DIVERSIFIED METAL FABRICATORS, INC.

Parts & Service Manual

RW-1019/1212
Chipper Railgear

May 2020

SERIAL NUMBER (FRONT) ________________________

SERIAL NUMBER (REAR) ________________________

NOTE:
Please refer to the serial numbers when ordering parts or
inquiring about warranty items.

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
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER
RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER
RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
`

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

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR
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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.

© 2020 DMF, Inc. All Rights Reserved. 1-3

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

Figure 1.2.2 RW-1212 Chipper Railgear Components

1-4 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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 © 2020 DMF, Inc. All Rights Reserved

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

2.2 HIGHWAY OPERATION

Beforetowing 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.

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

© 2020 DMF, Inc. All Rights Reserved. 2-5

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

2.4 GETTING OFF THE RAIL

NOTE:
The hydraulic power unit is turned on by pushing a momentary switch mounted next to
each spool valve. Release the switch when not in use to avoid overheating the power
unit.

2.4.1 Single Axle

1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the parking brake, leave the truck running and the transmission in neutral.
3. Follow the necessary steps outlined in the provided operations manual for stowing the tow
vehicle’s Railgear.
4. Disengage the Railgear pin offs on both sides of the trailer.
5. Push and hold the pump power button and use the spool valve to lift the Railgear
6. Release the power button when the hydraulics are not in use.
7. Re-engage all pin offs for safe travel on the highway.
8. Turn off the switch controlling the Railgear brakes, if applicable.
9. Make sure the surrounding area is free and clear of any obstacles and vehicles before
disengaging the parking brake and pulling onto the road.

2.4.2 Dual Axles

1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the parking brake, leave the truck running and the transmission in neutral.
3. Chock the rear Railgear wheels.
4. Disengage the pin offs on both axles.
5. Remove the draw bar and secure it in an appropriate location.
6. Back the tow vehicle up to hitch to the chipper.
7. Stow and pin off the front Railgear and remove the wheel chocks.
8. Fully stow the rear Railgear and pin off.
9. Follow the necessary steps in the provided operations manual for stowing the tow vehicle’s
Railgear.
10. Always release the power button when the hydraulics are not in use.
11. Disengage the switch controlling the Railgear brakes, if applicable.
12. Make sure the surrounding area is free and clear of any obstacles and vehicles before
disengaging the parking brake and pulling onto the road.

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

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DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

© 2020 DMF, Inc. All Rights Reserved. 3-3

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

3-4 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

© 2020 DMF, Inc. All Rights Reserved. 3-5

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

© 2020 DMF, Inc. All Rights Reserved. 3-7

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved. 4-1

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

4-2 © 2020 DMF, Inc. All Rights Reserved.

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. 4-3

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved. 4-5

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

4-6 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

TOWER ASSEMBLY

PINOFF

MOUNTING PLATE

AXLE ASSEMBLY

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.

© 2020 DMF, Inc. All Rights Reserved. 4-7

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

4-8 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

COMMON LOCATION
ON BOTH SIDES ABOUT
TRAILER HITCH

USE COMMON LOCATION

TO ALIGN AND SQUARE
RAILGEAR TO TRAILER HITCH

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.

© 2020 DMF, Inc. All Rights Reserved. 4-9

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

3" GROUND 10" ROLLING

CLEARANCE DIAMETER

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.

4-10 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

MEASURE FROM COMMON

RAILGEAR TOWER
LOCATION TO SQUARE UP
ASSEMBLY
TOWER ASSEMBLIES

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.

© 2020 DMF, Inc. All Rights Reserved. 4-11

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

TOWER
ASSEMBLY

LOWER CYLINDER ROD PIN

USED TO SECURE AXLE LIGS
AXLE LUGS AXLE LUG
TO TOWER ASSEMBLY

RW-1019 CHIPPER RAILGEAR RW-1212 CHIPPER RAILGEAR

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.

REMOVE CYLINDER
ROD PIN BEFORE
FULLY WELDING

TACK IN PLACE

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.

4-12 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

© 2020 DMF, Inc. All Rights Reserved. 4-13

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

4-14 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

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.

© 2020 DMF, Inc. All Rights Reserved. 4-15

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.

