-1

/2" X

D2A

AN

D 2

B

RW-1

019

TOLE

RAN

CES

(UN

LESS

SPE

CIF

IED

):

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DRA

WIN

G C

ON

TAIN

S C

ON

FIDEN

TIAL

PRO

PRIE

TARY

INFO

RMA

TION

OF

DIV

ERSI

FIED

APP

D B

Y:D

RAW

N B

Y:

04/1

4/95

TSH

.X .XX

.XXX

DRI

LL S

IZES

:A

NG

ULA

R:SU

RF F

INIS

H:TH

REA

DS:

± 1/

32"

±1/1

6"±

.063

± .0

30±

.005

+ .0

15±

1°12

5 M

ICRO

DM

F (4

04)8

75-1

512

REV

DA

TED

ESC

RIPT

ION

BYA

PP

D5/

9/20

17M

IGRA

TED

TO

SO

LID

WO

RKS

DJJ

C06

/20/

16#

6 JI

C O

-RIN

G W

AS

3/8

NPT

BJF

B02

/02/

10C

OTT

RELL

C95

050

WA

S BE

I 203

-100

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AD

DED

NO

TES

BJF

A05

/08/

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DRA

WN

KLC

TSH

NO

TE:

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X PR

ESSU

RE 1

850

PSI

ITEM

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RT N

UMBE

RQ

TY.

DES

CRI

PTIO

N

-C

ON

TTR

ELL

C95

050

HY

DR

AU

LIC

CY

LIN

DE

R

B

B

#6

JIC

O-R

ING

TYP

C

ROD1 1/2"

39" D

EPLO

YED

25" S

TOW

ED

2"TUBE ID

NO

TE: M

AX

PR

ES

SU

RE

185

0 P

SI

1.2"

TU

BE

ID, 1

.5" R

OD

OD

2.

DIV

ERSI

FIED

MET

AL

FABR

ICA

TORS

,INC

.(404

)875

-151

2

DES

CRI

PTIO

NRE

VBJ

F#

6 JI

C O

-RIN

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AS

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NPT

6/20

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1

A

A

.X

AN

GUL

AR:

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K SH

ARP

ED

GES

( 0.

030

X 45

° M

AX

)

± 1/

16"

± .0

05±

.030

+ .0

15

± 1/

32"

± .0

63

± 1°

2A A

ND

2B

125

MIC

RO

DRI

LL S

IZES

:

SURF

FIN

ISH:

THRE

AD

S:

.XXX

.XX

TOLE

RAN

CES

:

FRA

C, M

AC

H:

(UN

LESS

SPE

CIFI

ED)

FRA

C, O

THER

:RW

-121

2

63 5

CO

TTRE

LL H

YDRA

ULIC

CYL

IND

ER, 1

2" S

TRO

KE, 2

" TUB

E, 1

.5" R

OD

C95

030

ITEM 2 4

PART

NO

.

1

DRA

WN

BY:

QTY

DES

CRI

PTIO

N

VER

TICA

L G

EAR,

12"

STR

OKE

2/8/

1012

060

BJF

APP

BY

REV

:D

RAW

ING

NUM

BER:

TITLE

:

DA

TE:

APP

D B

Y:

DA

TE

HYD

RAUL

IC C

YLIN

DER

, 121

2

B

A 23.0

CLO

SED

35.0

OPE

N(1

2.0

STRO

KE)

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JIC

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ING

TO R

ED

/BLA

CK

OU

TPU

T FR

OM

BR

AK

E C

ON

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LLE

R

2 9

13

7 8

4

6

5

T

CIR

CU

IT D

IAG

RA

M

P

TP1

TP2

RB

FBDH

ITEM

PART

#Q

TYD

ESC

RIPT

ION

110

491

1FR

ON

T RE

LIEF

VA

LVE

210

469

1RE

AR

RELI

EF V

ALV

E3

1047

11

BRA

KE C

IRC

UIT

ENA

BLE

VA

LVE

(CA

RTRI

DG

E O

NLY

)4

1047

22

BRA

KE L

OC

KIN

G V

ALV

E (C

ART

RID

GE

ON

LY)

550

0727

3V

ALV

E SO

LEN

OID

610

438

2D

IAG

NO

STIC

NIP

PLE

710

470

4A

DA

PTER

, 1/4

MO

RB X

1/8

FPT

810

432

2BR

AKE

LIN

E EL

BOW

, 1/8

MPT

X 1

/8 IN

V. F

LARE

910

457

31/

4 M

ORB

X #

4 M

JIC

90

DEG

. ELB

OW

TYP

. 3 P

LAC

ES

DE

DIC

ATE

DG

RO

UN

D T

O

BA

TTE

RY

1700

PS

I

700

PS

IA

AB

5/20

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JDI

AD

DED

180

0 PS

I, 70

0 PS

I10

/21/

13

B

A

.X

AN

GUL

AR:

BREA

K SH

ARP

ED

GES

( 0.

