RW 1019

DIVERSIFIED METAL FABRICATORS, INC.
Parts & Service Manual

RW-1019
September 2017
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 parts@dmfatlanta.com
Service Department (404) 879-7882 service@dmfatlanta.com
Phone (404) 875-1512  Fax (404) 875-4835 info@dmfatlanta.com
http://www.dmfatlanta.com
DIVERSIFIED METAL FABRICATORS, INC. RW-1019
Message from DMF
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.
Manuals, service bulletins and general information are available on our website listed below.
Contact:
Diversified Metal Fabricators
665 Pylant St. NE
Atlanta, GA 30306
(404) 875-1512
(404) 875-4835 Fax
(404) 607-1684 Parts
info@dmfatlanta.com
Ship to:
668 Drewry St. NE
Atlanta, GA 30306
© 2017 DMF, Inc. All Rights Reserved.

SECTION 1.0 GENERAL INFORMATION

1.1 GENERAL DESCRIPTION.................................................................................... 1-2
1.2 CURRENTLY APPROVED CHASSIS...................................................................... 1-3
1.3 FRONT RAILGEAR ............................................................................................. 1-4
1.3.1 Standard Front Railgear Components ............................................................. 1-4
1.4 REAR RAILGEAR................................................................................................ 1-6
1.4.1 Rear Railgear Components ........................................................................... 1-6
1.5 ANTI-LOCK BRAKE (ABS), TRACTION CONTROL & ELECTRONIC STABILITY
CONTROL (ESC) ........................................................................................................ 1-7
1.5.1 Ford F4/550 ABS & Traction Control Electronic Stability Control (ESC) Details ...... 1-7
1.5.2 Dodge 4/5500 ABS & Traction Control Electronic Stability Control (ESC) Details ... 1-7
1.5.3 GM 4/5500 ABS & Traction Control Electronic Stability Control (ESC) Details ........ 1-7
© 2017 DMF, Inc. All Rights Reserved. 1-1

1.1 GENERAL DESCRIPTION

DMF’s RW-1019 Railgear is our for medium duty chassis in the 10,000 to 19,500 lb GVWR
range. The front Railgear attaches to the frame and front axle and lifts the front truck tires off
the track, thus utilizing the vehicle’s front suspension. This design supports the vehicle as it
was intended and helps the truck navigate curves smoothly and damps out the effects of track
irregularities. The rear Railgear attaches directly to the truck frame behind the rear axle spring
hangers. It deploys with an articulating dual scissor action that allows the rear Railgear to be
moved both vertically and horizontally. This mechanism provides the “side shift” action which
has made DMF gear so well known in the industry. It gives operators a greater margin for
aligning the vehicle to the track, which speeds and simplifies the process of getting the vehicle
on rail.
Materials:
All structural members and brackets are constructed of carbon steel. The 10” rail wheels for
DMF RW-1019 Railgear are machined from hardened steel castings and are fitted to high
strength alloy steel axles with heavy-duty tapered roller bearings.
Installation:
Both DMF front and Railgear bolt to the truck frame using only hand tools found in any shop.
They are designed to minimize the amount of space required and in many cases fit within the
existing boundaries of the vehicle. The front Railgear, however, sometimes require a bolt-on
frame extension to complete the installation. Rear RW-1019 Railgear mounts below the top of
frame and directly behind the rear axle spring hangers.
Brakes:
NOTE:
The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail
mode. As the vehicle rear tires are in contact with the railhead, the primary braking effort is
derived from the rubber tires. Rail wheel brakes alone are insufficient to stop the vehicle in a
reasonable distance.
The optional RW-1019 rail wheel brakes are of the hydraulic actuated external Cobra shoe type.
The rail wheel brakes use the truck’s hydraulic system to supply the clamping force. The rail
brakes are applied simultaneously with the truck brakes when the operator presses the brake
pedal. There is also a dashboard-mounted switch that permits the operator to enable or disable
the rail wheel braking system.
Options:
There are several options available for RW-1019 Railgear. The most commonly ordered options
include rail wheel brakes for improved stopping on rail, insulated wheels to prevent crossing
signal actuation, rail sweeps to clear the rail of potentially damaging materials, and various
retention systems to fit your application. Other less common options are non-standard track
gauges and slotted links for improved Railgear performance at crossings.
NOTE:
There are currently 4 approved chassis for our 1019 series of Railgear. While very
similar in some aspects, there are variances between the components and installation
procedures of these chassis-specific assemblies. To address this, we have established
this manual in a format giving general instructions that apply to all chassis followed by
specific instructions regarding each unique variation. Where necessary, notes will be
provided to ensure clarity regarding which chassis is applicable. Please locate and
become familiar with the sections specific to your application.
1-2 © 2017 DMF, Inc. All Rights Reserved.

1.2 CURRENTLY APPROVED CHASSIS

Ford
2008 - 2016 F-4/550 (w/ 245/70R19.5 tires) (Aft fuel tank not recommended)
Ram / Sterling
08-Present Ram 45/5500
08-09 Sterling Bullet 45/5500 (discontinued in 2009)
Chevy / GM
’02-‘09 C4/5500 (discontinued in 2010)
2008-2016 Ford F-4/550 08-Present Ram 45/5500

08-09 Sterling Bullet 45/
’02-’09 GM C45/5500

1.3 FRONT RAILGEAR

1.3.1 Standard Front Railgear Components
Figures 1.3.1.A thru 1.3.1.C identify the individual parts of the installed front Railgear. These
item descriptions will be used throughout this installation manual.
Front Railgear
GVWR Range: 10,000 to 19,500 lbs. @ 20 MPH
Approx. Installed Weight (Front): 847 (Ford), 847 (Dodge), 675 (GM) lbs.
Capacity: 8,200 pounds per Railgear axle @ 20 MPH
For detailed drawings, see Section 8.0, and for installation instructions, see Section 4.0.
TRUCK
FRAME
1 TRUCK
TIRE
2 TRUCK
AXLE Item Description
3 1 Frame Bracket
2 Front Mounting Pin
3 Long Arm
4 Front Cylinder
4 9 10 11 5 Pivot Arm
8 6 Railsweep (If Equipped)
5 7 7 Cobra Brake (If Equipped)
8 Rear Mounting Pin
9 Swing Link
6
10 Axle Bracket
M1019134
11 Suspension Radius Arm
1.3.1.A ’08-‘16 Ford F-4/550 Front Railgear Components

TRUCK
FRAME
ITEM DESCRIPTION
1 FRONT MOUNTING PIN
1 2 FRAME BRACKET
TRUCK 3 LONG ARM
2 TIRE
TRUCK 4 FRONT CYLINDER
AXLE
5 PIVOT ARM
3
6 RAILSWEEP (IF EQUIPPED)
7 COBRA BRAKE (IF EQUIPPED)
4 8 REAR MOUNTING PIN
9 SWING LINK
10 11 10 SWING LINK PIN
5 7 8 9
11 AXLE BRACKET
M1019132
6
1.3.1.B ’08 Dodge/Sterling 4/5500 Front Railgear Components
35" REF
1 Truck Frame
Front Leaf Springs
2 Item Description
12 1 Frame Extension
2 Cross Tube
11 3 Front Mounting Pin
13 4 Pivot Arm
3 10 5 Front Cylinder
6 Long Arm
7 Rear Mounting Pin
9 8 Spring Hanger Bracket
9 Lower Spacers
10 Rubber Spacer
22 1/2" 11 Top Spacer
12 Railsweep (If Equipped)
13 Cobra Brakes (If Equipped)
8 Front Axle
4 5 6 7 9 3/4"
M1019133
1.3.1.C ’08 GM 4/5500 Front Railgear Components

1.4 REAR RAILGEAR

1.4.1 Rear Railgear Components
Rear Railgear
GVWR Range: 10,000 to 19,500 lbs
Approx. Installed Weight (Rear): 950 lbs
Capacity: 8,200 lbs per Railgear axle at 20 MPH
Figure 1.4.1 shows the individual parts of the installed rear Railgear with the Rail Wheels in the
rail position. These item descriptions will be used throughout this installation manual.
Figure 1.4.1 Rear Railgear Components
For detailed drawings, see Section 7.0, and for installation instructions, see Section 4.0.

1.5 ANTI-LOCK BRAKE (ABS), TRACTION CONTROL & ELECTRONIC

STABILITY CONTROL (ESC)
Please refer to the following note relevant to your chassis:
1.5.1 Ford F4/550 ABS & Traction Control Electronic Stability Control (ESC) Details
Ford F4/550 ABS/Traction/ESC Notes:

There are unique guidelines for operation of RW-1019 equipped 2011 Ford F-4/550’s on
rail. It is imperative to ensure that the vehicle is in 2WD & the traction control system is
disengaged. Failure to do so will result in both acceleration & braking issues on rail due
to overcompensation by these systems.
1.5.2 Dodge 4/5500 ABS & Traction Control Electronic Stability Control (ESC) Details
Dodge 4/5500 ABS Notes:

Dodge 4/5500 chassis will display an ABS warning on the instrument panel when
operated on rail. This warning light will go off after being operated on road for 1-2 miles.
1.5.3 GM 4/5500 ABS & Traction Control Electronic Stability Control (ESC) Details
GM 4/5500 ABS Notes:

GM 4/5500 chassis will display an ABS warning on the instrument panel when operated
on rail. This warning light will go off after being operated on road for 1-2 miles.

SECTION 2.0 OPERATIONS

2.1 BEFORE YOU OPERATE THE RAILGEAR ........................................................ 2-2
2.1.1 Familiarize Yourself with the Railgear ........................................................... 2-2
2.1.2 Daily Inspection ........................................................................................ 2-2
2.2 HIGHWAY OPERATION ................................................................................ 2-3
2.3 GETTING ON THE RAIL ................................................................................ 2-3
2.3.1 Getting onto the Rail .................................................................................. 2-3
2.3.2 Lower Rear Railgear ................................................................................... 2-3
2.3.3 Lower Front Railgear .................................................................................. 2-3
2.3.4 On the Tracks ........................................................................................... 2-4
2.4 GETTING OFF OF THE RAIL ......................................................................... 2-4
2.4.1 Removing Truck From Track ........................................................................ 2-4

2.1 BEFORE YOU OPERATE THE RAILGEAR

2.1.1 Familiarize Yourself with the Railgear
Clearances & Approach Angles
The installation of Railgear typically reduces the ground clearance & approach angle in the front
and back. In some installations, the rail wheels extend slightly beyond the corners of the front
bumper. Operators should familiarize themselves with the modified clearance & approach
angles.
Railgear Retention Systems and Locations

Walk around vehicle and identify the location and type of Railgear retention system(s) that are
installed on your particular vehicle.
DMF offers the following Railgear retention options:
 Manual Pin-Offs
 Cable Remote Pin-Offs
 Hook Lock Mechanism (front only)
 Lever Pin-Offs (front only)
See Section 5.2 for more information on Railgear retention systems.
NOTE:
DMF’s Rear Cylinders are equipped with integral locking valves; however, Railgear retention
systems are still required to be engaged in both the highway and rail positions.
Operation Controls
 Locate and familiarize yourself with the front and rear Railgear operating controls.
 Locate Power Take-Off (PTO) toggle/switch control and indicator light, typically found on
the dashboard (if equipped).
 If your truck is equipped with Railgear brakes, locate the brake switch on the dashboard of
the truck.
2.1.2 Daily Inspection

Before operating your Railgear-equipped vehicle, whether for highway or rail use, it is
imperative that you perform a daily inspection – see Section 3.1.1 for Daily Inspection List. If
any items found during your inspection do not conform to requirements, it is your responsibility
to take corrective action before any use of the vehicle.

2.2 HIGHWAY OPERATION

Before operating a Railgear-equipped vehicle on the highway:
1.Verify Railgear is in highway position.
2.Verify that the retention systems (both front and rear) are properly engaged (even if the
Railgear on your truck is equipped with a locking valve system, you MUST verify that the
pins are correctly inserted).
3.Steering wheel lock has been removed (if applicable).
4.Verify that Railgear brakes have been disengaged (if applicable).
5.Verify PTO has been disengaged and that the indicator light is OFF (if applicable).
2.3 GETTING ON THE RAIL
NOTE:
For 2011 Ford F-4/550’s, there are unique guidelines for operation on rail. It is
imperative to ensure that the vehicle is in 2WD & the traction control system is
disengaged. Failure to do so will result in both acceleration & braking issues
on rail due to overcompensation by these systems.
2.3.1 Getting onto the Rail

1. At the track crossing, drive past the track, then back the vehicle onto the rails. Engaging
the rear Railgear first will allow your vehicle to side-shift and align itself to the rail, making
it easier to engage the front Railgear.
2. Engage the truck’s parking brake to prevent the truck from rolling.
2.3.2 Lower Rear Railgear
3. If the Railgear has brakes, turn brake switch on.
4. Engage the PTO (or auxiliary hydraulic power unit); leave the truck running and the
transmission in neutral gear.
5. Disengage the Railgear retention systems (both front and rear). If the retainers are too
tight to be disengaged, verify that Railgear is fully in highway position by briefly pulling the
valve handles toward you.
6. Push valve handles to lower wheels and engage rail.
7. To assist with alignment of the wheels to the rail, you can also use the valve handles
independently to lower one side at a time to engage the rail, at which point you can then
lower the opposite side. This will cause your vehicle to side-shift and align itself with the
rail.
8. When both wheels are fully down and properly engaging rail, re-engage safety retention
systems.
2.3.3 Lower Front Railgear
9. If necessary, drive the truck into position to line up the front Railgear with the rail.
10. Ensure that the PTO (or auxiliary hydraulic power unit) is engaged (this was engaged during
the lowering of the rear Railgear).
11. Ensure that the front Railgear retention system is disengaged.
12. Check and make sure that the front rail wheels line up with the rail.
13. Push valve handle to lower wheels and engage rail.
14. If you do not require the use of the PTO (or auxiliary hydraulic power unit) for additional
equipment, it can now be disengaged.
15. Disengage the truck’s parking brake when you are ready to proceed.
NOTE:
The front Railgear assembly is an over-center design and does not require the safety Railgear
retention system to be engaged in rail mode.

2.3.4 On the Tracks

 Do not exceed posted track speed limit, and at no time exceed 30 MPH while on the track.
 Be aware that some Railgear is insulated, and will not operate the crossing gate circuits.
You are responsible for knowing if your Railgear equipped vehicle has insulated or non-
insulated wheels. To assist in identifying insulated rail wheels, a grooved ring is machined
around the inside of the front and rear driver’s side wheels.
 All railroad rules and safety guidelines should be observed.
 Reduce speed while in reverse and/or at all crossings, curves, branch lines, switches and
frogs (no more than a slow walking pace is recommended).
 Traction is reduced on the track, especially in wet conditions.
 Braking distance is increased on the track, especially in wet conditions.
 Do not slide tires or guide wheels on the tracks as this will cause premature wear.
 Do not exceed the maximum rated capacity of the equipment.
 On newer trucks with Anti-Lock braking systems, the amber ‘ABS’ dash light may remain on
with the front wheels elevated. This will not reduce rear truck braking or rail wheel braking.
2.4 GETTING OFF OF THE RAIL

2.4.1 Removing Truck From Track
1. Safely pull onto the track crossing, paying attention to traffic and other obstacles.
2. Set the truck parking brakes and engage the PTO.
3. Leave the truck running and the transmission in neutral gear.
4. Lift both sets of Railgear (there is no preference for removal order).
5. Engage all 4 safety Railgear retention systems in highway position (passenger and driver
side, for both front and rear Railgear).
6. Disengage the switch that controls the Railgear brakes (if applicable).
7. Disengage the PTO (or auxiliary hydraulic power unit) and the parking brakes.
8. Make sure surrounding area is free and clear of any obstacles and vehicles before pulling off
of the rail and onto the road.
9. If the amber ABS dash light remains on during rail operation, the truck engine must be
turned off and restarted after returning to highway operation. This will clear the ABS light
after a few seconds. If the amber light remains on during road operation, the truck’s brake
system may have an active fault and should be checked out. Please refer to the truck’s
operation manual.