 A

REAR AXLE
DESCRIPTION DIMENSION DIMENSION TOLERANCE

H HITCH TO REAR A:__________ = B:__________ 1/4"

AXLE
RAIL WHEEL TO
FRAME C:__________ = D:__________ 1/8"
FRONT AXLE - WHEN APPLICABLE
DESCRIPTION DIMENSION DIMENSION TOLERANCE
G
FRONT AXLE TO E:__________ = F:__________
1/8"
REAR AXLE
DIAGONAL
FRONT AXLE TO G:__________ = H:__________ 1/4"
REAR AXLE

ALIGNMENT PROCEDURE:
1. ALIGNMENT OF RAILGEAR SHOULD BE DONE W/
RAILGEAR DEPLOYED AND PINNED OFF ON A LEVEL
SURFACE.
2. RECORD MEASUREMENTS WHERE INDICATED. PROVIDE
COMPLETED SHEET TO CUSTOMER WITH MANUALS.
3. MEASURE AND ADJUST REAR AXLE WITH RESPECT TO
HITCH AND FRAME RAILS. REV DATE
TOLERANCES (UNLESS SPECIFIED):
TITLE:
DESCRIPTION BY APP

4. MEASURE AND ADJUST FRONT RAILGEAR WITH RESPECT

FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" MANUAL, ALIGNMENT TEAR SHEET,
.X ± .063
- CHIPPER & TRAILER RAILGEAR
TO REAR RAILGEAR, IF APPLICABLE.
.XX ± .030
.XXX ± .005
DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
5. COMPLETE RAIL TEST PROCEDURE OUTLINED IN MANUAL. ANGULAR:
SURF FINISH:
THREADS:
± 1°
125 MICRO
2A AND 2B
DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:

6. COMPLETELY WELD ALL PREVIOUSLY TACK WELDED ITEMS. BREAK SHARP EDGES .03 X 45° MAX
DJJ - 09/08/17 M1019142 #
DMF (404)875-1512
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

4-18 © 2020 DMF, Inc. All Rights Reserved.

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved. 5-1

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

5-2 © 2020 DMF, Inc. All Rights Reserved.

 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 12471 1 RAILSWEEP BRACKET (PASSENGER'S SIDE) (10HD)
2 818503 2 RAILSWEEP RUBBER BELTING DETAIL
3 106241 4 FLAT WASHER, 3/8"

A 4
5
12475
12566
4
4
HHCS, 3/8-16 X 1", GR5
LOCK WASHER, 3/8", GR8
6 106243 4 HEX NUT, 3/8-16
7 12470 1 RAILSWEEP BRACKET (DRIVER'S SIDE) (10HD)

6
5
3
4

B 5/13/13 REDRAWN IN SOLIDWORKS, REMOVED NOTE JDI

A 1/25/96 ADDED MOUNTING HARDWARE TO B.O.M. MRV TSH
REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
RW-1019 RAILSWEEP ASSEMBLY
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16"
RW-1019
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
PRP TSH 3/16/95 12476 B
 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 10042 2 RW-1019 RAILSWEEP MOUNTING BRACKET, WELD ON
2 818503 2 RAILSWEEP RUBBER BELTING DETAIL
3 106241 4 FLAT WASHER, 3/8"
4 12566 4 3/8" LOCK WASHER, GRADE 8
5 12475 4 HHCS, 3/8-16 X 1", GR5
6 106243 4 HEX NUT, 3/8-16

6
4

REV DATE DESCRIPTION BY APP

TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
RW-1019 RAILSWEEP ASSEMBLY (WELD ON)
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16"
RW-1019
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
JDI - 12/12/13 10053 #
12477: RW-1212 RAILSWEEP ASSY, FRONT AXLE SET, BOLT-ON 12491: RW-1212 RAILSWEEP ASSY, REAR AXLE SET, BOLT-ON
ITEM NO. PART NUMBER QTY. DESCRIPTION ITEM NO. PART NUMBER QTY. DESCRIPTION
1 12472 1 RW-1212 RAILSWEEP BRACKET, LH, BOLT-ON 1 818626 1 RAILSWEEP REAR BRACKET, LH, FOR HYD. BRAKES
2 12473 1 RW-1212 RAILSWEEP BRACKET, RH, BOLT-ON 2 818627 1 RAILSWEEP REAR BRACKET, LH, FOR HYD. BRAKES
3 818503 2 RAILSWEEP RUBBER BELTING DETAIL 3 818503 2 RAILSWEEP RUBBER BELTING DETAIL
4 818508 8 FLAT WASHER, 3/8, GR8 4 818508 8 FLAT WASHER, 3/8, GR8
5 12566 4 LOCK WASHER, 3/8", GR8 5 12566 4 LOCK WASHER, 3/8", GR8
6 605103 4 HEX NUT, 3/8-16, GR5 6 605103 4 HEX NUT, 3/8-16, GR5
7 102408 4 HHCS, 3/8-16 X 1-1/2", GR8 7 102408 4 HHCS, 3/8-16 X 1-1/2", GR8