030

X 45

° M

AX

)

± 1/

16"

± .0

05±

.030

+ .0

15

± 1/

32"

± .0

63

± 1°

2A A

ND

2B

125

MIC

RO

DRI

LL S

IZES

:

SURF

FIN

ISH:

THRE

AD

S:

.XXX

.XX

TOLE

RAN

CES

:

FRA

C, M

AC

H:

(UN

LESS

SPE

CIFI

ED)

FRA

C, O

THER

:-

7/2/

14

HYD

RAFO

RCE,

RW

-101

9

1700

PSI

WA

S 18

00 P

SI

M10

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3.38



This Page Intentionally Left Blank.



SECTION 7.0 RAILGEAR PARTS 7.1 BEFORE ORDERING PARTS ............................................................................. 7-2

7.2 ASSEMBLY DRAWINGS ................................................................................... 7-3

7.3 AXLE DIAGRAMS ............................................................................................ 7-6



7.1 BEFORE ORDERING PARTS Required Information for Ordering Parts:

• You must have the Railgear serial numbers when ordering parts. This uniquely identifies the Railgear, as it was built to the customer’s specifications, and also allows DMF to help maintain a history of it. If you are placing a parts order through a maintenance facility, please inform them of the serial number, so that they can relay the information.

• Returns: DMF has a Return Authorization Procedure. You must contact DMF for an RA# before returning any parts for any reason. Parts will not be credited without an RA#.

• Labor: In extremely rare situations, on a discretionary basis and with prior approval, DMF will reimburse certain, specific labor costs. If you feel this may apply in your situation, you must contact DMF’s Service Department for a Service Authorization Number (SA#). No labor will be reimbursed without an SA#. The SA# must be included on your request for reimbursement.

• Please use driver’s side / passenger’s side terminology (instead of left/right side) when describing issues with the Railgear. This leaves no room for interpretation and ensures that everyone involved is clear about where the issue is occurring.

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. Wheels:

• If you are a customer using special wheel profiles (this is especially prevalent in Metros), please be sure to inform the DMF Parts Department that there may be a special wheel profile involved in your order.

• DMF offers both insulated and non-insulated wheels – Please confirm which wheel is need before ordering. Insulated wheels can be identified by a grooved ring machined around the inside of the rail wheel. This grooved ring can been seen and felt, and is located about an inch in from the outside tread.

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DM

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DMF 665 Pylant Street Atlanta, Georgia 30306

Parts (404) 607-1684 Parts Fax (404) 879-7888 [email protected] Service Department (404) 879-7882 [email protected]

Phone (404) 875-1512 Fax (404) 875-4835 [email protected] http://www.dmfatlanta.com

DMF LIMITED WARRANTY POLICY Diversified Metal Fabricators (DMF) products are designed to provide the utmost service and reliability. Competent workmen, guided by stringent quality standards, manufacture the products from high-grade material. DMF warrants products of its manufacture to be free of defects in material and workmanship, under normal use and service, for a period of ONE CALENDAR YEAR. DMF’s obligation under this warranty is limited to repairing or replacing at its factory, or other location designated by us, any part or parts there-of which shall, within 30 DAYS of the date of failure or notice of defect, be returned, and which upon examination shall appear to DMF’s satisfaction to have been defective. Such repair or replacement does not include the cost of installing the new part or any other expenses incident thereto; however, the outbound direct ground freight on the part will be prepaid to locations within the continental 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. Ordinary wear and tear, abuse, misuse, neglect, or alteration is not covered by this warranty. DMF assumes no liability for expenses or repairs made outside its factory except by written consent. Warranty is null and void if instructions and operating procedures specifically referring to warranty coverage are not followed. Equipment or parts not manufactured by this company, but which are furnished in connection with DMF products are covered directly and solely by the warranty of the manufacturer supplying them. This warranty is in lieu of other warranties, expressed or implied, including any implied warranties of merchantability or fitness for a particular purpose and any liability for special or consequential damages. All warranty claims must reference a serial number. Returns must reference a RA number.

parts & service manual rw-1019/1212 chipper railgear · align the rear railgear of the chipper...

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