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 ........................................................... 3-3
3.1.4 Annual Maintenance or as required............................................................... 3-3
3.2 LUBRICATION SPECIFICATION ................................................................... 3-3
3.3 WHEEL WEAR GAUGE .................................................................................. 3-6
3.4 TROUBLESHOOTING .................................................................................... 3-8
3.5 DERAILMENT............................................................................................... 3-9

3.1 INSPECTION AND MAINTENANCE

If your Railgear vehicle is high-use or operated under extreme conditions, such as operating in
mountainous regions or extreme temperatures, the levels of inspections listed below may need
to be performed more frequently than stated.
The following are instructions for routine inspections recommended by Diversified Metal
Fabricators. In some circumstances, government or corporate regulations may require
additional inspections be performed. Please ensure that you are aware of any inspection
requirements that pertain to your Railgear and that you abide by all local and national laws
regarding Railgear maintenance and safety.
3.1.1 DAILY MAINTENANCE
 Visually inspect for hydraulic fluid leaks.

 Check and make sure that all threaded fasteners are secured. NOTE: All hex nuts are either
nylon insert or slotted hex nuts with cotter pins.
 Check and make sure all tie straps that secure hoses from moving parts and exhaust
systems are in place. Replace if cracked or worn.
 Inspect wheel flanges for excessive wear, primarily noting differences in wear between
wheels on the same axle or diagonally. If an abnormal pattern is noted, check Railgear
alignment (see alignment procedure in Section 4.6).
 Inspect wheel “end-play”: Placing one hand at the 9 o’clock position and your other hand at
the 3 o’clock position, firmly grab the wheel and push and pull it a few times. There should
be no discernable movement in and out, and the wheel should rotate freely. If you feel
there is too much movement in and out, or if the wheel does not rotate freely, a detailed
inspection should be performed. See Sections 7.0 & 8.0 for appropriate axle assembly
drawings.
 Throughout the day, inspect wheel temperature. If extremely hot, this could indicate
bearing adjustment is too tight. For adjustment information, see Section 7.0 & 8.0 for
appropriate axle assembly drawings.
3.1.2 WEEKLY MAINTENANCE
Perform standard daily inspection points as listed above, and then check the following:
 Grease and lubricate all grease fittings on front and rear Railgear assemblies.
NOTE:
There are eight (8) locations on the GM/Chevy front assembly, twelve (12) on the
Dodge/Ford front assembly and fourteen (14) locations on all rear assemblies. See
drawings in Sections 3.2 for details.
 Check level of hydraulic oil and all other fluids.

 Check air pressure in tires and inflate to proper inflation pressure (if necessary).
 Inspect brakes and adjust if necessary. Refer to Section 5.2.1
 Test Railgear brakes on a test track.
- With the Railgear brake switch “on”, verify that pressing vehicle brake pedal causes the
Railgear brakes to slow but not stop the rail wheels.
- Locking up the rail wheels on rail can lead to flat spotting of wheels. Railgear brakes
should properly release when the vehicle brake pedal is released.
- Contact a Service Representative at DMF if you need additional assistance.

3.1.3 BI-ANNUAL MAINTENANCE OR AS REQUIRED
Perform standard daily and weekly inspection points as listed above, and then check the
following:
 Remove the hubcaps from the rail wheels and inspect for deterioration or loss of wheel
bearing grease. Unless there is a problem, the cavity may be topped off with the
recommended grease without removing and/or re-packing the bearings. If parts appear
worn or damaged, replace and repack as shown in Section 7.0 and 8.0.
 Clean the hubcap and mating surfaces and apply a bead of silicone gasket and re-attach
securely.
 Clean the strainer / filter in the hydraulic power unit tank.
 Rail test for proper traction and braking and adjust as appropriate. See Section 4.7.
 Check Railgear alignment per Sections 4.6.
3.1.4 ANNUAL MAINTENANCE OR AS REQUIRED
In addition to the items listed in 3.1.1 Daily Maintenance, 3.1.2 Weekly Maintenance and 3.1.3
Bi-annual Maintenance perform the following:
 Disassemble, inspect repack and reassemble Rail Wheel Bearings as shown in Section 7.0
and 8.0.
3.2 LUBRICATION SPECIFICATION

Hydraulic Oil:
 Dexron III ATF fluid is standard for DMF supplied hydraulic power units
Wheel Bearing Grease / Grease Fittings:

 Factory Standard: Citgo Syndurance Premium Synthetic 460 #2
 Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose Grease #2 (or equivalent)

LOCATION QTY DESCRIPTION
1 4 UPPER LINK MAIN PIVOT LUBRICATION SPECIFICATION:
2 4 LOWER LINK MAIN PIVOT • Factory Standard: Citgo Syndurance Premium
3 2 AXLE SADDLE PIVOT Synthetic 460 # 2
4 2 CROSSTUBE PIVOT • Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose
Grease #2 (or equivalent)
5 2 CYLINDER ROD END
6 2 BRAKE ARM PIVOT - UPPER
7 2 BRAKE ARM PIVOT - LOWER
8 2 BRAKE CYLINDER ROD END
5
1
6
3 APPLIES TO ALL CURRENTLY
8
APPROVED CHASSIS
B
A 5/20/15 CHANGED GREASE STANDARD JDI
REV DATE DESCRIPTION BY APP
7 TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
MANUAL, REAR GREASE POINT LOCATIONS,
NOTE: LOCATIONS TYPICAL BOTH SIDES FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" - RW-1019
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
*AS A WEEKLY PREVENTITIVE MAINTENANCE PROCEDURE: .XXX
DRILL SIZES:
± .005
+ .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
GREASE ALL LOCATIONS AND CHECK FOR UNUSUAL WEAR ANGULAR:
SURF FINISH:
± 1°
125 MICRO
THREADS: 2A AND 2B
BREAK SHARP EDGES ( 0.030 X 45° MAX )
NEH 4/21/11 M1019118 A
LOCATION QTY DESCRIPTION LOCATION QTY. DESCRIPTION
1 2 FRONT CROSSTUBE PIVOT 1 2 FRONT CROSS TUBE PIVOT
2 2 MAIN PIVOT - INBOARD 2 2 MAIN PIVOT - INBOARD
3 2 MAIN PIVOT - OUTBOARD 3 2 MAIN PIVOT - OUTBOARD
4 2 SPRING HANGER PIVOT (CYLINDER ROD END) 4 2 SWING BLOCK UPPER PIVOT
5 2 BRAKE ARM PIVOT - FRONT 5 2 SWING BLOCK LOWER PIVOT
6 2 BRAKE ARM PIVOT - REAR 6 2 CYLINDER ROD END PIVOT
7 2 BRAKE CYLINDER ROD END 7 2 BRAKE ARM PIVOT - FRONT
'08 GM/CHEVY C4/5500 FRONT HI-RAIL GEAR 8 2 BRAKE ARM PIVOT - REAR
9 2 BRAKE CYLINDER END PIVOT
'08 FORD F-4/550 & DODGE 4/5500 FRONT HI-RAIL GEAR (FORD SHOWN)
4
7 5 4
6 5
6
6 9
8
3 2 2 3 5 1 3 2 1 2 3 7
1 1
NOTE: MAIN PIVOT GREASE ZERT FITTINGS ARE LOCATED ON THE SIDE ADJACENT TO THE CYLINDER BODY NOTE: MAIN PIVOT GREASE ZERT FITTINGS ARE LOCATED ON THE SIDE ADJACENT TO THE CYLINDER BODY
*AS A WEEKLY PREVENTITIVE MAINTENANCE PROCEDURE:

GREASE ALL LOCATIONS AND CHECK FOR UNUSUAL WEAR
B
A 5/20/15 UPDATED GREASE STANDARDS JDI
LUBRICATION SPECIFICATION: TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
• Factory Standard: Citgo Syndurance Premium MANUAL, FRONT GREASE POINT LOCATIONS,
Synthetic 460 #2
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" - RW-1019
.X ± .063
• Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose .XX

.XXX
DRILL SIZES:
± .030
± .005
+ .015
DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
Grease #2 (or equivalent) ANGULAR:
SURF FINISH:
± 1°
125 MICRO
THREADS: 2A AND 2B
NEH 4/21/11 M1019117 A
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 treads as well as tolerance on wheel
back-to-back spacing.

3.4 TROUBLESHOOTING
Symptom Possible Cause Diagnostic Step Corrective Action

Rail wheel vibration/ Damaged Inspect Replace wheel
noise Tread/Flange treads/Flange
Patterned Wear on Inspect Replace wheel

Tread/Flange treads/Flange
Loose Wheel Check wheel end Follow detailed

play (detailed instructions at
instructions at Section 7.0 and 8.0
Section 7.0 and 8.0
for appropriate
wheel & axle assy.
drawings)
Vehicle tracking to Misalignment Check Alignment Adjust Alignment

one side, wandering (see Sections 4.6)
Overload or load Visually inspect, Unload and/or

imbalance scale vehicle redistribute load
Un-Even Rail Wheel Weigh Vehicle and Adjust Load

Load/ Vehicle Load Check Rail Wheel Distribution and Re-
Load set Rail Wheel Load
Excessive Wheel Check Alignment and Adjust Alignment,

Wear Wheel Wear Replace Worn
Wheels
Insufficient traction Rail Wheel Load set See Section 4.6 Set Rail Wheel Load
or braking too low
Tires worn Inspect Tires Replace tires
Table 3.4 Troubleshooting On-Track Problems

3.5 DERAILMENT
The following are instructions for derailment inspection recommended by Diversified Metal
Fabricators. In some circumstances, government or corporate regulations may require
additional inspections be performed. Please ensure that you are aware of any inspection
requirements that pertain to your Railgear and that you abide by all local and national laws
regarding Railgear maintenance and safety.
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 rail wheels to ensure that tread and flange are not severely damaged.
 Spin all 4 rail wheels, noting any bearing noise, resistance, and end play.
Any items noted should be repaired using Section 4.0 and 5.0, 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 long arms, pivot arms, and links, to ensure they are not bent, cracked, or
broken.
 Inspect and test rail brake system (see Sections 3.1.2 and 5.2).
 Ensure spring brackets are securely fastened, and are not bent, cracked or broken.
 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 should be performed. See Sections 4.6.
 Wheels should be removed and the bore, bearing, races, and insulation (if applicable)
should be inspected for any damage. For further wheel details, see Section 7.0 and 8.0
for appropriate wheel & axle assembly drawings.
 Ensure axle threads are not stripped or damaged.
Any items noted should be repaired using Section 4.0, to ensure they are repaired to initial
install standards.
Please contact DMF for any assistance you may require.

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 Welding Information ............................................................................................... 4-3
4.1.5 Bolt Torque Specifications ....................................................................................... 4-3
4.2 INITIAL INSTRUCTIONS ................................................................................ 4-5
4.2.1 Work Area ............................................................................................................ 4-5
4.2.2 Truck Condition ..................................................................................................... 4-5
4.2.3 Front and Rear Installation Rails ............................................................................... 4-5
4.3 HYDRAULIC SYSTEM ...................................................................................... 4-7
4.3.1 Using Hydraulic Power Unit Provided by DMF .............................................................. 4-7
4.3.2 Hydraulic System for Multiple Uses, Railgear and other application(s) ............................ 4-7
4.4 INSTALLATION OF REAR RAILGEAR ............................................................... 4-8
4.4.1 General Information ............................................................................................... 4-8
4.4.2 Diagram of Key Components ................................................................................... 4-9
4.4.3 Location of Rear Railgear ........................................................................................ 4-9
4.4.4 Location and Clearance of Railgear ......................................................................... 4-10
4.4.5 Shimming and Temporarily Spacing Rear Bracket ..................................................... 4-12
4.4.6 Square Rear Railgear with Truck Axle ...................................................................... 4-12
4.4.7 Temporarily Securing Rear Bracket ......................................................................... 4-13
4.4.8 Mounting Plate Installation .................................................................................... 4-13
4.4.9 Welding of Spacer ................................................................................................ 4-14
4.4.10 Final Rear Railgear Alignment and Weight Settings ................................................... 4-14
4.5 INSTALLATION OF FRONT RAILGEAR ........................................................... 4-16
4.5.1 General Information ............................................................................................. 4-16
4.5.2 Ford 4/550 Installation ......................................................................................... 4-16
4.5.3 Dodge/Sterling 45/5500 Installation ....................................................................... 4-20
4.5.4 GM 4/5500 Installation ......................................................................................... 4-24
4.6 OVERALL ALIGNMENT PROCEDURE .............................................................. 4-30
4.7 RAIL TEST .................................................................................................... 4-32
4.8 FINAL WELD-OUT ......................................................................................... 4-32
4.9 INSTALL DECALS .......................................................................................... 4-32
4.10 INSTALL VELCRO STEERING WHEEL LOCK ................................................... 4-35
4.11 INSTALLATION REVIEW CHECKLIST ............................................................ 4-36

4.1 PRE-INSTALL
NOTE:
The proper installation of this equipment is solely the responsibility of you, the installer.
When in doubt, contact DMF for assistance.
NOTE:
There are currently 4 approved chassis for our 1019 series of Railgear. While very
similar in some aspects, there are variances between the components and installation
procedures of these chassis-specific assemblies. To address this, we have established
this manual in a format giving general instructions that apply to all chassis followed by
specific instructions regarding each unique variation. Where necessary, notes will be
provided to ensure clarity regarding which chassis is applicable. Please locate and
become familiar with the sections specific to your application.
NOTE:
During Railgear installation, there are 3 different alignments - front Railgear to truck
frame, rear Railgear to truck frame, and a final procedure that aligns both sets of
Railgear to each other.
4.1.1 Safety Statements

 Always block up gear before getting underneath.
 Always use jack stands when jacking up vehicle.
 Use personal protective equipment and clothing.
4.1.2 Installation Order
This manual presents the installation information in the order that we find to work best. Your
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
Aside from general shop tools and safety equipment the following tools will be required:
 Arc or MIG Welder
 Surge Protector (Protects ECM from damage during welding)
 Cutting Torch
 Hand Grinder
 Frame Drill
 Air Saw
 Angle Finder
 Test Rail – See Section 4.2.3
 Shims for weight setting (ASTM A36 3” wide x 10" long)
Additionally the following tools are recommended:

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

4.1.4 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
4.1.5 Bolt Torque Specifications

See following page for recommended torque specifications.

4.2 INITIAL INSTRUCTIONS

4.2.1 Work Area
The area in which the Railgear installation is to occur should meet minimum requirements in
order to facilitate the process and provide adequate conditions in which the work can be
completed safely, accurately and in a timely manner.
 Floor - The floor should be level in order to provide good measurements required to check
the alignment of the Railgear.
 Lighting - The work area should be adequately lighted.
 Space - There should be enough space to maneuver the Railgear components into position
and to safely work around other equipment.
4.2.2 Truck Condition

Before installation, the truck should be checked in some important areas.
 Tires - The tire pressure should be checked for the manufacturer’s recommended inflation
and for consistent pressure readings from all the tires. This will ensure correct traction of
the tires on the rail. Also the condition of the rear tires needs to be determined. If the rear
tires are worn, they should be replaced.
 Alignment - Rear truck axle must be square with truck frame. DMF recommends that a
reputable alignment shop check this. 0-degree thrust angle (which may be different than
the factory specification) is required for proper Railgear operation.
 Frame & Suspension - On a new truck, these should be in good condition. On a used truck,
the frame should be inspected to ensure that it has not been damaged or bent. The
suspension bushings should also be examined for excessive wear and replaced if necessary.
If any problems in these areas are not corrected, it will cause difficulties aligning and
operating the Railgear.
 Transverse Torque Rods - On vehicles that will regularly experience high center of gravity
loads on rail (e.g. spray trucks, material loaders), it is advisable to install rear tandem
control rods to limit transverse axle displacement. This is also necessary on long wheelbase
vehicles to prevent front tandem walking off in curves.
4.2.3 Front and Rear Installation Rails

In order to install the Railgear to get proper tire traction on the rail, it is necessary that
standard gauge rails or Installation Rails be fabricated from 3” square tubing per Figure 4.2.3.
Drive the truck into the work area (pulling forward and back several times to align the axles)
and up onto the Rear Installation Rails. The rear inside tires should be on the rails with the rear
outside tires off the floor. The Front Installation Rails are not needed at this point.
NOTE:
Before proceeding, be certain that the front truck tires are chocked & the parking brake
is set.
NOTE:
Inside-to-Inside measurement of 56-1/2” is the standard gauge for the United States. If
your equipment is to be operated on any other gauge, adjust measurements
accordingly.