2
2
1
1

6
6

3 3

7 5 7 5

4 4

2 7

5
3
4
12489: RW-1212 RAILSWEEP ASSY, AXLE SET, WELD-ON 6 REV DATE DESCRIPTION BY APP
ITEM NO. PART NUMBER QTY. DESCRIPTION TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
1 12484 2 RW-1212 RAILSWEEP BRACKET DETAIL, WELD-ON FRAC, OTHER: ±1/16" RW-1212 RAILSWEEP OPTIONS
.X ± .063
2 818501 2 RAILSWEEP RUBBER MOUNTING PLATE .XX ± .030 RW-1212
.XXX ± .005
3 818503 2 RAILSWEEP RUBBER BELTING DETAIL DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
4 818508 12 FLAT WASHER, 3/8, GR8 ANGULAR:
SURF FINISH:
± 1°
125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
5 12566 8 LOCK WASHER, 3/8", GR8 THREADS: 2A AND 2B
6 102408 8 HHCS, 3/8-16 X 1-1/2", GR8 BREAK SHARP EDGES .03 X 45° MAX
BJF - 5/22/17 M1214003 #
7 605103 8 HEX NUT, 3/8-16, GR5 DMF (404)875-1512
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

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.

5-6 © 2020 DMF, Inc. All Rights Reserved.

 ITEM PART QTY. DESCRIPTION
NO. NUMBER
1 12710 1 HYDRAULIC BRAKE CYLINDER; RW-1019/1212
2 12745 2 HYDRAULIC BRAKE SIDE BRACKET, RW-1019/1212
COAT W/
9 7 3 12735 1 HYD. BRAKE LEVER ARM ASSEMBLY W/ STOP, RW-1212
ANTI-SIEZE
4 12434 1 HYDRAULIC BRAKE SHOE, COBRA CUTOFF, RW-1019/1212
5 12436 2 HYDRAULIC BRAKE SHOE MOUNTING BLOCK, RW-1019/1212

3 6 818452 1 AIR BRAKE SHOE PIN

7 12424 1 PIN WELDMENT, 1019/1212/1420 HYDRAULIC BRAKE SHOE
8 12760 1 HYDRAULIC BRAKES CYLINDER ROD PIN, RW-1019/1212
9 818456 3 COTTER PIN, 1/8" X 1-1/2"
9 8
10 818105 2 GREASE FITTING, 1/4"-28 (ALEMITE 1641-B)
11 12479 4 HHCS, 1/2-13 X 1-1/4", GR8
12 12481 4 LOCK WASHER, 1/2", GR8
13 12750 REF HYDRAULIC BRAKE AXLE SADDLE, 10" WHEEL

10

4
5

2
13

K 01/11/17 MIGRATED TO SOLIDWORKS; REMOVED NOTES; REMOVED 12710 EXPLODED VIEW; DJJ
11 12 REMOVED 12476; 12750 QTY REF WAS 12750 QTY 2
REV DATE DESCRIPTION BY APP

COAT W/
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"

6 FRAC, OTHER: ±1/16" RW-1019 FRONT HYD. BRAKE ASSY. (1-1/16"

ANTI-SIEZE RW-1019
.X ± .063
.XX ± .030 BORE)
.XXX ± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
MRV TSH 11/28/95 12700 K
DMF (404)875-1512
 ITEM PART QTY. DESCRIPTION
NO. NUMBER
COAT W/ 1 12710 1 HYDRAULIC BRAKE CYLINDER; RW-1019/1212
2 12745 2 HYDRAULIC BRAKE SIDE BRACKET, RW-1019/1212
ANTI-SIEZE 9 7
3 12735 1 HYD. BRAKE LEVER ARM ASSEMBLY W/ STOP, RW-1212
4 12434 1 HYDRAULIC BRAKE SHOE, COBRA CUTOFF, RW-1019/1212
5 12436 2 HYDRAULIC BRAKE SHOE MOUNTING BLOCK, RW-1019/1212
3 6 818452 1 AIR BRAKE SHOE PIN
7 12424 1 PIN WELDMENT, 1019/1212/1420 HYDRAULIC BRAKE SHOE

9 8 8 12760 1 HYDRAULIC BRAKES CYLINDER ROD PIN, RW-1019/1212

9 818456 3 COTTER PIN, 1/8" X 1-1/2"
10 818105 2 GREASE FITTING, 1/4"-28 (ALEMITE 1641-B)
11 12479 4 HHCS, 1/2-13 X 1-1/4", GR8
12 12481 4 LOCK WASHER, 1/2", GR8
13 12755 REF RW-1212 HYDRAULIC BRAKE AXLE SADDLE