Figure 4.2.3 Installation Rails

4.3 HYDRAULIC SYSTEM

For Hydraulic System drawings, maintenance and repair information, please see Section 6.0.
Once your new Railgear is installed, if your vehicle is going to have multiple applications for the
hydraulic system, please proceed to Section 4.3.2 for instructions on installing a diverter valve.
4.3.1 Using Hydraulic Power Unit Provided by DMF

DMF typically provides an electric over hydraulic power unit (Monarch M-304) to power the
Railgear. The unit includes a pump, motor and reservoir. This unit can be located in the truck
body, under the cab, or elsewhere as required. The unit should be protected from road spray
and moisture. This unit operates on Dexron III.
4.3.2 Hydraulic System for Multiple Uses, Railgear and other application(s)
DMF RW-1019 Railgear can be integrated with other hydraulic equipment through the use of a
diverter valve. RW-1019 requires 1.25gpm at 2,000psi. A suitable relief and reservoir (3gal
min) must be provided. Please contact DMF for assistance in integrating Railgear with other
hydraulic equipment. Due to RW-1019's use of hydraulic Railgear brakes, many customers
avoid the extra complications of integrating by installing the provided hydraulic power unit
(above) in parallel.
****WARNING****
Railgear control manifold has pressure reliefs and the hydraulic working pressure of the
system is 2,000 psi. The front brake relief should be set to 1,700 psi. The rear brake
relief should be set to 700 psi and all other parts supplied by DMF are rated to 2500 psi.
Care must be exercised that the relief in any of the valves is not inadvertently exceeded.
It is possible for a relief to be adjusted much higher than its valve can withstand. To
ensure correct system pressure, check with a gauge.
See Section 6.0 for hydraulic system drawings.

4.4 INSTALLATION OF REAR RAILGEAR
NOTE:
Only use GRADE 5 bolts when attaching rear bracket on the truck frame. The rear
bracket should break away from the truck frame in an accident otherwise it will damage
your truck frame.
4.4.1 General Information

There are several items to note before you begin the installation of the rear Railgear:
 Before you begin Railgear installation, please read installation instructions for the
options you have ordered. Some options may affect the Railgear installation process.
 It is important to note that there is a difference between “shims” and “spacers”. Shims
are vertical fillers, used to fill in the gaps between the truck frame and rear mounting
bracket side plates. Spacers are solid steel pieces varying in thickness, used between
the rear mounting bracket and the bottom of the truck frame to achieve proper weight
settings between the truck tires and rail wheels while on rail.
 Spacers used in adjusting the height of the rear bracket must be solid steel pieces
because they will experience the full structural load seen by the rear frame.
 When setting the height of the rear bracket using spacers, you must be within the range
of ½” minimum to 3” of spacers maximum. If you are outside of this range it may be
necessary to change out your links. See Section 7.3 for different link measurements
and contact DMF for final consultation before ordering a different set of links. DMF will
not be responsible if the links are changed from the initial order without consulting with
DMF.
 Before permanently affixing your rear bracket to the truck frame (including welding or
drilling holes), be aware that during the locating, shimming (if necessary), spacing,
squaring, and weight setting procedures, your rear bracket will be making slight
movements during each of these steps. So you will want to only TEMPORARILY secure
Railgear using clamps, chains, fork lift, etc. after each procedure.
 It is important that the truck tire pressure (especially the rear tires) be checked and
brought to the tire manufacturer’s intended pressure for a given load. Reference your
tire manufacturer’s load rating and inflation chart. (Inflating tires to their max side wall
pressure may result in drastically reduced contact with the rail if under-loaded.)
 If the Railgear is being mounted behind an aft fuel tank, the frame may require
extension. (Applies to the Ford F4/550 & Dodge 45/5500)
 The rear Railgear drops straight down, but it can articulate from side-to-side to allow
alignment of the vehicle with the rail. It is important that nothing encroach upon this
space (e.g., outriggers, lift-gates, and body tie-down bolts).

4.4.2 Diagram of Key Components

Figure 4.4.2 shows the key components and terminology that will be used throughout the
installation procedure.
Figure 4.4.2 Diagram of Key Components
4.4.3 Location of Rear Railgear

Position the rear Railgear as close to the rear tires as practical (allowing clearance for mud
flaps). Table 4.4.3 gives standard location and clearance guidelines for the rear Railgear and
these dimensions are shown in Section 4.4.4. Generally, leave a minimum of 2” clearance to
any tire, spring, or suspension components.
Rear Axle to Rear Railgear Center Midship Aft Fuel Transit

to Center Distances Fuel* Bracket
Ford F4/550 40.5 +/- 1” 49.3 +/- 1” 33.3 +/- 1”
Dodge/Sterling 45/5500 40.0 +/- 1” 56 +/- 1” N/A
GM 45/5500 39.0 +/- 1” N/A N/A
Table 4.4.3 Location of Rear Railgear
*DMF recommends the mid-mount fuel option to improve on rail performance by minimizing the
distance between the Railgear and rear axle.

4.4.4 Location and Clearance of Railgear

The rear Railgear drops straight down, but it can articulate from side-to-side to allow alignment
of the vehicle with the rail. It is important that nothing encroach upon this space (e.g.,
outriggers, lift-gates, and body tie-down bolts). Refer to drawing on the next page.

4.4.5 Shimming and Temporarily Spacing Rear Bracket

Once Railgear is correctly located on rear frame, as above, if more than a 1/16” gap exists
between the rear Railgear bracket side plate and the side of the truck frame, install equal
amount of shims on each side to fill the gap, thus keeping the Railgear bracket centered. Note
that DMF provides shims of different thicknesses, and it is important that the same amount of
shim measurement is achieved on both sides.
With the rear bracket correctly located against bottom of frame rail and centered, there are two
differing methods of setting a preliminary weight setting:
1. The first method is to measure from top of rear bracket plate to floor, and adjust bracket
with temporary spacers, as shown in Table 4.4.5. This should provide a good starting
point for final weight setting.
23” 24” 25” 26” 27” 28” 29” 30”

Xtra Short Links 0” 1” 2” 3”
Short Links 0” 1” 2” 3”
Long Links 0” 1” 2” 3”
Table 4.4.5 Shimming Chart
2. The second method is to insert the minimum (1/2”) or maximum (3”) of spacers, and
then during the final weight setting, add or remove spacers as appropriate until optimal
weight setting is achieved.
Once spacers are positioned, temporarily clamp, chain, or otherwise secure rear Railgear to
truck frame. Keep in mind that spacers and rear bracket may have to be adjusted for final
weight setting and squaring/aligning with the truck axle.
4.4.6 Square Rear Railgear with Truck Axle

The Rear Railgear needs to be made absolutely square with the rear truck axle. Four
measurements (shown in Figure 4.4.6) need to be taken to ensure this requirement:
(1) The distance from the truck axle to the Rear Railgear Axle at each end. In Figure 4.4.6,
distance “A” must be equal to “B” (within 1/8”). This is an important alignment check.
(2) The diagonal from the truck axle to the opposite Rear Rail Wheel. In Figure 4.4.6
distance “C” must be equal to “D” (within 1/4”).
Figure 4.4.6 Squaring Rear Railgear

NOTE:
Although the previous mounting conditions and alignment may be met, be certain that
enough room exists between the Rear Railgear and other equipment. In general, this
should include a 2” clearance around the Railgear (more clearance will be needed if
Remote Pin-offs are installed). Also ensure that there is clearance to remove the Pin-
Offs from their holes.
4.4.7 Temporarily Securing Rear Bracket

Now that the rear bracket is correctly centered, vertically positioned, and aligned, measure 1”
up from the bottom of the slot in the rear bracket slide plate, and drill your first 5/8” hole
through the shims (if applicable) and truck frame. Align this first hole with the 4-hole mounting
plate, ensure that the mounting plate is level, and then drill the additional 3 holes. Once all 4
holes are drilled, install four 5/8-11 Grade-5 bolts and secure them with the appropriate
washers and nylon lock nuts. Repeat this mounting bracket procedure for the other side of the
Railgear. Temporarily tack weld the mounting plate to the rear frame bracket. If re-
adjustment is later needed, the welds may be ground off, and the rear frame bracket may be
slid up or down by loosening the bolts in the slots. Also, temporarily tack the spacers into
place, so that if further adjustment is necessary, the welds can easily be ground off and spacers
added/removed as necessary.
NOTE:
Only use Grade 5 bolts on rear Railgear.
4.4.8 Mounting Plate Installation
Figure 4.4.8 Mounting Plate Installation

4.4.9 Welding of Spacer
Figure 4.4.9 Welding of Spacer
4.4.10 Final Rear Railgear Alignment and Weight Settings

See drawing M1019105 on the following page for more information. Rear Railgear alignment
and weight settings can only be performed after the front Railgear is installed. The procedures
for these final steps can be found in Section 4.6.

FOR SPECIFIC PART NUMBERS REFERENCE DRAWING #M1019104
NOTE #1: GRADE 5 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME
2" WELD @ CENTER
TOP AND BOTTOM
(AFTER FINAL ALIGNMENT AND NOTE #2: AT FINAL INSTALLATION:
WEIGHT SETTING) (AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT & WEIGHT SETTING HAVE BEEN COMPLETED)
FOR ALL STRUCTURAL WELDS, EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE SHOULD BE USED.
WARNING: DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL WHEELS. THIS WILL
CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS & LEAD TO PREMATURE BEARING FAILURE.
• ENSURE SPACERS ARE PRESSED FULLY AGAINST SIDE BRACKET (OR SHIMS) & ALIGNED WITH THE
REAR BRACKET (WELD AS INDICATED IN THE DETAIL ABOVE)
• IF MULTIPLE SPACERS ARE USED, ENSURE THAT THEY ARE WELDED TO ONE ANOTHER (WELD AS
INDICATED IN DETAIL ABOVE)
• ENSURE BOLTS ARE TIGHTENED TO TORGUE SPECS: 154 LB-FT
2" APR. • WELD 4-HOLE MOUNTING PLATE TO REAR BRACKET SIDE PLATE AS SHOWN IN THE DETAIL ABOVE
NOT PROVIDED:
(4X) 5/8-11X2-1/4" BOLTS (GR5)
REARMOST SPRING (8X) 5/8" FLAT WASHERS
HANGER BRACKET (4X) 5/8"-11 NYLOCK NUTS
(FORD SHOWN) TORQUE TO 154 LB-FT
IF SHIMMING IS REQ'D,
BRACKET MUST
BE EQUAL ON BOTH
SIDES
SPACERS: MIN. 1/2" - MAX. 3"

IF OUTSIDE THIS RANGE AT FINAL
INSTALLATION CONTACT DMF.
FORD/DODGE ONLY
PRIOR TO ATTACHING REAR FRAME BRACKET:
TRIM INTERIOR PROTRUSION AT FUEL PASSTHROUGH
AND PATCH HOLE WITH COMPARABLE THICKNESS
MATERIAL.
TACK WELDS
APPLIES TO ALL CURRENTLY

APPROVED CHASSIS
B
ENSURE ALL SPACERS ARE FIRMLY AGAINST SIDE A - - -
BRACKET & ALIGNED WITH THE REAR MOUNTING BRACKET. REV DATE DESCRIPTION BY APP
FULLY WELD SPACER TO MOUNTING BRACKET AS SHOWN TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
(IF MULTIPLE SPACERS ARE USED, SPACERS NEED TO BE FRAC, MACH: ± 1/32" MANUAL, REAR ASSY INSTALL, RW-1019
-
WELDED TO ONE ANOTHER AT THE REAR AND TACK WELDED FRAC, OTHER:
.X
± 1/16"
± .063
ON THE SIDES) .XX

.XXX
DRILL SIZES:
± .030
± .005
+ .015
ANGULAR: ± 1°
SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
NEH 4/7/11 M1019105 #
4.5 INSTALLATION OF FRONT RAILGEAR

4.5.1 General Information
There are several items to note before you begin the installation of the front Railgear:
 The Railgear unit that we have shipped to you has been designed for your specific truck.
 Installation instructions vary depending on chassis type. Prior to beginning front
installation, please locate and become familiar with the section specific to your
application.
 Check for sufficient clearances to prevent interference with Railgear and other parts of
the truck (i.e. Frame, steering boxes, shocks, oil filters, etc.) See further details below
for more clearance information.
 In normal applications, mount the front valve plate assembly between the frame
extensions (with the energy valve on the underside and the handle facing forward) and
weld in place. If this is not possible, mount valve assembly in the most appropriate and
easily accessible location.
4.5.2 Ford 4/550 Installation

Figure 4.5.2.A shows the individual parts of the installed front Railgear. Please familiarize
yourself with these item descriptions as they will be used throughout this installation manual.
TRUCK
FRAME
1 TRUCK
TIRE
2 TRUCK
AXLE Item Description
3 1 Frame Bracket
2 Front Mounting Pin
3 Long Arm
4 Front Cylinder
4 9 10 11 5 Pivot Arm
8 6 Railsweep (If Equipped)
5 7 7 Cobra Brake (If Equipped)
8 Rear Mounting Pin
9 Swing Link
6
10 Axle Bracket
M1019134
11 Suspension Radius Arm
Figure 4.5.2.A 2008- 2016 Ford 45/550 Front Railgear - Key Components
Refer to drawing M1019102 on the following page for more details.

FOR INDIVIDUAL PARTS LIST OR PARTS ORDERING, REFER TO DRAWING #M1019101 NOTE #1: GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME.
NOTE #2: AT FINAL INSTALLATION: (AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT & WEIGHT
SETTING HAVE BEEN COMPLETED) FOR ALL STRUCTURAL WELDS, EITHER LOW HYDROGEN ROD OR DUAL
SHIELD MIG WIRE SHOULD BE USED.
CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS LEAD TO PRE-MATURE BEARING FAILURE
RAILGEAR ALIGNMENT ADJUSTMENT:

IF SLIGHT ADJUSTMENTS NEEDED:
- ADD SHIM STOCK TO ADJUST ALIGNMENT
- 1/4" MAX. ALLOWABLE, CONTACT DMF IF OUTSIDE MAX. RANGE
- SHIMS SHOULD BE PLACED ON BOTH PIVOT ARMS
FOR A GIVEN SIDE OF THE TRUCK
- ONCE PROPER ALIGNMENT IS ACHIEVED,COMPLETELY
WELD ALL SHIMS IN PLACE.
NOTE: BEFORE INSTALLING AXLE BRACKETS:

RAISE VEHICLE AND SUPPORT WITH JACKSTANDS,
REMOVE FRONT WHEELS AND TIRES
NOTE: WHEN INSTALLING AXLE BRACKETS:

DISCONNECT LOWER SHOCK MOUNT AND SUPPORT
RADIUS ARM WITH A JACKSTAND OR OTHER MEANS,
REMOVE FACTORY HARDWARE AND ATTACH AXLE
NOT PROVIDED: BRACKETS USING PROVIDED HARDWARE (KIT#11342)
1/2-13 FLAT WASHERS
12-13 NYLOCK NUT
1/2-13 X 2" BOLT (GR8) KIT #:11342
4X M18 FLAT WASHERS,
4X M18X2.5X140mm LONG
4X M18X2.5 LOCK NUT
NOT PROVIDED:
5/8-11 BOLTS (GR8)
5/8-11 FLAT WASHERS
5/8-11 NYLOCK NUTS
*MUST BE WELDED IN RAIL POSITION: THE INBOARD FORD F-4/550 FRONT INSTALLATION
SIDE OF THE OUTER PIVOT ARM (FOR BOTH
PASSENGER & DRIVER SIDE) MUST BE FULLY B
WELDED (COMPLETE STRUCTURAL WELDS) A - - -
ALL THE WAY AROUND, ONCE FINAL ALIGNMENT REV
TOLERANCES:
DATE DESCRIPTION BY APP
TITLE:
& WEIGHTS ARE SET. (UNLESS SPECIFIED)
FRAC, MACH: ± 1/32" MANUAL, '08 F-550 FRONT ASSY INSTALL, RW-1019
FRAC, OTHER: ± 1/16" -
.X ± .063
DRIVER'S SIDE VIEW OF DRIVER'S SIDE .XXX
DRILL SIZES:
ANGULAR:
± .005
+ .015
± 1°
ASSEMBLY SURF FINISH:
THREADS:
125 MICRO
2A AND 2B NEH 4/6/11 M1019102 #
Mounting Axle Brackets:

1. Raise vehicle and support with jack stands
2. Remove front wheels and tires
3. Disconnect lower shock mount to allow clearance
4. Support the radius arm with a jack stand or other means
5. Remove the radius arm mounting bolts and nuts. Note the upper passenger side nut is
tack welded to arm. Grind to remove.
6. Install axle brackets with provided M18 nuts and bolts. Be sure that the axle bracket
with a pin stop is to the outboard side of the vehicle.
7. Re-attach lower shock mount
8. Re-install wheels and tires
9. Remove jack stands and lower truck
Mounting Frame Brackets:

1. Remove front bumper. Refer to chassis manufacturer’s manual.
2. Bolt brackets in position through the existing slot in the sidewall of the frame rail.
3. Leave fasteners loose to allow movement during alignment procedures.
NOTE:
Do not match drill vertical holes in bottom of frame brackets at this point. These
fasteners will be installed after a rough overall alignment has been completed. This
allows for the necessary adjustment to achieve proper alignment.
Install Railgear:
1. Slide Railgear under truck.
2. Attach front of long arms to the frame brackets using the provided front pins.
3. Attach rear of long arms to the axle brackets using the provided rear pins.
Check Clearance:
1. Check for truck frame, spring, steering gear or other truck component interference with
the Railgear, particularly the long arms. See CLEARANCE NOTE and Figure 4.5.2.B.
2. Repeat process on passenger side.
Truck
Frame
CHECK THIS
AREA FOR
INTERFERENCE Axle
Tire
FORD F-4/550
Figure 4.5.2.B Ford F-4/550 Clearance Envelope

CLEARANCE NOTES
Proper clearances will allow the Railgear to move up and down with the truck front
suspension. As the truck tire hits bumps in the road, the truck spring allows the front
axle to move upward (see above figure relevant to your chassis). Since the Railgear is
attached to the spring just in front of the axle, sufficient clearance must be allowed to
prevent interference with other parts on the truck (i.e. frame, steering linkages or
boxes, shocks, oil filters, spring hangers, hydraulic lines, etc.). The front mounting pin
does not move in relation to the vehicle frame because it is fastened through the frame
extension (or directly to the truck frame). As the front mounting pin does not move and
the rear mounting pin (at the axle) does, the Railgear effectively rotates about the front
mounting pin. Therefore, the part of the Railgear near the rear mounting pin moves
more than the part near the front mounting pin, and attention needs to be paid to the
possible clearance problems that can be caused by this movement.
Route Hydraulic lines:

1. Route Railgear hydraulic lines following the schematic in Section 6.0
2. Route brake hydraulic lines following the schematic in Section 6.0.
Align Front Railgear:

1. Ensure that the long arms are parallel with each other and the truck frame. The outside
long arms should be the same distance apart at the rear mounting pin as they are at the
front mounting pin. This prevents the mechanism from binding during highway/rail
operation of the Railgear. Also, the distance from the outboard side of the frame rail to
the outside face of the long arm should be the same on each side.
2. Ensure that the front mounting pins are the same distance forward. Measure the frame
brackets back to a common point on the chassis. These dimensions should not vary
more than 1/16”.
3. Check placement of axle brackets. As the axle brackets are attached directly to a
common point on the suspension, these components should be in the proper location.
Verify that this is the case and that the axle brackets are parallel to each other. If not,
loosen the mounting bolts and correct the misalignment.
4. Secure frame brackets. After performing the above alignment checks and ensuring
there are sufficient clearances for the Railgear, you may now match drill the vertical
holes in the front frame brackets and fully secure the brackets to the frame.
5. Align axle and orient brakes. Raise the front rail wheels just above the floor, enough to
slide the front installation rails into place under the rail wheels. Because the Railgear
axle assembly is not fixed to the pivot arms (outside pivot arms will be completely
welded to axle on inboard side at final weld-out), the rail wheels need to be centered. To
center, measure the distance from the inside of the rail wheel to the truck frame. If the
measurements are off, slide the rail wheels and axle assembly to one side (the axle tube
will slide through the holes in the pivot arms).
6. The cobra brakes need to be rotated so that they are oriented in the correct position
(see Figure 4.5.2.C).

5.0°
FRONT OF VEHICLE
M1019136
Figure 4.5.2.C Front Brake Orientation
7. With the axle tubes now centered and brake configuration determined, the axle tubes
should be temporarily tacked to the inboard side of the outside pivot arm. At final
adjustment, the tacks can be ground off and the axle re-adjusted if necessary. The
inside pivot arms should not be welded to the axle tube to facilitate ease of disassembly
for repair or future maintenance. The front Railgear is ready to be lowered on the
installation rails. As the Railgear is lowered, check the clearance from the truck tire to
the rail wheels. If there is any interference, stop lowering the wheels, and retrace the
installation steps to fix the problem. When the Railgear is completely lowered, the front
truck tires should be approximately 2 inches above the installation rails. If Railgear will
not lift the truck, check that the cylinders are not cross plumbed, that the system
pressure relief valve (if present) is set high enough and that the pressure relief on the
front Railgear valve is set high enough. As a final review, recheck the center alignment
of the rail wheels to the truck frame. If it is off, break the tacks between the outside
pivot arms and axle tube and slide the axle tube to the correct position and re-tack in
place.
4.5.3 Dodge/Sterling 45/5500 Installation

Refer to drawing M101119 on the next page for additional installation guidelines. Note that
2013 and newer Ram 45/5500 models with a diesel engine will require slightly different frame
mounting components than other Ram models. See Section 8.0 for additional parts details.

FOR SPECIFIC PART NUMBERS REFER TO DRAWING: M1019120 NOTE #1: GRADE 8 BOLTS MUST BE USED WHEN MOUNTING GEAR TO TRUCK FRAME.
NOTE #2: AT FINAL INSTALLATION: (AFTER OVERALL FRONT TO BACK RAILGEAR ALIGNMENT & WEIGHT
SETTING HAVE BEEN COMPLETED) FOR ALL STRUCTURAL WELDS, EITHER LOW HYDROGEN ROD OR DUAL
SHIELD MIG WIRE SHOULD BE USED.
CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS LEAD TO PRE-MATURE BEARING FAILURE
RAILGEAR ALIGNMENT ADJUSTMENT:

IF SLIGHT ADJUSTMENTS NEEDED:
- ADD SHIM STOCK TO ADJUST ALIGNMENT
- 1/4" MAX. ALLOWABLE, CONTACT DMF IF OUTSIDE MAX. RANGE
- SHIMS SHOULD BE PLACED ON BOTH PIVOT ARMS
FOR A GIVEN SIDE OF THE TRUCK
- ONCE PROPER ALIGNMENT IS ACHIEVED,COMPLETELY
WELD ALL SHIMS IN PLACE.
NOTE:
• ALIGN FORMED BRACKET WITH WELDMENT ON AXLE
• MATCH DRILL HOLES FOR MOUNTING
• BOLT BRACKET IN PLACE AND POSITION CROSSTUBE
AND BRACKET SIDE PLATES
• AFTER FINAL ALIGNMENT, FULLY WELD BRACKET SIDE PLATES
AND CROSSTUBE TO AXLE BRACKET
NOT SUPPLIED:
5/8-11 X 1-1/2 GRADE 8 BOLTS
5/8 FLAT WASHERS
5/8-11 NYLOCK NUTS
NOTE: AFTER FINAL ALIGNMENT AND

WEIGHTS ARE SET, FULLY WELD FRAME
BRACKETS TO CROSSTUBE NOT PROVIDED:
3/4-10 GRADE 8 BOLTS
3/4 FLAT WASHERS
3/4-10 NYLOCK NUTS
NOTE: BEFORE INSTALLING AXLE BRACKETS:

RAISE VEHICLE AND SUPPORT WITH JACKSTANDS,
REMOVE FRONT WHEELS AND TIRES
*MUST BE WELDED IN RAIL POSITION: THE INBOARD

DODGE/STERLING 45/5500 FRONT
SIDE OF THE OUTER PIVOT ARM (FOR BOTH INSTALLATION
PASSENGER & DRIVER SIDE) MUST BE FULLY
B
WELDED (COMPLETE STRUCTURAL WELDS)
A - - -
ALL THE WAY AROUND, ONCE FINAL ALIGNMENT REV DATE DESCRIPTION BY APP
& WEIGHTS ARE SET. TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
MANUAL, '08 DODGE/STER 4/5500, FRONT ASSY
FRAC, MACH: ± 1/32"
- INSTALL, RW-1019
DRIVER'S SIDE VIEW OF DRIVER'S SIDE FRAC, OTHER:
.X
± 1/16"
± .063
ASSEMBLY .XXX
DRILL SIZES:
± .005
+ .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 4/27/11 M1019119 #
TRUCK
FRAME
ITEM DESCRIPTION
1 FRONT MOUNTING PIN
1 2 FRAME BRACKET
TRUCK 3 LONG ARM
2 TIRE
TRUCK 4 FRONT CYLINDER
AXLE
5 PIVOT ARM
3
6 RAILSWEEP (IF EQUIPPED)
7 COBRA BRAKE (IF EQUIPPED)
4 8 REAR MOUNTING PIN
9 SWING LINK
10 11 10 SWING LINK PIN
5 7 8 9
11 AXLE BRACKET
M1019132
6
Figure 4.5.3.A ‘08- Present Dodge/Sterling 45/5500 Front Railgear - Key Components
Mounting Axle Brackets:

1. Raise vehicle and support with jack stands.
2. Remove front wheels and tires.
3. Align formed axle bracket with weldment on chassis axle.
4. Match drill holes through axle bracket and bolt in place.
5. Position cross tube and bracket side plates as shown on drawing. Note, these will be
welded to the axle bracket after completion of final alignment.
Mounting Frame Brackets:

1. Remove front bumper (refer to chassis manufacturer’s manual).
2. Remove factory installed front tow eyes (if applicable).
3. Bolt frame brackets to rail as shown on drawing using existing holes in frame.
4. Install cross tube. Note, the cross tube will be welded in place after final alignment and
weight settings.
Install Railgear:
1. Slide Railgear under truck.
2. Attach front of long arms to the frame brackets using the provided front pins.
3. Attach rear of long arms to the axle brackets using the provided rear pins.
Check Clearance:

TRUCK
FRAME
TIRE
CHECK THIS AXLE
AREA FOR
INTERFERENCE
DODGE/STERLING 45/5500
Figure 4.5.3.B Dodge/Sterling 45/5500 Clearance Envelope
CLEARANCE NOTES

1. Route Railgear hydraulic lines following the schematic in Section 6.0.

2. Check placement of frame brackets. Measure the frame brackets back to a common
point on the chassis. These dimensions should not vary more than 1/16”. After
achieving this tolerance, snug the mounting bolts to hold the position of the brackets.
3. Check placement of axle brackets. As the axle brackets are attached directly to a
common point on the suspension, these components should be in the proper location.
Verify that this is the case and that the axle brackets are parallel to each other. If not,
loosen the mounting bolts and correct the misalignment.

4. Secure frame brackets. After performing the above alignment checks and ensuring
there are sufficient clearances for the Railgear, you may now tighten the frame bracket
mounting bolts.
slide the front installation rails into place under the rail wheels. Because the Railgear
axle assembly is not fixed to the pivot arms (outside pivot arms will be completely
welded to axle on inboard side at final weld-out), the rail wheels need to be centered. To
center, measure the distance from the inside of the rail wheel to the truck frame. If the
measurements are off, slide the rail wheels and axle assembly to one side (the axle tube
will slide through the holes in the pivot arms).
(see Figure 4.5.2.B).
should be temporarily tacked to the inboard side of the outside pivot arm (at final
adjustment, the tacks can be ground off and the axle re-adjusted if necessary). The
the rail wheels. If there is any interference, stop lowering the wheels, and retrace the
installation steps to fix the problem. When the Railgear is completely lowered, the front
front railgear valve is set high enough. As a final review, recheck the center alignment
place.
4.5.4 GM 4/5500 Installation

Refer to drawing M101103 on the next page for additional installation guidelines.

FOR SPECIFIC PART NUMBERS REFER TO DRAWING: M1019110
TRUCK FRAME RUBBER SPACER MUST BE
FRAME EXT.
DIRECTLY ON TOP OF LEAF
SPRING
22 1/2
9 3/4
INSTALL SHIMS HERE
MAX. ALLOWABLE 1/4"
CONTACT DMF IF
OUTSIDE MAX. RANGE
NOTE:SHIMS SHOULD
BE PLACED ON BOTH
PIVOT ARMS FOR A
GIVEN SIDE OF THE
TRUCK.
NOTE: DRAWING IS FOR ILLUSTRATIVE PURPOSES ONLY

DEPENDING ON OPTIONS YOUR PART MAY NOT BE
EXACTLY AS PICTURED
NOTE #1: GRADE 8 BOLTS MUST BE USED WHEN MOUNTING FRAME EXTENSIONS TO TRUCK FRAME
NOTE #2: AT FINAL INSTALLATION

• FOR ALL STRUCTURAL WELDS, EITHER LOW HYDROGEN ROD OR DUAL SHIELD MIG WIRE
SHOULD BE USED.
• WARNING: DO NOT ATTACH THE WELDING MACHINE GROUND CLAMP ONTO THE RAIL
WHEELS. THIS WILL CAUSE ARCING ACROSS THE BEARINGS INSIDE THE WHEELS & LEAD
TO PREMATURE BEARING FAILURE.
• MUST BE WELDED IN RAIL POSITION: THE INBOARD SIDE OF THE OUTER PIVOT ARM (FOR BOTH
PASSENGER & DRIVER SIDE) MUST BE FULLY WELDED (COMPLETE STRUCTURAL WELDS) ALL
THE WAY AROUND, ONCE FINAL ALIGNMENT & WEIGHTS ARE SET) MUST BE WELDED IN RAIL POSITION: THE INBOARD
SIDE OF THE OUTER PIVOT ARM (FOR BOTH
• FRONT CROSS TUBES MUST BE FULLY WELDED (COMPLETE STRUCTURAL WELDS) TO TRUCK
FRAME OR FRAME EXTENSIONS ALL THE WAY AROUND.
PASSENGER & DRIVERSIDE) MUST BE FULLY WELDED
(COMPLETE STRUCTURAL WELDS) ALL THE WAY AROUND,
GM/CHEVY 45/5500 FRONT
ONCE FINAL ALIGNMENT & WEIGHTS ARE SET. INSTALLATION
• IF SHIMS REQUIRED, RULLY WELD ALL SHIMS IN ALL LOCATIONS, IN PLACE, ONCE ALIGNMENT IS
ACHIEVED (IF MORE THAN ONE SHIM PER LOCATION, THEN ALL SHIMS USED AT LOCATION SHOULD B
BE WELDED TO ONE ANOTHER.) A - - -

TOLERANCES:
TITLE:
NOTE #3: (UNLESS SPECIFIED)
MANUAL, '08 C4/5500 FRONT ASSY INSTALL,
• ONCE SPRING BRACKET IS FINALLY SET, WHERE CLEARANCE ALLOWS, LEAVE 1" THREADED FRAC, MACH:
FRAC, OTHER:
.X
± 1/32"
± 1/16"
± .063
- RW-1019
ROD EXPOSED ABOVE NUT (2 THREADS MIN.) - SEE ABOVE ILLUSTRATION .XX
.XXX
± .030
± .005
DRILL SIZES: + .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 4/7/11 M1019103 #
Figure 4.5.4.A ‘02- 09 GM 45/5500 Front Railgear - Key Components
NOTE:
DMF front frame extensions are designed to support the Railgear only. It is the
installer’s responsibility to properly engineer brackets for rail racks, boom rests and etc.
Mounting spring bracket hangers:

1. Remove the truck’s front bumper.
2. Bolt the frame extensions to the truck frame. Make sure that the tilt of the cab’s hood
will clear the frame extensions. Trim the brackets and re-gusset them if necessary. All
truck frame extensions that are bolt-on brackets must use 5/8” Gr. 8 bolts, hardened
steel washers and Gr. 8 prevailing torque locknuts. All of the 5/8 Gr. 8 fasteners should
be tightened per the drawing in Section 4.1.5. Check that the frame extension tubes are
level front to rear and side to side with the frame.
3. Slide the front Railgear under the truck frame, positioning the spring bracket hangers as
close as possible to the front truck axle. Make sure at least half of the spacer is seated
on the leaf spring closest to the front truck axle. If the spacer is not at least half-
seated, move spring bracket hanger forward to next leaf spring.
4. Once positioned, place a floor jack under the outboard and inboard long arm, close to
the spring hanger on the driver’s side. Using the jack, raise the spring hanger up
toward the truck’s leaf springs. You will raise and lower the long arms until the rear
mounting pin is 9-3/4” (+/- ½”) from the floor. See Figure 4.5.4.A.
5. Once you achieve the desired height, insert 1”x2” flat bar spacers between spring
hanger and leaf spring, up to a maximum of 4”. If you need more than 4” of spacers, a
change of spring brackets may be required. See Section 8.0 for spring bracket
information. Contact DMF for assistance.
6. Once spacers are in place with spring bracket at the appropriate height, attach the
spring bracket to the truck spring using a rubber spacer (already supplied) directly on
top of the leaf springs, and then a 1" x 2" flat bar Spacer (already supplied) on top of
the rubber spacer and two 3/4"-10 hex nuts per stud. The top spacer has no effect on
the height of the Railgear and is only used for clamping purposes.
7. The nuts should be tightened down until the rubber spacer begins to deform from the
downward pressure. Caution: Do not over tighten.