10

4
5

2
13

11 12
J 5/25/17 MIGRATED TO SOLIDWORKS BJF
REV DATE DESCRIPTION BY APP
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" RW-1212 HYDRAULIC BRAKE ASSEMBLY
COAT W/
.X ± .063
.XX ± .030 RW-1212
6 .XXX ± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
ANTI-SIEZE DRILL SIZES:
ANGULAR:
SURF FINISH:
+ .015
± 1°
125 MICRO DRAWN BY: APPD BY: DATE:
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
MRV TSH 11/28/95 12702 J
DMF (404)875-1512
 ITEM PART QTY. DESCRIPTION
NO. NUMBER
1 12712 1 CYL BODY DETAIL 1019/1212
K 2 12763 1 GLAND DETAIL; GEN2 HYD. BRAKE CYLINDER; RW-1019/1212
3 12720 1 O-RING; #022; 90A DURO
13 4 12719 1 BACK UP RING, #022
5 605165 1 ROD WIPER, AN 959/940, .75" ID, 1/8" W
K 6 605545 1 ROD SEAL, STD POLYPAK, .75" ID, 1/8"W
7 12717 1 EXTERNAL SNAP RING; 3/4" DIA SHAFT
8 12715 1 CYLINDER ROD 1019/1212
12 9 12722 1 COMPRESSION SPRING; HYDRAULIC BRAKE CYLINDER
10 12718 1 INTERNAL SNAP RING; 1-3/16" BORE; #118
11 605071 1 JAMB NUT, 3/8-24 UNF
12 12716 1 RW-1019/1212 HYD.BRAKE CYL.ROD EXTENTION
13 818105 1 GREASE FITTING, 1/4"-28 (ALEMITE 1641-B)
11 14 12726 1 RW-1019/1212 HYD.BRAKE CYL.BLEEDER SCREW (40160)
15 10432 1 FITTING 402X3 90 DEG BRAKE LINE 1/8 MPT X 1/8 INVERTED FLARE
ASSEMBLY PROCEDURE:
1. Ensure all parts are clean and free of burrs and sharp edges.
10 10
2. Lubricate rod, gland, and all seals lightly with blue assembly goo.
3. Install wiper (#5), rod seal (#6), backup ring (#4), and o-ring (#3) in gland (#2) in
2 3 4 5 6 orientations shown in Detail A.
5 4. Install external snap ring (#7) and spring (#9) onto rod (#8).
SEE DETAIL A 5. Place rod into body (#1) with threaded end facing upwards.
6
6. Slide gland assembly over rod, compress spring, and secure with internal snap ring (#10).
4 7. Install jamb nut (#11) onto rod extension (#12). Coat exposed threads with antizieze.
3 Thread extension completley into rod, and tighten jamb nut.
8. Install grease fitting (#13), bleed valve (#14), and hydraulic fitting (#15). Observe
9 2
orientation shown.
TEST PROCEDURE:
1. DURING TEST PROCEDURE, DO NOT ALLOW ROD TO REACH FULL EXTENSION. MAX ROD
EXTENSION SHOULD BE PHYSICALLY RESTRAINED TO 3/4" OR LESS.
2. Connect hydraulic power unit; set pressure relief to 2,000 psi.
3. Open bleed valve, cycle cylinder to purge air, and close bleed valve.
8
4. With rod extension limited to 3/4", pressure test for 15 sec. while inspecting for leaks.
5. Disconnect power unit and cap hydraulic fitting.

7
9

1 7

14

MIGRATED TO SOLIDWORKS. 12763 WAS 12714, 605545 WAS 12725, ADDED

K 02/01/16 TAM
605165
REV DATE DESCRIPTION BY APP

DETAIL A: INTERNAL COMPONENTS

TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
HYDRAULIC BRAKE CYLINDER; RW-1019/1212
FRAC, MACH: ± 1/32"
RW-1019
(FITTINGS #14 & #15 HIDDEN FOR CLARITY) FRAC, OTHER:
.X
± 1/16"
± .063

15
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
MRV TSH 11/28/95 12710 K
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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

© 2020 DMF, Inc. All Rights Reserved. 6-1

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

6-2 © 2020 DMF, Inc. All Rights Reserved.

 ITEM NO. PART NUMBER QTY. DESCRIPTION

CONTTRELL C95050
B - HYDRAULIC CYLINDER

E
24 15/16" STOWED
38 7/16" DEPLOYED

#6 JIC O-RING TYP C

ROD
1 1/2"
TUBE ID
2"