1. Route Railgear hydraulic lines following the schematic in Section 6.0

Mounting Front Cross Tubes:

3. Ensure that both spring bracket hangers are properly installed before attempting to
install front cross tubes.
4. Connect hydraulic system to Railgear.
5. Disengage the front Railgear pin offs and set the steering tires straight ahead. The front
Railgear can now be actuated with the hydraulic system, which will cause the long arms
to be raised up to the frame. See Figure 4.5.4.A. The frame mounting bracket only
needs to be brought up to where it touches the frame extension or truck frame, not
raised all the way to lift the truck frame and raise the truck tires.
6. In order to install the front of the front Railgear at the correct height, the center of the
front mounting pins must be located at 22-1/2” (+/- ½”) from the ground (with the
truck tires on the ground) as shown in Figure 4.5.4. If required, space the cross tubes
down to obtain this 22-1/2” up to a maximum of 3” of spacers. Any spacers used
should be load bearing members (no thin wall tubing). If you need more than 3” of
shims, a change of cross tubes / mounting block may be required. See section 8.0 for
information. Contact DMF for assistance.
7. Once properly shimmed, the hydraulic system should already be properly positioned to
hold the shims in place until alignment can be completed.
Figure 4.5.4.B GM 45/5500 Clearance Envelope
CLEARANCE NOTES


2. Check placement of front cross tubes. Measure the frame brackets back to a common
point on the chassis. These dimensions should not vary more than 1/16”. After
achieving this tolerance, snug the mounting bolts to hold the position of the brackets.
3. Check placement of spring bracket. Measure the distance from each spring bracket (or
axle bracket) back to the truck axle. Since the forward position of the long arms has
been verified (Check #2), an off measurement here probably means the front truck axle
is misaligned and needs to be corrected.
4. Secure Front Cross Tubes. After performing the above alignment checks and ensuring
there are sufficient clearances for the Railgear, you may now tack the cross tubes to the
front frame extensions.
slide the front installation rails into place under the rail wheels. Because the railgear axle
assembly is not fixed to the pivot arms (outside pivot arms will be completely welded to
axle on inboard side at final weld-out), the rail wheels need to be centered. To center,
measure the distance from the inside of the rail wheel to the truck frame. If the
measurements are off, slide the rail wheels and axle assembly to one side. The axle
tube will slide through the holes in the pivot arms.
(see Figure 4.5.4.C).
5.0°
FRONT OF VEHICLE
M1019136
Figure 4.5.4.C Front Brake Orientation
should be temporarily tacked to the inboard side of the outside pivot arm (at final
adjustment, the tacks can be ground off and the axle re-adjusted if necessary). The
the rail wheels. (If there is any interference, stop lowering the wheels, and retrace the
installation steps to fix the problem.) When the Railgear is completely lowered, the front

front railgear valve is set high enough. As a final review, recheck the center alignment
place.
Completing Front Installation:

1. If the spring bracket location had to be adjusted, make sure that the hex nuts (two per
stud) on both spring brackets have been tightened down. Then with a torch, cut the
excess stud length on the spring brackets. If these studs are not trimmed down, they
may pose a clearance problem with other parts on the truck. See CLEARANCE NOTE and
Figure 4.5.4.B.
NOTE:
Remount the truck front bumper or use 8" standard channel welded onto the ends of
the Frame Extensions.

4.6 OVERALL ALIGNMENT PROCEDURE

With the front and rear Railgear both installed and each squared individually to the truck frame,
you must perform a final overall alignment of front to rear Railgear, and also adjust the weight
setting.
See drawing M1630115 on the next page for alignment and weight information. Once you have
completed the alignment procedure, return to Section 4.7 for continued installation instructions.

4.7 RAIL TEST

 Run vehicle forwards and backwards on rail.
 If available, run the vehicle through curves and switches.
 Verify alignment by observing the wear pattern on the wheel and the behavior of the
vehicle. If adjustment is required refer to section 4.6 Overall Alignment Procedure.
4.8 FINAL WELD-OUT

Front Railgear:
 Weld inboard side of outside pivot arm to axle tube all the way around.
 Fully weld, on all sides, front mounting blocks / cross tubes to truck frame.
 If shims were required, fully weld shims into place on all sides for each shim location.
Rear Railgear:
 Weld 4-hole mounting plate to rear frame bracket as shown in Section 4.4.8.
 Ensure all spacers are firmly against side bracket and aligned with the rear mounting
bracket, then fully weld spacer to mounting bracket as shown in Section 4.4.9.
 If multiple spacers are used, spacers must be fully welded to one another on the rear,
and tack welded on the sides, as shown in Section 4.4.9.
4.9 INSTALL DECALS

 Label the vehicle according to the diagram on the back of the decal sheet. See decal
drawings on the following pages.

4.10 INSTALL VELCRO STEERING WHEEL LOCK

The DMF steering wheel lock consists of two 2” wide adhesive backed “hook” strips and a 4”
wide piece of “loop” fabric. A piece of adhesive backed hook is placed on the steering wheel
column and a second piece placed on the top flat of the steering wheel hub. The 4” wide piece
of loop fabric can then be applied to bridge the gap between column and wheel preventing the
front tires from accidentally being turned while on the rail. However, in the event of an
emergency, the steering wheel can be forcibly turned and the Velcro fasteners will separate.
1. Clean the top of the steering column and wheel with rubbing alcohol and a clean cloth.
2. Allow the column and wheel to dry.
3. Remove the adhesive backing from the “hook” strips and apply them to the top of the
steering wheel hub and the column as close to the wheel-column gap as possible.
NOTE: Trim the strips to fit around obstructions such as hazard light switches.
4.10.A Steering Wheel Lock Installation
4. Allow the adhesive to cure for 24 hours prior to attaching the 4” loop fabric.
5. When putting the truck on the rail, position the 4” loop fabric to bridge the gap between
the hooks on both the column and wheel as shown below and press firmly.
4.10.B Steering Wheel Lock Installed
6. To remove the lock, pull on the ‘D’ ring and store the piece of Velcro fabric.

4.11 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.
 Rail test the truck to check for good traction and braking. A good industrial siding or some
authorized track time will be required. Check that rail wheels with brakes do not lock-up or
slide.
 Adjust the Railgear height as required.
 Re-check alignment of the rear Railgear to the rear axle.
 Weld the mounting plate to the rear frame bracket with two 2” welds (at the top center).
Welding the plates must be done; DO NOT forget to do it.
 Double check all welds and fasteners, and mounting cotter pins. Tie strap all hydraulic
hoses, air hoses, and electrical wires away from exhausts and moving parts. Ensure that all
hydraulic and air hoses have sufficient radius at bends.
 Top off the hydraulic oil in the tank.
 Verify grease installed at all grease fittings per Section 3.2.
 Touch-up the black acrylic enamel paint on the front and rear Railgear.
 Raise the Railgear (highway position) and install all optional retention systems.
 Apply the decal kit.
 Check tire pressures.
 Check front alignment per Sections 4.5.2, 4.5.3, or 4.5.4 as appropriate.
 Check rear alignment per Sections 4.4.6
 Check overall alignment measurements:
o Rear Truck Axle to Rear Railgear Axle (straight): A1 = A2 (within 1/8”)
o Rear Truck Axle to Rear Railgear Axle (diagonal): B1 = B2 (within 1/4”)
o Front Railgear to Rear Railgear (straight): C1 = C2 (within 1/8”)
o Front Railgear to Rear Railgear (diagonal): D1 = D2 (within 1/4”)
 Raise and lower Railgear and verify retention system operation at highway and rail positions
 Verify that all bodywork is replaced and secure.
 In a parking lot or open area, verify that the tires, rims or Railgear do not contact the
frame, suspension or other items.
 Inspect brake lines and ABS sensor lines to verify clearance from rim.
 Check for any rattles and vibration.

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 ................................................................................................. 5-4
5.2.1 Brake Adjustment ......................................................................................... 5-4
5.2.2 Brake Parts .................................................................................................. 5-4
5.3 REAR PIN-OFFS .............................................................................................. 5-7
5.4 FRONT PIN-OFFS ............................................................................................ 5-8

5.1 RAIL SWEEPS

5.1.1 Rail Sweep Adjustment
Installation and adjustment of rail sweeps is done with the Railgear in rail 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 bolted onto the axle.
 Axles without brakes: Weld-on rail sweeps are shipped loose and should be welded to
the axle by the installer.
Figure 5.1.1 Rail Sweep Orientation
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.

ITEM PART # QTY. DESCRIPTION ITEM PART # DESCRIPTION
A 12482 1 RAILSWEEP ASSEMBLY FRONT RH 1 12470 RAILSWEEP MOUNTING BRACKET FRONT LH (W/BRAKES)
B 12483 1 RAILSWEEP ASSEMBLY FRONT LH 2 12471 RAILSWEEP MOUNTING BRACKET FRONT RH (W/BRAKES)
C 12476 1 RAILSWEEP ASSEMBLY FRONT AXLE SET 3 818503 RAILSWEEP RUBBER PAD
D 10037 1 RAILSWEEP ASSEMBLY (SINGLE) (WELD ON) 4 12475 MOUNTING BOLTS (HHCS3/8-16X1)
E 10053 1 RAILSWEEP ASSEMBLY AXLE SET (WELD ON) 5 818508 3/8" FLAT WASHER
F 12491 1 RAILSWEEP ASSEMBLY REAR AXLE SET (BOLT ON) 6 818520 3/8 LOCK WASHER
RAILSWEEP ASSEMBLY VARIATIONS 7 106243 3/8-16 HEX HEAD NUT
8 818626 RAILSWEEP MOUNGTING BRACKET REAR LH (W/BRAKES)
D 9 818627 RAILSWEEP MOUNGTING BRACKET REAR RH (W/BRAKES)
10 10042 RAILSWEEP MOUNTING BRACKETS REAR EITHER SIDE (WELD ON)
10
E RAILSWEEP ASSY - WELD ON (USE W/O BRAKES)
A
2
1
9
F REAR RAILSWEEP ASSY - BOLT ON (USE W/BRAKES)
7
B
6 A - - -
3 REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
FRAC, MACH: ± 1/32" RAILSWEEP OPTIONS AND PARTS DIAGRAM,

-
5 FRAC, OTHER:
.X
± 1/16"
± .063
RW-1019
4 B .XX
.XXX
± .030
± .005
+ .015
DRILL SIZES:
ANGULAR: ± 1°
C FRONT RAILSWEEP ASSY - BOLT ON (USE W/ BRAKES) SURF FINISH:
THREADS:
125 MICRO
2A AND 2B NEH 4/29/11 M1019121 #
5.2 RAIL BRAKES
NOTE:
The rail wheel brake system is intended to assist the existing vehicle brakes when in the rail
mode. As the vehicle rear tires are in contact with the railhead, the primary braking effort is
derived from the rubber tires. Rail wheel brakes alone are insufficient to stop the vehicle in a
reasonable distance.
5.2.1 Brake Adjustment

It may be periodically necessary to adjust the rail brakes to compensate for pad and wheel
wear. See diagram below for brake adjustment procedures.
1/8" MIN. SHOE

TO ADJUST, REMOVE ROD END THICKNESS
PIN AND THREAD ADAPTER TO
DESIRED LENGTH, TIGHTEN
JAM NUT TO CYLINDER BODY,
REINSERT ROD END PIN
ADJUST TO 1/16"
(REPLACE SHOE IF UNABLE TO
ADJUST TO MAX. ALLOWED 1/4")
Figure 5.2.1 Rail Brake Adjustment
5.2.2 Brake Parts

 See diagrams on following pages for replacement brake actuation parts.
 See Section 6.0 for hydraulic and electrical brake control components.

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
COAT W/
TOLERANCES (UNLESS SPECIFIED):
TITLE:
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
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
DETAIL A: INTERNAL COMPONENTS

TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
HYDRAULIC BRAKE CYLINDER; RW-1019/1212
RW-1019
(FITTINGS #14 & #15 HIDDEN FOR CLARITY) FRAC, OTHER:
.X
± 1/16"
± .063
15
.XXX ± .005
DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
ANGULAR: ± 1°
THREADS: 2A AND 2B
MRV TSH 11/28/95 12710 K
ITEM PART # QTY DESCRIPTION ITEM PART # QTY DESCRIPTION
LEVER PIN-OFF 1 818785 1 REMOTE PINOFF WELDMENT 1 818577 1 REM.P/O CABLE ASSY.,41"w/HANDLE
DRIVER SIDE: 818890 PASSENGER SIDE: 818891 2 818766 1 RW-1630 CABLE REMOTE PINOFF PIN DETAIL, FRONT 2 818571 1 REM.P/O PLASTIC TEE HANDLE (MORSE)
1 3 818893 1 STOP BAR, 1019 LEVER PINOFF 3 818785 1 REMOTE PINOFF WELDMENT
4 818892 1 LEVER DETAIL, 1019 LEVER PINOFF 4 818766 1 REM.P/O PIN, FRONT (CABLE)(RW-1019)2-3/8"
5 82654 1 1/4" LOCK WASHER 5 818767 1 1019 PIN OFF STOP WASHER
6 11255 1 HHCS 1/4-20 UNC X 3/4" LONG
CABLE REMOTE PIN-OFF RETENTION SYSTEM
AVAILABLE ACROSS PRODUCT LINE
LEVER PIN-OFF RETENTION SYSTEM FOR RETRO-FIT OPTIONS CONTACT DMF
2 STANDARD ON FORD/DODGE/STERLING
FOR RETRO-FIT OPTIONS CONTACT DMF
3
5 6
5 4
6
5 3 4
2 1
5/8" NC HEX JAM NUT 7/16" NC HEX JAM NUT
5/8" INTERNAL TOOTH LOCK WASHER 7/16" FLAT WASHER
SEAL 7/16" LOCK WASHER 1/4" NC HEX JAM NUT
5/8" NC HEX END CAP 7/16" NC HEX END CAP

SEAL
7/16: NC HEX JAM NUT
7/16" INTERNAL TOOTH LOCK WASHER
HOOK LOCK RETENTION SYSTEM

5 CURRENTLY AVAILABLE FOR '08 FORD F-4/550'S ONLY
FOR RETRO-FIT OPTIONS OR POSSIBLE OPTIONS
4 FOR OTHER CHASSIS CONTACT DMF MANUAL PIN-OFF RETENTION SYSTEM
AVAILABLE ON GM/CHEVY ONLY
3 FOR RETRO-FIT OPTIONS CONTACT DMF
ITEM PART # QTY DESCRIPTION

2
1 818853 1 HOOK LOCK, 1019, FRONT - DETAIL
1 2 818858 1 HOOK LOCK PIN WELDMENT
6 3 FW3/4 2 3/4" FLAT WASHER, GRADE 8
4 818854 1 CLEVIS, 9/16" THROAT, 1/2" PIN B
- - -
5 818859 1 KEYHOLE PLATE
A
6 818861 1 PULL ROD WELDMENT, LH TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
MANUAL, FRONT RETENTION OPTIONS, RW-1019

818864 - PULL ROD WELDMENT, RH FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" -
.X ± .063
7 818855 1 LATCH PIN, BOLT ON - HOOK LOCK PART #: 10168 .XX
.XXX
± .030
± .005
8 241103 1 3/4-16 NF LOCKNUT

DRILL SIZES: + .015
7 8 9 ANGULAR:
SURF FINISH:
± 1°
125 MICRO
NEH 5/2/11 M1019124 #
9 818851 1 3/4-16 X 2-3/4" LONG HEX HEAD CAP SCREW
THREADS: 2A AND 2B
SECTION 6.0 HYDRAULIC & ELECTRICAL

SYSTEMS
6.1 VALVE ASSEMBLIES........................................................................................ 6-2
6.2 HYDRAULIC & ELECTRICAL SCHEMATIC ......................................................... 6-4
6.3 HYDRAULIC BRAKE TIMER SCHEMATIC .......................................................... 6-5
6.4 BRAKE MANIFOLD FOR FRONT & REAR BRAKES ............................................. 6-6
6.5 BRAKE MANIFOLD FOR FRONT BRAKES .......................................................... 6-7
6.6 HYDRAULIC BRAKE LINE ROUTING ................................................................ 6-8
6.7 REAR HYDRAULIC CYLINDER DRAWINGS ....................................................... 6-9
6.8 FRONT HYDRAULIC CYLINDER DRAWINGS................................................... 6-15
6.9 HYDRAULIC CYLINDER ASSEMBLY & TEST PROCEDURE ............................... 6-19
6.10 FITTING INSTALLATION ............................................................................... 6-20

ITEM NO. PART NUMBER QTY. DESCRIPTION
1 810443 1 PRINCE FRONT VALVE W/O FITTINGS, O-RING PORTS
2 605462 2 #04 MJIC X #10 MORB, 90 DEG (6801-04-10)
A 3 605574 2 #08 MAORB X #06 FORB, STRAIGHT REDUCER (6410-08-06)
4 605575 2 #04 MJIC X #04 MJIC X #06 MAORB, TEE (6803-04-04-06)
5 800135 1 DECAL, RELIEF VALVE SETTING SAFETY INSTRUCTIONS (NOT SHOWN)
A 12/6/16 810443 WAS 810206; 605462 WAS 810301; 605574 WAS 810306; 605575 WAS 810308 BJF
TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, OTHER: ±1/16" 1019 FRONT HYDRAULIC VALVE W/ FITTINGS
.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°
THREADS: 2A AND 2B
WEG - 6/10/93 10288 A
DMF (404)875-1512
ITEM PART NO. QTY. DESCRIPTION
1 810446 1 PRINCE REAR VALVE W/O FITTINGS, O-RING PORTS

2 605462 4 #04 MJIC X #10 MORB, 90 DEG (6801-04-10)
A 3 605579 2 #12 MORB X #04 FORB, STRAIGHT REDUCER (6410-12-04)
4 10457 2 #04 MJIC X #04 MAORB X 90 FITTING (6801-04-04)
5 800135 1 DECAL, RELIEF VALVE SETTING SAFETY INSTRUCTIONS (NOT SHOWN)
B - - -
A 12/6/16 810446 WAS 810212; 605462 WAS 10297; 605579 & 10457 WAS 810301 BJF
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
1019 REAR HYD VALVE w/ FITTINGS
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019
.X ± .063
.XXX ± .005
ANGULAR: ± 1°
THREADS: 2A AND 2B
JTM 3/7/12 810211 A
14
200 A
4 GA 10A
12 12V DC IGNITION
8
BROWN
+ RED
12V DC BRAKE PURPLE 11
BATTERY CONTROLLER RED/BLACK 4
BLACK
13
2
7
6
10 TANK 10
3
HYDRAULIC POWER UNIT GROUNDS THROUGH
9 THE MOUNTING FEET. THIS CONNECTION MUST
BE MADE FREE OF PAINT AND PROTECTED
BRAKE MANIFOLD MUST HAVE DEDICATED GROUND TO BATTERY AFTERWARDS W/ PAINT. iF REQUIRED A SEPERATE
GROUND MAY BE RUN TO THE FRAME OR BATTERY.
ITEM PART # QTY DESCRIPTION ITEM PART # QTY DESCRIPTION D

C
5/26/17
5/23/14
REMOVED CYLINDER PART NUMBERS
ADDED ITEM 14, REDRAWN
BJF
JDI
1 REF 1 DRIVER'S SIDE FRONT CYLINDER 8 10483 1 RW-1019 HYDRAULIC BRAKE CONTROLLER B 6/28/11 REVISE PUMP GROUNDING, ADDED NOTES WAK
2 REF 1 PASSENGER'S SIDE FRONT CYLINDER 9 10501 1 BRAKE MANIFOLD W/ FITTINGS, F & R BRAKES A
REV
5/24/11
DATE
REDRAWN IN SOLIDWORKS, REVISED TO CURRENT PART #'S AND PRODUCTION
DESCRIPTION
NEH
BY APP
3 REF 1 DRIVER'S SIDE REAR CYLINDER 10 10442 4 STAINLESS STEEL BRAKE LINE (1/4" X 48") TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
4 REF 1 PASSENGER'S SIDE REAR CYLINDER 11 10758 2 SWITCH, PUSHBUTTON: COLE HERSEE 90030-12 MANUAL, HYDRAULIC SYSTEM W/ LOCKING
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 / 1212 / 1420 VALVES AND TIMER, RW-1019
5 10752 1 MONARCH POWER UNIT
.X ± .063
12 10417 1 SWITCH, TOGGLE DPST-7803K31 .XX
.XXX
± .030
± .005
6 10288 1 FRONT VALVE WITH FITTINGS

+ .015
13 18611 1 LED INDICATOR LIGHT
DRILL SIZES:
ANGULAR: ± 1°
NEH 5/2/11 M1019126 D
7 810211 1 REAR VALVE WITH FITTINGS
THREADS:
14 605309 1 CIRCUIT BREAKER, 200 AMP

2A AND 2B
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
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
.XXX ± .005
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 5/20/11 M1019135 B
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
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
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 5/23/11 M1019137 C
NOTE:
PLUG WELD "J" CLIPS IN PLACE AND CAREFULLY ACTUATE RAILGEAR TO ENSURE
PROPER CLEARANCE AROUND ALL HYDRAULIC LINES.
NOTE:
PLUG WELD "J" CLIPS IN PLACE AND CAREFULLY ACTUATE RAILGEAR TO ENSURE
PROPER CLEARANCE AROUND ALL HYDRAULIC LINES.
"J" CLIPS
"J" CLIPS ALLOW SLACK

FOR RAILGEAR
LEAVE SLACK PRIOR MOVEMENT
TO FIRST "J" CLIP TO
ALLOW FOR RAILGEAR MOVEMENT

APPROVED CHASSIS
B
A - - -
FRONT BRAKE LINE SCHEMATIC REV

TOLERANCES:
DATE DESCRIPTION
TITLE:
BY APP
GENERAL ARRANGEMENT APPLIES TO ALL REAR BRAKE LINE SCHEMATIC (UNLESS SPECIFIED)

-
MANUAL, COBRA BRAKE HYDRAULIC LINE
FRAC, OTHER: ± 1/16" INSTALLATION, RW-1019
CHASSIS TYPES GENERAL ARRANGEMENT APPLIES TO ALL .X
.XX
.XXX
± .063
± .030
± .005
(DODGE/STERLING SHOWN) CHASSIS TYPES DRILL SIZES:

ANGULAR:
SURF FINISH:
+ .015
± 1°
125 MICRO
THREADS: 2A AND 2B
NEH 5/4/11 M1019129 #
ITEM PART # DESCRIPTION QTY.
15 16 14 C 1 241016 PARKER LOCKING VALVE 1
DMF P/N 241225 - SEAL KIT 2 241103 3/4-16 LOCKNUT 1
(SEAL KIT INCLUDES ITEM #'S 3,4,5,9,10,11 3 241105 ROD SEAL 1
A A
4 241106 ROD WIPER 1
5 241107 3/4" ORING 1
6 241200 ROD ASSEMBLY 1
7 241202 GLAND 1
8 241203 PISTON 1
9 241204 PISTON SEAL 2
10 241208 2-1/2" ORING 1
11 241209 2-1/2" BACKUP RING 1
12 241516 TUBE WELDMENT 1
D 13 818235 GREASE FITTING, 1/8"NPT, STRAIGHT 1
SEE PP008 FOR CYLINDER ASS'Y & TEST PROCEDURE 14 241335 REAR LVLV CYL. COMP. FITTING 90deg 2
B 15 108129 TUBE NUT 3/8 2
TORQUE: 2 9 12 16 108130 TUBE FERRULE 3/8 2
B 300 ft-lbs
10 11 3 7 4 13 D
6
SECTION A-A
SCALE 7 : 16
1.438 REF
8 5 A
12.875 (CLOSED)
4.313
22.500 (OPEN)
B A
APPROVED CHASSIS
D 2/29/12 818235 WAS 240123 JTM
C 12/1/11 241016 WAS 241013 JTM
B 7/16/11 ADDED ITEMS 14-16, ADDED TORQUE SPEC NEH
A 5/2/11 ADDED DIMENSIONS AND BALLOON FOR ITEM #1 NEH
TOLERANCES:
TITLE:
1 A (UNLESS SPECIFIED)
1019 REAR HYDRAULIC CYLINDER, DRIVER SIDE
B FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019
.X ± .063
C .XX
.XXX
± .030
± .005
SECTION B-B DRILL SIZES:
ANGULAR:
+ .015
± 1°
SCALE 1 : 6 SURF FINISH:

THREADS:
125 MICRO
2A AND 2B NEH 4/20/11 241504 D
B 1 241016 PARKER LOCKING VALVE 1
A A (SEAL KIT INCLUDES ITEM #'S 3,4,5,9,10,11 3 241105 ROD SEAL 1
5 241107 3/4" ORING 1
7 241202 GLAND 1
8 241203 PISTON 1
10 241208 2-1/2" ORING 1
11 241209 2-1/2" BACKUP RING 1
15 16 14 12 241515 TUBE WELDMENT 1
C 13 818235 GREASE FITTING, 1/8"NPT, STRAIGHT 1
14 241335 REAR LVLV CYL. COMP. FITTING 90deg 2
SEE PP008 FOR CYLINDER ASS'Y & TEST PROCEDURE
A 15 108129 TUBE NUT 3/8 2
TORQUE: 16 108130 TUBE FERRULE 3/8 2
A 300 ft-lbs 2 9 12
10 11 3 7 4 13 C
SECTION A-A 1.438 REF

8 5 SCALE 7 : 16
12.875 (CLOSED)
4.313
22.500 (OPEN)
B
APPROVED CHASSIS
C 2/17/12 818235 WAS 240123 JTM
B 12/1/11 241016 WAS 241013 JTM
A 7/16/11 ADDED ITEMS 14-16 TO BOM, ADDED TORQUE SPEC NEH
TOLERANCES:
TITLE:
B (UNLESS SPECIFIED)
B FRAC, MACH: ± 1/32"

RW-1019
1019 REAR HYDRAULIC CYLINDER, PASSENGER
1 FRAC, OTHER:
.X
± 1/16"
± .063
SIDE
SECTION B-B .XXX
DRILL SIZES:
± .005
+ .015
SCALE 1 : 6 ANGULAR:
SURF FINISH:
± 1°
125 MICRO
THREADS: 2A AND 2B
NEH 4/20/11 241503 C
DMF P/N 241225 - SEAL KIT B 1 241016 PARKER LOCKING VALVE 1
15 16 14 (SEAL KIT INCLUDES ITEM #'S 3,4,5,9,10,11 2 241103 3/4-16 LOCKNUT 1
A A 3 241105 ROD SEAL 1
5 241107 3/4" ORING 1
7 241202 GLAND 1
8 241203 PISTON 1
10 241208 2-1/2" ORING 1
11 241209 2-1/2" BACKUP RING 1
12 241416 TUBE WELDMENT 1
15 108129 TUBE NUT 3/8 2
A
16 108130 TUBE FERRULE 3/8 2
TORQUE: 2 9
A 300 ft-lbs 10 11 3 7 4 13 C
6
SECTION A-A
SCALE 7 : 16
8 5 12 1.438 REF
11.89 (CLOSED)
6.55
22.766 (OPEN)
B APPLIES TO ALL CURRENTLY

APPROVED CHASSIS
C 2/20/12 818235 WAS 240123 JTM
B 12/1/11 241016 WAS 241013 JTM
A 7/16/11 ADDED ITEMS 14-16, ADDED TORQUE SPEC NEH
B 1 REV DATE DESCRIPTION BY APP

B TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
FRAC, MACH: ± 1/32" 1019 REAR HYDRAULIC CYLINDER, LONG LINKS,

FRAC, OTHER: ± 1/16" RW-1019 DRIVER SIDE
.X ± .063
SECTION B-B .XX

.XXX
± .030
± .005
SCALE 1 : 6 DRILL SIZES:

ANGULAR:
SURF FINISH:
+ .015
± 1°
125 MICRO
THREADS: 2A AND 2B
NEH 4/21/11 241404 C
B 1 241016 PARKER LOCKING VALVE 1
A A (SEAL KIT INCLUDES ITEM #'S 3,4,5,9,10,11 3 241105 ROD SEAL 1
5 241107 3/4" ORING 1
7 241202 GLAND 1
8 241203 PISTON 1
10 241208 2-1/2" ORING 1
11 241209 2-1/2" BACKUP RING 1
16 15 14 12 241415 TUBE WELDMENT 1
A 15 108129 TUBE NUT 3/8 2
16 108130 TUBE FERRULE 3/8 2
TORQUE: 2 9 12 10 11 3 7 4 13 C
A 300 ft-lbs
6
SECTION A-A
SCALE 7 : 16
8 5
1.438 REF
11.891 (CLOSED)
6.55
22.766 (OPEN)

B
APPROVED CHASSIS
C 2/20/12 818235 WAS 240123 JTM
B 12/1/11 241016 WAS 241013 JTM
A 7/16/11 ADDED ITEMS 14-16, ADDED TORQUE SPEC NEH
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
1019 REAR HYDRAULIC CYLINDER, LONG LINKS,
B FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 PASSENGER SIDE
1 .X
.XX
± .063
± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
B SECTION B-B .XXX
DRILL SIZES:
± .005
+ .015
SCALE 1 : 6 ANGULAR:
SURF FINISH:
± 1°
125 MICRO
4/20/11
THREADS: 2A AND 2B
NEH 241403 C
ITEM
NO. PART NUMBER QTY. DESCRIPTION
9 10 8 C 1 241520 1 WELDMENT, 2-1/2" TUBE, LVALVE, XTRA SHORT, REAR LH

A A 2 241200 1 2-1/2" 1019 REAR CYLINDER ROD ASSY, LVL
3 241202 1 GLAND, 2-1/2" BORE X 1-1/2" ROD
4 241203 1 DETAIL, 2-1/2" PISTON, LV
5 241103 1 NYLOCK NUT, 3/4 - 16 UNF
B 6 818235 1 GREASE FITTING, 1/8" NPT, STRAIGHT
A 7 241016 1 VALVE, LOCKING, CPD-084P, PARKER

8 241335 2 3/8 TUBE COMPRESSION FITTING TO #4 JIC MALE, 90 DEGREE
9 108129 2 TUBE NUT, 3/8"
SEE PP008 FOR CYLINDER ASS'Y & TEST PROCEDURE 10 108130 2 TUBE FERRULE, 3/8"
DMF P/N 241225 - SEAL KIT INCLUDES ITEM #'S 11, 12, 13, 14, 15, 16 11 241208 1 O-RING; 2-330
12 241209 1 BACK UP RING, 8-330
TORQUE: 13 241105 1 POLYPAK ROD SEAL 2500-1500

300 ft-lbs 14 241106 1 ROD WIPER 940-17
16 15 241107 1 O-RING 2-210
5
16 241204 2 POLYPAK PISTON SEAL 2500-2000
13 6 B
2
14
SECTION A-A
SCALE 7 : 16
15 1 11 12 3
4 14.56 CLOSED
21.81 OPEN
D APPLIES TO ALL CURRENTLY
B
APPROVED CHASSIS
D 7/10/13 21.81 WAS 21.99 BJF
C 4/2/13 241520 WAS 241516; REMOVED SPACER 241207 BJF
B 2/29/12 818235 WAS 240123 JTM
A 12/1/11 241016 WAS 241013 JTM
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
1019 REAR HYDRAULIC CYLINDER, DRIVER SIDE,
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 X-SH LINKS
.X ± .063
SECTION B-B 7 .XXX ± .005
A DRILL SIZES:
ANGULAR:
+ .015
± 1°
B SCALE 1 : 6 SURF FINISH: 125 MICRO