E 2/12/2020 24 15/16 WAS 25; 38 7/16 WAS 39 BJF

D 5/9/2017 MIGRATED TO SOLIDWORKS DJJ

C 06/20/16 #6 JIC O-RING WAS 3/8 NPT BJF
B 02/02/10 COTTRELL C95050 WAS BEI 203-100-14; ADDED NOTES BJF
A 05/08/98 REDRAWN KLC TSH
REV DATE DESCRIPTION BY APP
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
HYDRAULIC CYLINDER, CHIPPER, 2" X 1-1/2" X
B NOTE: FRAC, OTHER:
.X
.XX
±1/16"
± .063
± .030 RW-1019 13.5"
-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°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
PRP TSH 04/14/95 09765 E
DMF (404)875-1512
 ITEM PART NO. QTY DESCRIPTION
1 C95030 1 COTTRELL HYDRAULIC CYLINDER, 12" STROKE, 2" TUBE, 1.5" ROD
2
3
4
NOTE: 5
1. MAX PRESSURE 1850 PSI 6
2. 2" TUBE ID, 1.5" ROD OD

#6 JIC O-RING A

23.0 CLOSED
35.0 OPEN
(12.0 STROKE)

B
A 6/20/16 #6 JIC O-RING WAS 3/8 NPT BJF
REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
HYDRAULIC CYLINDER, 1212
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1212 VERTICAL GEAR, 12" STROKE
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
BJF 2/8/10 12060 A
 ITEM PART # QTY DESCRIPTION
P T 1 10491 1 FRONT RELIEF VALVE
2 10469 1 REAR RELIEF VALVE
3 10471 1 BRAKE CIRCUIT ENABLE VALVE (CARTRIDGE ONLY)
DH 4 10472 2 BRAKE LOCKING VALVE (CARTRIDGE ONLY)
5 500727 3 VALVE SOLENOID
6 10438 2 DIAGNOSTIC NIPPLE
1700 PSI A B 7 10470 4 ADAPTER, 1/4 MORB X 1/8 FPT
TP1 TP2 8 10432 2 BRAKE LINE ELBOW, 1/8 MPT X 1/8 INV. FLARE
9 10457 3 1/4 MORB X #4 MJIC 90 DEG. ELBOW
FB 700 PSI
RB
A

CIRCUIT DIAGRAM

TO RED/BLACK
OUTPUT FROM
BRAKE CONTROLLER
4
3
1

DEDICATED
GROUND TO
BATTERY 2

5 TYP. 3 PLACES

7
B 7/2/14 1700 PSI WAS 1800 PSI JDI
8 A 10/21/13 ADDED 1800 PSI, 700 PSI JDI
REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
6 9 MANUAL, BRAKE VALVE MANIFOLD ASSY (F&R),
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" - HYDRAFORCE, RW-1019
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
NEH 5/20/11 M1019135 B
 ITEM PART # QTY DESCRIPTION
1 10491 1 FRONT RELIEF VALVE
P T 2 10471 1 BRAKE CIRCUIT ENABLE VALVE (CARTRIDGE ONLY)
3 10472 2 BRAKE LOCKING VALVE (CARTRIDGE ONLY)
4 500727 3 VALVE SOLENOID
DH 5 10438 1 DIAGNOSTIC NIPPLE
6 10470 2 ADAPTER, 1/4 MORB X 1/8 FPT
7 10432 1 BRAKE LINE ELBOW, 1/8 MPT X 1/8 INV. FLARE
1700 PSI 8 10457 3 1/4 MORB X #4 MJIC 90 DEG. ELBOW
A B
TP1 TP2
FB RB
8.0
CIRCUIT DIAGRAM
5.9
.34
THRU
MOUNTING HOLE

5.8
3.2
TO RED/BLACK .34
OUTPUT FROM 3 THRU 2.9
BRAKE CONTROLLER MOUNTING HOLE
2 4.6
1

DEDICATED 4 TYP. 2 PLACES

GROUND TO
BATTERY

C 12/2/14 CORRECTED QUANTITIES OF 10438, 10470, 10432 BJF

B 7/2/14 1700 PSI WAS 1800 PSI JDI
A 10/21/13 ADDED 1800 PSI JDI
REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
8 (UNLESS SPECIFIED)
MANUAL, BRAKE VALVE MANIFOLD ASSY
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 (F ONLY), HYDRAFORCE, RW-1019
5 6 .X
.XX
± .063
± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
NEH 5/23/11 M1019137 C
 MANIFOLD LABELED "HYDRAFORCE 7024840" MANIFOLD LABELED "DMF#701061"
REQUIRES ORRIFICE NO ORRIFICE REQUIRED (INTEGRATED INTO MANIFOLD)

3
2

ORIFICE ORIENTATION:
BEVELED FACE INTO MANIFOLD;
FLAT EDGE TOWARDS LOCKING VALVE

ITEM NO. PART NUMBER QTY. DESCRIPTION

1 600612 1 1015 LOCKING VLV BODY ONLY (7024840) ITEM NO. PART NUMBER QTY. DESCRIPTION
2 10457 4 #04 MJIC X #04 MAORB X 90 FITTING (6801-04-04) 1 10457 4 #04 MJIC X #04 MAORB X 90 FITTING (6801-04-04)
3 600613 1 ORIFICE .070" (7051-070) 2 241016 1 VALVE, LOCKING, CPD-084P, PARKER
4 241016 1 VALVE, LOCKING, CPD-084P, PARKER 3 701061 1 LOCKING VALVE BODY W/ BUILT-IN .070" ORIFICE