THREADS: 2A AND 2B
NEH 7/16/11 241507 D
ITEM PART NUMBER QTY.
NO. DESCRIPTION
1 241519 1 WELDMENT, 2-1/2" TUBE, LVALVE, XTRA SHORT, REAR RH
A A C
2 241200 1 2-1/2" 1019 REAR CYLINDER ROD ASSY, LVL
3 241202 1 GLAND, 2-1/2" BORE X 1-1/2" ROD
4 241203 1 DETAIL, 2-1/2" PISTON, LV
5 241103 1 NYLOCK NUT, 3/4 - 16 UNF
B 6 818235 1 GREASE FITTING, 1/8" NPT, STRAIGHT
A 7 241016 1 VALVE, LOCKING, CPD-084P, PARKER
9 10 8 8 241335 2
3/8 TUBE COMPRESSION FITTING TO #4 JIC MALE, 90
DEGREE
9 108129 2 TUBE NUT, 3/8"
NOTES: 10 108130 2 TUBE FERRULE, 3/8"
SEE PP008 FOR CYLINDER ASSEMBLY & TEST PROCEDURE
DMF P/N 241225 - SEAL KIT INCLUDES ITEM #'S 11, 12, 13, 14, 15, 16 11 241208 1 O-RING; 2-330
12 241209 1 BACK UP RING, 8-330
13 241105 1 POLYPAK ROD SEAL 2500-1500
TORQUE: 5 14 241106 1 ROD WIPER 940-17
300 ft-lbs 16 1 15 241107 1 O-RING 2-210
16 241204 2 POLYPAK PISTON SEAL 2500-2000
11 12 3 6 B
2
14
SECTION A-A
SCALE 7 : 16
15 13
14.56 CLOSED
4 21.81 OPEN
B D APPLIES TO ALL CURRENTLY
APPROVED CHASSIS
D 7/10/13 21.81 WAS 21.99 BJF
C 4/1/13 241519 WAS 241515; REMOVED 241207 BJF
B 2/29/12 818235 WAS 240123 JTM
A 12/1/11 241016 WAS 241013 JTM
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
1019 REAR HYDRAULIC CYLINDER, PASSENGER
7 FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 SIDE, X-SHORT LINKS
B .X
.XX
.XXX
± .063
± .030
± .005
A SECTION B-B DRILL SIZES:

ANGULAR:
+ .015
± 1°
SCALE 1 : 6 THREADS: 2A AND 2B
NEH 7/15/11 241506 D
1 240102 1 HYDRAULIC CYLINDER GLAND, 4-1/2" BORE
A A 2 240110 1 RW-1630 FRONT CYLINDER BBL WELDMENT, DS
3 240101 1 PISTON DETAIL, 4-1/2" CYLINDER
4 240120 1 HYDRAULIC CYLINDER ROD ASSEMBLY, RW-1630 FRONT
5 818235 1 GREASE FITTING, 1/8" NPT, STRAIGHT
6 18952 2 #04 MJIC X #06 MAORB X 90 FITTING
7 240104 2 PISTON SEAL, POLYPAK, 4.5" ID, .312"W, 3.875" BORE (3120-3875)
8 240105 1 GLAND SEAL, POLYPAK, 2.75" BORE, .375"W, 2" ROD (3750-2000)
11" RETRACTED 9 240106 1 2" ROD WIPER (AN-21)
20-11/16" EXTENDED 10 240107 1 O-RING, 1" ID X 1-1/4" OD (2-214)

11 240108 1 O-RING 4-1/2" OD X 3/16" (2-346)
12 240109 1 BACKUP RING FOR 4-1/2" OD X 3/16" WALL O-RING (8-346)
13 605119 1 NYLON LOCK NUT, 1-14
6
7 2 12
11 1
13 9
TORQUE
300 FT-LBS
8
3 SECTION A-A
10 4 SCALE 1 : 2
J 7/14/2017 MIGRATED TO SOLIDWORKS BJF
NOTES: TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, OTHER: ±1/16" HYDRAULIC CYLINDER ASSEMBLY, FRONT
DMF P/N 240125 SEAL KIT INCLUDES ITEM #'S 7, 8, 9, 10, 11, 12 .X ± .063 RW-1630 / 1420 /
DRIVER SIDE, RW-1630/1420/1212/1019
.XX
.XXX
± .030
± .005 1212 / 1019
DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°

THREADS: 2A AND 2B
TSH - 11/10/92 240099 J
DMF (404)875-1512
1 240102 1 HYDRAULIC CYLINDER GLAND, 4-1/2" BORE
A A 2 240115 1 RW-1630 FRONT CYLINDER BARREL WELDMENT (PS)
3 240101 1 PISTON DETAIL, 4-1/2" CYLINDER
4 240120 1 HYDRAULIC CYLINDER ROD ASSEMBLY, RW-1630 FRONT
5 818235 1 GREASE FITTING, 1/8" NPT, STRAIGHT
6 18952 2 #04 MJIC X #06 MAORB X 90 FITTING
7 240104 2 PISTON SEAL, POLYPAK, 4.5" ID, .312"W, 3.875" BORE (3120-3875)
8 240105 1 GLAND SEAL, POLYPAK, 2.75" BORE, .375"W, 2" ROD (3750-2000)
9 240106 1 2" ROD WIPER (AN-21)
6 11" RETRACTED
10 240107 1 O-RING, 1" ID X 1-1/4" OD (2-214)
20-11/16" EXTENDED
11 240108 1 O-RING 4-1/2" OD X 3/16" (2-346)
12 240109 1 BACKUP RING FOR 4-1/2" OD X 3/16" WALL O-RING (8-346)
13 605119 1 NYLON LOCK NUT, 1-14
7 2 12
11 1
9
13
TORQUE
300 FT-LBS
8
3 SECTION A-A
10 4 SCALE 1 : 2
J 7/17/2017 MIGRATED TO SOLIDWORKS BJF
NOTES: TOLERANCES (UNLESS SPECIFIED):
TITLE:
FRAC, OTHER: ±1/16" HYDRAULIC CYLINDER ASSEMBLY, FRONT
DMF P/N 240125 SEAL KIT INCLUDES ITEM #'S 7, 8, 9, 10, 11, 12 .X ± .063 RW-1630 / 1420 /
PASSENGER SIDE, RW-1630/1420/1212/1019
.XX
.XXX
± .030
± .005 1212 / 1019
DRILL SIZES: + .015 THIS DRAWING CONTAINS CONFIDENTIAL PROPRIETARY INFORMATION OF DIVERSIFIED
METAL FABRICATORS, INC (DMF). COPYRIGHT DMF, ALL RIGHTS RESERVED.
ANGULAR: ± 1°

THREADS: 2A AND 2B
TSH - 11/10/92 240100 J
DMF (404)875-1512
DMF P/N 240225 - SEAL KIT 1 240103 1" NUT 1
(SEAL KIT INCLUDES ITEM #'S 2,3,4,8,9,10 2 240105 ROD SEAL 1
A A
3 240106 WIPER 959-21 AN-21 1
4 240107 O'RING 2-214 1
5 240201 PISTON 1
6 240202 GLAND 1
7 240204 PISTON SEAL 3120-2875 2
8 240208 O'RING 2-338 1
9 240209 B'UP RING 8-338 1
10 240810 TUBE ASSEMBLY 1
F 12 818235 GREASE FITTING, 1/8"NPT, STRAIGHT 1
SECTION A-A 13 241006 HYD. CYL. FITTINGS 2
7 4 SCALE 1 : 2 E
D 8 9 2 6 3 12 F
11
13
TORQUE:
E 1 300 ft-lbs
5 10 FORD/DODGE/STERLING
DRIVER FRONT HYD.
CYLINDER ASSY.
F 2/17/12 818235 WAS 240123 JTM
E 7/16/11 ADDED ITEM 13, ADDED TORQUE SPEC NEH
D 5/16/11 CLARIFIED COMPONENT ORDER NEH
C 4/21/11 ADDED SEAL KIT NOTE NEH
B 3/17/11 COMPLETED DRAWING, CORRECTED ORIENTATION NEH
SEE PP008 FOR CYLINDER ASS'Y & TEST PROCEDURE A 11/19/10 REDRAWN IN SOLIDWORKS BJF
TOLERANCES:
TITLE:
(UNLESS SPECIFIED) RW-1019 FRONT HYDRAULIC
RW-1019 CYLINDER ASSEMBLY, DRIVER'S SIDE
FRAC, OTHER: ± 1/16"
.X ± .063
.XXX ± .005
DRILL SIZES: + .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
MSM 10/13/94 240800 F
DMF P/N 240225 - SEAL KIT 1 240103 1" NUT 1
AM AM (SEAL KIT INCLUDES ITEM #'S 2,3,4,8,9,10
2 240105 ROD SEAL 1
3 240106 WIPER 959-21 AN-21 1
4 240107 O'RING 2-214 1
5 240201 PISTON 1
6 240202 GLAND 1
7 240204 PISTON SEAL 3120-2875 2
8 240208 O'RING 2-338 1
9 240209 B'UP RING 8-338 1
10 240816 TUBE ASSEMBLY 1
F D SECTION AM-AM F 12 818235 GREASE FITTING, 1/8"NPT, STRAIGHT 1
3 6 2 9 8 SCALE 1 : 2 4 7 13 241006 HYD. CYL. FITTINGS 2
12
E
11
13
1 3/4" REF
10 5 TORQUE: 1
FORD/DODGE/STERLING
6.546 (CLOSED)
300 ft-lbs E PASSENGER FRONT
11.329 (OPEN)
6.693 REF HYD. CYLINDER ASSY.
F 2/17/12 818235 WAS 240123 JTM
E 7/16/11 ADDED ITEM 13, ADDED TORQUE SPEC NEH
D 5/16/11 CLARIFIED COMPONENT ORDER NEH
C 5/2/11 REWORDED TITLE NEH
B 4/21/11 ADDED SEAL KIT NOTE NEH
A 3/17/11 REDRAWN IN SOLIDWORKS, ORIENTATION CORRECTED NEH
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
SEE PP008 FOR CYLINDER ASS'Y & TEST PROCEDURE FRAC, MACH: ± 1/32" RW-1019 FRONT HYDRAULIC CYLINDER
FRAC, OTHER: ± 1/16" RW-1019 ASSEMBLY, PASSENGER'S SIDE
.X ± .063
.XXX ± .005
DRILL SIZES: + .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
MSM 10/14/94 240801 F
SECTION 7.0 REAR RAILGEAR PARTS

7.1 BEFORE ORDERING PARTS – REAR RAILGEAR ................................................ 7-2
7.2 REAR PARTS DETAIL DRAWING...................................................................... 7-4
7.3 LINK DIMENSIONS ......................................................................................... 7-5
7.4 EXTRA-SHORT LINKS...................................................................................... 7-6
7.5 SHORT LINKS ................................................................................................. 7-7
7.6 LONG LINKS ................................................................................................... 7-8
7.7 REAR AXLE ASSEMBLY .................................................................................... 7-9
7.8 REAR FRAME BRACKETS ............................................................................... 7-10

7.1 BEFORE ORDERING PARTS – REAR RAILGEAR

Required Information for Ordering Parts:
 You must have the Railgear serial number when ordering parts. This uniquely identifies
your Railgear, as it was built to your specifications, and also allows DMF to help you
maintain a history of your Railgear. 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 when placing your order.
 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 your Railgear. This 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 you can provide to us when placing an order, the more likely that we will be
able to help you 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 you
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.
Links:
 DMF’s links come in 3 sizes: x-short, short, and long. The sizes cannot be mixed
between upper and lower links (i.e. Long upper link can only be used with long lower
link. Each link has a slotted version as well.
 Links are sold individually, unless you require an entire set of 8 (4 front, 4 rear). See
drawings for additional clarification on link type (i.e. long, short, or extra-short), and the
appropriate part numbers for ordering.
 Note: Short links are DMF’s default configuration for our Railgear.

Cylinders / Brakes:
 Note that there are three sizes of rear cylinders and they match with each of the three
length variants of rear links. Please confirm the length of your cylinder and select the
appropriate drawing for part numbers.
Rear Mounting Bracket:

 DMF’s 1019 series of Railgear comes with a standard rear mounting bracket. This
bracket works on all currently approved chassis.
 For special applications, other bracket widths or heights are available. Please contact
the DMF parts department for more information.
 For the Ford F-4/550 series chassis, a special transit bracket is available to meet specific
criteria regarding curve performance. Refer to the drawing in Section 7.8.

PART
NOTE: OPTIONAL BRACKET AVAILABLE FOR LABEL DESCRIPTION QTY.
NUMBER
SPECIAL APPLICATIONS (FORD ONLY) RW1019 REAR BRACKET ASSY.,34-1/4"w/BIG
REFERENCE DRAWING #:M1019130 1 10083 1
GUSSET
1 RW-1019HD WHEEL & AXLE
2 10676 1
ASSY.,REAR,INSULATED,EXT. BRAKES
3 RW1019/12/1420 REAR BRACKET 4 HOLE
3 10047 2
PLATE
15 4 10764 REAR LINK, SHORT, UPPER FRONT DRIVER SIDE 1
5 10233 REAR LINK, SHORT, LOWER FRONT EITHER SIDE 2
6 10782 REAR LINK, SHORT, LOWER DRIVER SIDE 1
REAR LINK, SHORT, UPPER REAR DRIVER
7 10774 REMOTES P/O'S 1
13 14
8 10765 REAR LINK, SHORT, UPPER FRONT PASSENGER 1
9 10775 REAR LINK, SHORT, UPPER REAR PASSENGER 1
REMOTE P/O'S
2 24 10 10783 REAR LINK, SHORT, LOWER PASSENGER SIDE 1
17 23 11 241504 ASSY, CYL, RR, L'VLV, LH (2-1/2x 9-5/8) 1
12 7 12 241503 ASSY, CYL, RR, L'VLV, RH (2-1/2x 9-5/8) 1
13 818582 REM.DBL.P/O ASSY.(CABLE)(5- 2
25 3/8")(1019,1212,1420)
REMP/O SLIDE PLATE DETAIL (CABLE)(1/2"
14 818563 2
22 THICK)
15 10250 RW-1019 PIN ASSY., REAR UPPER MOUNTING 2
16 10251 RW-1019 PIN ASSY., REAR LOWER MOUNTING 2
17 10240 1019 REAR CYL. ROD PIN 2
RW-1019 FRONT HYDRAULIC BRAKE
18 12700 2
ASSY.,(1.063 BORE)
16 RAILSWEEP REAR WELDMENT,LH (BOLT-
19 818626 1
11 ON),w/HYD. BRAKES
RAILSWEEP REAR WELDMENT,RH (BOLT-
20 818627 ON),w/HYD. BRAKES 1
21 818503 RAILSWEEP RUBBER BELTING DETAIL 2
6
22 818127 RW-1630 FRONT HEX NUT, SLOTTED (SLHN;1"-8) 4
23 818289 RW-1630 REAR CYL. TURNNION FLAT WASHER 4
(FW1-1/4")
19 21 24 818256 RW-1630 REAR SLOTTED NUT (1-1/4"-7) 4
25 818116 HEX NUT 1/2-13 8
RW-1019/1212 BOLT (HHCS 1/2"-13 X 1-
26 12479 8
1/4"GR8)
24 23 4 27 12481 RW-1019/1212 WASHER, LOCK (1/2" GR8) 8
28 12475 RW-1019/1212 BOLT (HHCS 3/8"-16 X 1") 4
28
22 5 29 818508 3/8" FLAT WASHER 4
29 30 818520 LW3/8 RAIL SWEEP 4
31 810410 3/8 HEX NUT FOR VALVE MOUNTS 4
NS 818258 RW-1630 REAR COTTER PIN (1/4"X2-1/2") 4
NS 818248 RW-1630 REAR COTTER PIN (3/16"X2") 8
31 30
9 *MUST HAVE SERIAL # WHEN ORDERING PARTS*