A 11/20/17 ADDED INTEGRAL ORIFICE CONFIGURATION TAM

REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
LOCKING VALVE w/ ORFICE/FTGS/CART; RW-
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16"
RW-1016 1016
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
TAM - 12/03/15 701035 A
 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 600612 1 1015 LOCKING VLV BODY ONLY (7024840)
2 10457 3 #04 MJIC X #04 MAORB X 90 FITTING (6801-04-04)
3 600613 1 ORIFICE .070" (7051-070)
4 241016 1 VALVE, LOCKING, CPD-084P, PARKER
5 605324 1 04JIC MALE X 04 O-RING MALE
6 605206 1 TEE, #04 MJIC X #04 FJIC SWIVEL X #04 MJIC

1
3

6 5

REV DATE DESCRIPTION BY APP

TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" LOCKING VALVE w/ ORFICE/FTGS/CART,
.X ± .063
.XX ± .030 RW-1212 CHIPPER
.XXX ± .005
DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
DJJ - 07/21/17 600650 #
DMF (404)875-1512
 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 12073 1 FLOW DIVIDER, 12 GPM
2 600511 3 FITTING, STRAIGHT, #6 MAORB X #4 MJIC

4
3
3.38

2
2

2.56 1.48

REV DATE DESCRIPTION BY APP

TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" FLOW DIVIDER W/ FITTINGS, CHIPPER
.X ± .063
.XX ± .030 RW-1019/1212
.XXX ± .005
DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
DJJ - 07/26/17 12069 #
DMF (404)875-1512
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

SECTION 7.0 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. 7-1

DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

7-2 © 2020 DMF, Inc. All Rights Reserved.

 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 09746 1 CHIPPER, OUTER TUBE ASSEMBLY, LH
2 09765 1 HYDRAULIC CYLINDER, CHIPPER, 2" X 1-1/2" X 13.5"
3 09751 1 CHIPPER INNER TUBE ASSEMBLY
4 09766 1 CHIPPER BASE END PIN
5 818456 2 COTTER PIN, 1/8" X 1-1/2"
6 18952 2 #04 MJIC X #06 MAORB X 90 FITTING

A 5 4

1
2

24 15/16"
STOWED
A B

PLATE SHIPPED LOOSE,

DEPLOYED
38 7/16"
WELDED AT INSTALL
A A
B

A 6

3
B 2/12/2020 24 15/16 WAS 25; 38 7/16 WAS 39 BJF

MIGRATED TO SOLIDWORKS, ADDED REF DIMENSIONS, 818456 WAS 09770, ADDED 18952,
A 05/09/17 DJJ
ADDED NOTE
REV DATE DESCRIPTION BY APP
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" CHIPPER TOWER ASSEMBLY, LH
.X
.XX
± .063
± .030 RW-1019
.XXX ± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
LOR - 08/13/99 09744 B
DMF (404)875-1512
 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 09747 1 CHIPPER, OUTER TUBE ASSEMBLY, RH
2 09751 1 CHIPPER INNER TUBE ASSEMBLY
3 09765 1 HYDRAULIC CYLINDER, CHIPPER, 2" X 1-1/2" X 14"
4 09766 1 CHIPPER BASE END PIN
5 818456 2 COTTER PIN, 1/8" X 1-1/2"
PLATE SHIPPED LOOSE. 6 18952 2 #04 MJIC X #06 MAORB X 90 FITTING
WELDED AT INSTALL A

4 5 A

6 A

24 15/16"
STOWED
A
B

DEPLOYED
38 7/16"

A
B

B 2/12/20 24 15/16 WAS 25; 38 7/16 WAS 39 BJF

MIGRATED TO SOLIDWORKS, ADDED 18952 & ADDED REFERENCE DIM, 818456 WAS 09770,
A 07/11/17 DJJ
ADDED NOTE
REV DATE DESCRIPTION BY APP
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, MACH: ± 1/32"
FRAC, OTHER: ±1/16" CHIPPER TOWER ASSEMBLY, RH
.X
.XX
± .063
± .030 RW-1019
.XXX ± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
DRILL SIZES: + .015 METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
LOR - 08/13/99 09745 B
DMF (404)875-1512
 ITEM PART QTY. DESCRIPTION
NO. NUMBER
1 12055 1 OUTER GUIDE TUBE WELDMENT, 1212 VERTICAL GEAR
2 12058 1 INNER GUIDE TUBE WELDMENT, 1212 VERTICAL GEAR
4 5 A 3 12060 2 HYDRAULIC CYLINDER, 1212 VERTICAL GEAR, 12" STROKE
4 09766 2 CHIPPER BASE END PIN
5 10563 5 COTTER PIN; 1/8" X 1.5"
6 12062 2 AXLE SADDLE, 1212 VERTICAL GEAR
7 12065 1 PIN WELDMENT, CYLINDER ROD, 1212 VERTICAL GEAR
8 18952 4 #04 MJIC X #06 MAORB X 90 FITTING

8 A
3

PLATE SHIPPED LOOSE,

WELDED AT INSTALL A

7 5 A 07/11/17 ADDED 18952, 10563 WAS 09770, ADDED NOTE DJJ

REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
6 (UNLESS SPECIFIED)
TOWER ASSEMBLY, 1212 VERTICAL GEAR
2 FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1212
.X ± .063

10.50
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
BJF 2/9/10 12053 A
 ITEM PART
NO. NUMBER QTY. DESCRIPTION
7 1 10570 2 RW-1019-HD WHEEL,NON-INS., W/RACES
2 10682 1 RW 1019 HD REAR TUBE DETAIL
3 10603 1 RW-1019-HD AXLE
8 4 10592 2 RW-1019-HD SEAL, STANDARD
14 19 5 10516 2 RW-1019 HUBCAP, H.D. STYLE
6 12750 4 RW-1019 HYD.BRAKE AXLE SADDLE 10" WHEEL
7 12700 2 RW-1019 FRONT HYD. BRAKE ASSY. (1-1/16" BORE)
9 WELDED IN PLACE 8
9
09761
09762
2
2
RW-1019 CHIPPER AXLE LUG
CHIPPER CYLINDER LUG ON AXLE
DURING FINAL 10
11
10591
10595
4
2
RW-1019-HD BEARING CONE
NUT, AXLE (TIMKEN TN-08)
2 ASSEMBLY OF 12 10596 2 WASHER,TONGUE (TIMKEN K-91508)
13 10598 2 WASHER, AXLE TAB (TIMKEN WH-08)
RAILGEAR 14 09767 2 CHIPPER HYDRAULIC CYLINDER, ROD PIN ASSEMBLY
15 108220 8 LOCK WASHER, 5/16", GR8
16 800108 8 HHCS, 5/16-18 X 3/4", GR5
17 12566 1 LOCK WASHER, 3/8", GR8
18 12564 1 PIN, AXLE, ANTI-ROTATION
19 818456 2 COTTER PIN, 1/8" X 1-1/2"

17 18

WHEEL ASSEMBLY PROCEDURE: 3

1. PACK ALL BEARINGS ENSURING COMPLETE COVERAGE, BOTH
INSIDE AND OUT.
1
2. INSERT BEARING IN INBOARD SIDE OF WHEEL (FLANGE SIDE).
3. PACK GREASE ON INBOARD SIDE OF BEARING, COVERING 12
BACK SIDE OF BEARING. 6
4. INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH 4 13
WITH WHEEL HUB 11
10
5. PLACE WHEEL ON AXLE. 16 15
6. FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL
FLUSH WITH OUTBOARD RACE. RW-1019 AXLE ASSEMBLIES: 10
7. INSTALL AXLE WASHERS ALIGN THEM WITH KEYWAYS. NON INSULATED AXLE- 09760
8. INSTALL AXLE NUT. NON INSULATED AXLE, W/ HYD BRAKES - 09773
9. ADJUST BEARING ENDPLAY. INSULATED AXLE - 09793
A) TIGHTEN AXLE NUT TO 200 FT-LBS WHILE ROTATING WHEEL. INSULATED AXLE, W/ HYD BRAKES - 09771 5
B) BACK OFF AXLE NUT ONE FULL TURN.
C) TIGHTEN AXLE NUT TO 50 FT-LBS WHILE ROTATING WHEEL. RW-1019 WHEELS:
D) BACK OFF AXLE NUT BY ONE NOTCH OF THE TAB WASHER. NON INSULATED W/ RACES - 10570
10. SELECT TABS ON TAB WASHER THAT MOST NEARLY LINE UP WITH INSULATED W/ RACES - 10580
SLOTS IN AXLE NUT. BEND THE TABS UP TO SECURE THE NUT. INSULATOR SLEEVE - 10581
11. VERIFY BEARING END PLAY IS 0.001" TO 0.005" WITH DIAL BEARING RACE (TIMKEN HM-903210) - 10590
INDICATOR.
12. FILL OUTBOARD CAVITY WITH GREASE. REV DATE DESCRIPTION BY APP
TOLERANCES (UNLESS SPECIFIED):
TITLE:
13. RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE FRAC, MACH:
FRAC, OTHER:
± 1/32"
±1/16" NON-INSULATED WHEEL & AXLE ASSEMBLY,
.X ± .063
(OUTBOARD FACE). .XX ± .030 RW-1019 CHIPPER W/ BRAKES
.XXX ± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
14. INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK
DRILL SIZES: + .015
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°
SURF FINISH: 125 MICRO DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
WASHERS. THREADS: 2A AND 2B
BREAK SHARP EDGES .03 X 45° MAX
DJJ - 06/28/17 09773 #
DMF (404)875-1512
 ITEM NO. PART NUMBER QTY. DESCRIPTION
1 12693 1 REAR AXLE WELDMENT ASSEMBLY, SHOE BRAKES, NO SADDLE
2 12510 2 RW-1212 WHEEL, NON-INSULATED, w/RACES (HT)
3 12591 4 BEARING; TIMKEN HM-807049
4 12595 2 AXLE NUT; TIMKEN TN-10
5 12596 2 TOUNGE WASHER; HARDENED, TIMKEN K-91510
6 12598 2 TAB WASHER; TIMKEN TW-110
7 12702 2 RW-1212 HYDRAULIC BRAKE ASSEMBLY
1 8 12560 2 RW-1212/1420 HUBCAP DETAIL
9 12592 2 SEAL, STANDARD (CR-34868), RW-1212/1420
10 108220 8 LOCK WASHER, 5/16", GR8
11 800108 8 HHCS, 5/16-18 X 3/4", GR5

9
WHEEL ASSEMBLY PROCEDURE:
1. PACK ALL BEARINGS ENSURING COMPLETE COVERAGE , INSIDE
AND OUT. 2
2. INSERT BEARING IN INBOARD SIDE OF WHEEL (FLANGE SIDE).
3. PACK GREASE ON INBOARD SIDE OF BEARING, COVERING
BACK SIDE OF BEARING. 3
4. INSTALL A NEW SEAL BY GENTLY TAPPING WITH HAMMER UNTIL 4
FLUSH WITH WHEEL HUB.
5. PLACE WHEEL ON AXLE. 8
6. FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL 11 10
FLUSH WITH OUTBOARD RACE. WHEEL & AXLE ASSEMBLIES:
7. INSERT BEARING IN OUTBOARD SIDE OF WHEEL. INSULATED, NO BRAKES - 12683
8. INSTALL TONGUE WASHER. INSULATED, HYDRAULIC BRAKES - 12679
9. INSTALL A NEW TAB WASHER. NON-INSULATED, NO BRAKES - 12681
10. INSALL AXLE NUT. NON-INSULATED, HYDRAULIC BRAKES - 12677 6
11. ADJUST BEARING END-PLAY:
RW-1212 WHEELS: 5
A) TIGHTEN AXLE NUT TO 200 FT-LBS WHILE ROTATING WHEEL.
B) BACK OFF AXLE NUT ONE FULL TURN. NON-INSULATED W/ RACES - 12510
C) TIGHTEN AXLE NUT OT 50 FT-LBS WHILE ROTATION WHEEL. INSULATED W/ RACES - 12530
D) BACK OFF AXLE NUT BY ONE TAB OF TAB WASHER. INSULATOR IN BOARD - 14527
12. BEND DOWN TAB THAT MOST NEARLY LINES UP WITH A NOTCH INSULATOR OUT BOARD - 14528
IN AXLE NUT. WHEEL RACE, TIMKEN HM-807010 - 12590
13. VERIFY BEARING END-PLAY IS 0.001" TO 0.005" WITH A DIAL
INDICATOR.
14. FILL OUTBOARD CAVITY WITH GREASE. REV DATE
TOLERANCES (UNLESS SPECIFIED):
DESCRIPTION BY APP
TITLE:
15. RUN A BEAD OF SILICONE ON HUB MOUNTING SURFACE FRAC, MACH:
FRAC, OTHER:
.X
± 1/32"
±1/16"
± .063
WHEEL & AXLE ASSEMBLY, REAR, NON
RW-1212 INSULATED, NO SADDLES
(OUTBOARD FACE OF HUB). .XX
.XXX
± .030
± .005
THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
DRILL SIZES: + .015
16. INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK ANGULAR:
SURF FINISH:
± 1°
125 MICRO DRAWN BY: APPD BY: DATE:
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
DRAWING NUMBER: REV:
THREADS: 2A AND 2B
WASHERS. BREAK SHARP EDGES .03 X 45° MAX
DJJ - 06/29/17 12677 #
DMF (404)875-1512
DIVERSIFIED METAL FABRICATORS, INC. CHIPPER RAILGEAR

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.

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