DEPENDING ON OPTIONS, PART #'S MAY VARY; SEE LINK VARIATIONS
8 IN SECTION 5.4
18
27

26
5
APPROVED CHASSIS
10 B
A - - -
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
MANUAL, '08 F-550 REAR ASSY PARTS DIAGRAM,
20 FRAC, MACH:
FRAC, OTHER:
.X
± 1/32"
± 1/16"
± .063
- RW-1019
.XXX ± .005
NOTE: DRAWING IS FOR ILLUSTRATIVE PURPOSES ONLY, YOUR PARTS MAY NOT BE EXACTLY AS PICTURED DRILL SIZES:
ANGULAR:
+ .015
± 1°
PASSENGER SIDE VIEW SURF FINISH:
THREADS:
125 MICRO
2A AND 2B NEH 4/19/11 M1019104 #
UPPER LOWER - A LOWER- A
STANDARD SLOTTED
12.594 10.688 10.688
6.69 6.69 6.69 1.00
X-SHORT
4.0 4.0 4.0
14.094 12.188 12.188

STANDARD/SHORT
8.19 8.19 8.19 1.00
4.0 4.0 4.0
15.344 13.438 13.438

9.44 9.44 9.44 1.00
LONG
4.0 4.0 4.0
B
A 5/16/11 ADDED CLARIFICATION OF UPPER VS. LOWER NEH
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
NOTE: DMF LINKS COME IN 3 SIZES: X-SHORT, STD./SHORT, & LONG. FRAC, MACH: ± 1/32"
RW-1019/1212/1420 RW- 1019 REAR LINK OPTIONS & DIMENSIONS
THE SIZES CAN NOT BE MIXED BETWEEN UPPER & LOWER LINKS.
FRAC, OTHER: ± 1/16"
.X ± .063
EXAMPLE: LONG UPPER LINK CAN ONLY BE USED WITH LONG LOWER .XXX
DRILL SIZES:
ANGULAR:
± .005
+ .015
± 1°
LINK. EACH LINK HAS A SLOTTED VERSION. SURF FINISH:

THREADS:
125 MICRO
2A AND 2B
JBG 4/23/10 M1019111 A
X-SHORT LINKS Note: Links are sold individually unless X-SHORT (SLOTTED) LINKS
you want a full set of all 8. Please refer to
10769 full set p/n's shown below. 10769
The "Rear Set of Rear Links" differ in p/n's
10768 according to pin-off option. Your "Front Set
10235 10247
of Rear Links" are the same, for x-short links,
no matter what pin-off option you have. 10768
10771 10770
MANUAL - XSHORT MANUAL - XSHORT (SLOTTED)

P/N 10719 P/N 10726
10235 10247
10770
Truck Front 10771 Truck Front
10785
10247 10247
10784
Truck Rear Truck Rear
AIR REMOTE - XSHORT AIR REMOTE - XSHORT (SLOTTED)

Not used for 1019, refer to 1420 Not used for 1019, refer to 1420
10769
10768
10235 10777 CABLE REMOTE - XSHORT (SLOTTED) 10247
10768
P/N 10725 10769
10776 10776
818582
CABLE REMOTE - XSHORT 818582
P/N 10724
10235 818563 10247
TITLE:
X-SHORT (STANDARD & SLOTTED LINKS) 10247 10777 Truck Front

Truck Front
10785 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
818563 DATE: DRAWING NUMBER: REV: 10247
10784 5/2/2011 M1019107 Truck Rear
Truck Rear #
SHORT LINKS Note: Links are sold individually unless SHORT (SLOTTED) LINKS
you want a full set of all 8. Please refer to
10765 full set p/n's shown below. 10764
The "Rear Set of Rear Links" differ in p/n's
10233 according to pin-off option. Your "Front Set 10245
of Rear Links" are the same, for short links, 10766
10764 10767 10765
no matter what pin-off option you have.
MANUAL - SHORT (SLOTTED)

P/N 10718
10233 MANUAL - SHORT
P/N 10717
10245
Truck Front Truck Front
10766
10783 10245 10767
10782 10245
Truck Rear Truck Rear
AIR REMOTE - SHORT AIR REMOTE - SHORT (SLOTTED)

10765 10764
10233 10775 10774 10245

CABLE REMOTE - SHORT 10765
10764 P/N 10722 CABLE REMOTE - SHORT (SLOTTED)
P/N 10723
818582
818563 818582
10233
818563
TITLE:
10245
10783 10245
SHORT (STANDARD & SLOTTED LINKS)
Truck Front Truck Front
10775
DATE: DRAWING NUMBER: REV: 10245
10782
Truck Rear 5/3/2011 M1019108 # Truck Rear
LONG LINKS Note: Links are sold individually unless LONG (SLOTTED) LINKS
10761 you want a full set of all 8. Please refer to
full set p/n's shown below. 10760
10760 The "Rear Set of Rear Links" differ in p/n's

10230 according to pin-off option. Your "Front Set 10762 10243
of Rear Links" are the same, for short links, 10761
10763 no matter what pin-off option you have.
10230
MANUAL - LONG
P/N 10715 MANUAL - LONG (SLOTTED)
P/N 10716 10243
Truck Front 10762 Truck Front
10781 10243
10780 10763
Truck Rear 10243 Truck Rear
AIR REMOTE - LONG AIR REMOTE - LONG (SLOTTED)

10761 10760
10230 10773 10772 10243

10761
10760
CABLE REMOTE - LONG CABLE REMOTE - LONG (SLOTTED)
P/N 10720 P/N 10721
818582
818582
818563
10230 818563
TITLE: 10243
LONG (STANDARD & SLOTTED LINKS) 10243
Truck Front 10781 10773 Truck Front
DATE: DRAWING NUMBER: REV:
10243
10780
Truck Rear 5/3/2011 M1019109 # Truck Rear
PARTS: (MUST HAVE SERIAL # WHEN ORDERING) ITEM NO. PART NUMBER QTY. DESCRIPTION
COMPLETE REAR AXLE ASSEMBLY OPTIONS (AXLE, AXLE TUBE, 1 10680 1 RW-1019-HD AXLE & TUBE REAR WELDMENT, W/ BRAKE SADDLES
AND WHEELS)
NON-INSULATED, WITH BRAKES - 10674
2 10570 1 RW-1019-HD WHEEL,NON-INS., W/RACES
NON-INSULATED, NO BRAKES - 10670 3 10580 1 RW-1019-HD WHEEL,INSULATED,w/RACES
INSULATED, WITH BRAKES - 10676
INSULATED, NO BRAKES - 10672 4 10592 2 RW-1019-HD SEAL, STANDARD
REAR AXLE TUBE OPTIONS:
W/ BRAKE SADDLES: 10680 5 10591 4 RW-1019-HD BEARING CONE
NO BRAKE SADDLES: 10678
6 10596 2 WASHER,TONGUE (TIMKEN K-91508)
1019 WHEEL (W/RACES) OPTIONS:
INSULATED: 10580 7 10598 2 WASHER, AXLE TAB (TIMKEN WH-08)
NON-INSULATED: 10570
8 10595 2 NUT, AXLE (TIMKEN TN-08)
9 10516 2 RW-1019 HUBCAP, H.D. STYLE
10 800109 8 HUBCAP LOCK WASHERS, (LW-5/16)
11 800108 8 HUBCAP BOLTS, (HHCS 5/16-18X3/4")
12 10586 1 RW-1019-HD INSULATOR RING
13 10590 - RW-1019-HD BEARING RACE
14 10587 - 10" HD WHL STEEL SLEEVE DETAIL
15 10588 - 10" HD WHL INSULATOR DETAIL
16 10584 - 10" HD WHL: INSUL MACHINE DETTAIL
3 NOTE: ITEMS 13-16 ARE

COMPONENTS OF ITEM 3
2
1
4 5
WHEEL ASSEMBLY PROCEDURE
13
A- PACK ALL BEARINGS ENSURING COMPLETE COVERAGE (INSIDE AND OUT) 16 15
B- INSERT BEARING IN INBOARD SIDE OF WHEEL (FLANGE SIDE) 14
C- PACK GREASE ON INBOARD SIDE OF BEARING, COVERING BACK SIDE OF BEARING 13 5 6 7 8 12 9 11 10
D- INSTALL SEAL BY GENTLY TAPPING WITH HAMMER UNTIL FLUSH WITH WHEEL HUB
E- PLACE WHEEL ON AXLE
F- FILL CAVITY BETWEEN BEARINGS AND AROUND AXLE UNTIL FLUSH WITH OUTBOARD RACE
G- INSERT BEARING IN OUTBOARD SIDE OF WHEEL
H- INSTALL AXLE WASHERS ALIGNING THEM WITH KEYWAY (ITEMS 6 AND 7)
I- INSTALL AXLE NUT (ITEM 8)
J- ADJUST BEARING END-PLAY
APPROVED CHASSIS
1- TIGHTEN AXLE NUT TO 200 FT-LBS WHILE ROTATING WHEEL B 1/24/17 REVISED BEARING SETTING PROCEDURE BJF
2- BACK OFF AXLE NUT ONE FULL TURN A 7/5/11 UPDATED TO SHOW INSULATED ASSEMBLY NEH
B 3- TIGHTEN AXLE NUT TO 50 FT-LBS WHILE ROTATING WHEEL REV DATE DESCRIPTION BY APP
4- BACK OFF AXLE NUT (ITEM 8) BY ONE NOTCH OF THE TAB WASHER (ITEM 7) TOLERANCES:
TITLE:
K- SELECT TABS ON TAB WASHER THAT MOST NEARLY LINE UP WITH THE SLOTS IN THE AXLE NUT (UNLESS SPECIFIED)
AND BEND THEM UP TO SECURE THE NUT REAR WHEEL & AXLE ASSEMBLY PARTS DIAGRAM
L- VERIFY BEARING END-PLAY IS 0.001”-0.005” WITH A DIAL INDICATOR
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 RW-1019
.X ± .063
M- FILL OUTBOARD CAVITY WITH GREASE .XX ± .030 DIVERSIFIED METAL FABRICATORS,INC.(404)875-1512
.XXX ± .005
N- RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE (OUTBOARD FACE OF HUB) DRILL SIZES: + .015 DRAWN BY: APPD BY: DATE: DRAWING NUMBER: REV:
O- INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK WASHERS ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 4/19/11 M1019113 B
34 10" 34
8 3/4" 1/ 1 /4
4" "
" "
10 10
A
PART # 10083 - STANDARD 1019 REAR BRACKET PART # 10246 - SPECIALTY TRANSIT BRACKET (FORD ONLY)
NOTE: SPECIALTY REAR BRACKET FOR TIGHT CURVATURE
NOTE: THIS IS THE DEFAULT CONFIGURATION FOR THE REAR BRACKET SPECIFICATIONS. CURRENTLY ONLY AVAILABLE FOR THE FORD
ON ALL 1019 SERIES ASSEMBLIES. OTHER CONFIGURATIONS ARE F-4/550. CONTACT DMF WITH QUESTIONS ABOUT POSSIBLE
AVAILABLE TO FIT YOUR SPECIFIC NEEDS. CONTACT DMF FOR SOLUTIONS FOR OTHER CHASSIS.
INFORMATION ON ALTERNATE CONFIGURATIONS.
B
A 10/14/14 10246 WAS 10199 JDI
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
MANUAL, REAR BRACKET OPTIONS AND
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" - DIMENSIONS, RW-1019
.X ± .063
.XXX ± .005
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 5/5/11 M1019130 A
SECTION 8.0 FRONT RAILGEAR PARTS

8.1 BEFORE ORDERING PARTS – FRONT RAILGEAR.............................................. 8-2
8.2 2008 – 2016 FORD F-4/550 FRONT PARTS DRAWING .................................... 8-3
8.3 RAM / STERLING FRONT PARTS DRAWING .................................................... 8-4
8.4 GM / CHEVY 45/5500 FRONT PARTS DRAWING ............................................. 8-5
8.5 LONG ARM VARIATIONS ................................................................................. 8-6
8.6 FORD / RAM / STERLING FRONT AXLE ASSEMBLY.......................................... 8-7
8.7 GM / CHEVY 45/5500 FRONT AXLE ASSEMBLY ............................................... 8-8
8.8 FRONT CROSS TUBE CONFIGURATIONS ......................................................... 8-9
8.9 SPRING HANGER CONFIGURATIONS ............................................................ 8-10

8.1. BEFORE ORDERING PARTS – FRONT RAILGEAR

Required Information for Ordering Parts:
 You must have the Railgear serial number when ordering parts. This uniquely identifies
your Railgear, as it was built to your specifications, and also allows DMF to help you
maintain a history of your Railgear. 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 your Railgear. This 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 you can provide to us when placing an order, the more likely that we will be
able to help you quickly and efficiently.
 Cross Tubes, Spring Hangers, and Long Arms are available in a variety of sizes and
lengths. Please be sure to check drawings for details before placing your order.
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 you
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.
Cylinders:
 The driver’s side and passenger’s side cylinders are different – please see information on
drawing to determine which cylinder you need to order.
Frame Extensions:
 Please call DMF for assistance. The truck year and model number must be provided, so
that DMF can correctly identify the frame extension needed.

NOTE: DRAWING IS FOR ILLUSTRATIVE PURPOSES, ITEM NO. PART NUMBER DESCRIPTION QTY.
YOUR PARTS MAY NOT BE EXACTLY AS PICTURED
1 11424 WELDMENT,FRONTBK,DS,1019,08F-4/550 1
2 11425 WELDMENT,FRONTBK,PS,1019,08F-4/550 1
3 11445 LARM WLDMT,1019,08F4/5,DS OUTER 1
4 11446 LARM WLDMT,1019,08F4/5,DS INNER 1
5 11447 LARM WLDMT,1019,08F4/5,PS OUTER 1
6 11448 LARM WLDMT,1019,08F4/5,PS INNER 1
7 240800 HYD.CYL.ASSY.,FRONT LH (3-1/2")(3500HD) 1
8 240801 HYD.CYL.ASSY.,FRONT RH (3-1/2")(3500HD) 1
9 11451 ASSY, SWINGLINK, RW1019 DS 1
10 11452 ASSY, SWINGLINK, RW1019 PS 1
11 11437 AXLE BRACKET DETAIL, RW-1019, 08F4/550 4
10 12 11668 RW1019HD FRONT AXLE,ICF,08 F-4/550 1
5 13 11079 RW-1019 TIE PIN SPACER TUBE 2
14 818700 REM. CABLE P/O ASSY.,FRONT (3/4" PIN)(1019) 1
27 15 11124 RW-1019 PIN ASSY.,FRONT (1-1/4"DIAX10-1/4"L) 8
16 11450 RW-1019 REAR PIN ASSY FOR SWING BLOCK 2
18 818134 RW-1630 FRONT HEX NUT, SLOTTED (SLHN; 1-1/2"-6) 4
19 818136 RW-1630 FRONT WASHER, FLAT (FW-1-1/2") 4
2 20 HHCS1/2-13X8GR8 HEX HD CAP SCREW 1/2-13 X 8" GRADE 8 2
11 21 HN1/2-13 1/2-13 HEX NUT 2
6
29 22 HHCS1/2-13X2GR8 HEX HD CAP SCREW 1/2-13 X 2" GRADE 8 2
8 30 23 FW1/2 1/2" FLAT WASHER 4
24 LN1/2-13 1/2-13 NYLOCK NUT 2
AM
17 28 25 HHCS5/8-11X1-3/4GR8 HEX HD CAP SCREW 5/8-11 X 1-3/4" GRADE 8 4
26 FW5/8 5/8" FLAT WASHER 8
27 LN5/8-11 5/8-11 NYLOCK NUT 4
4 28 HHCSM18X140 HES HD CAP SCREW M18-2.5X140 4
29 FWM18 M18 FLAT WASHER 8
16 30 LNM18 M18-2.5 NYLOCK NUT 4
9 NS 818137 RW-1630 FRONT COTTER PIN (1/4"X2-1/2") 4
14 NS 818128 RW-1630 FRONT COTTER PIN (3/16"X2") 8
15
18 3 NOTE: NS = NOT SHOWN ON DRAWING
*MUST HAVE SERIAL # WHEN ORDERING PARTS*
1 DEPENDING ON OPTIONS, PART #'S MAY VARY;
15 SEE LONG ARM VARIATIONS IN SECTION 5.5
24
4
23
19 15
18
25
26
22 FORD F-4/550 FRONT ASSY.
21 PARTS DIAGRAM
B
A - - -
13 REV DATE DESCRIPTION BY APP
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
DETAIL AM FRAC, MACH: ± 1/32" MANUAL, '08 F-550 FRONT ASSY PART DIAGRAM,
- RW-1019
20 SCALE 1 : 5
FRAC, OTHER:
.X
± 1/16"
± .063
.XX ± .030
12 .XXX
DRILL SIZES:
± .005
+ .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 4/18/11 M1019101 #
NOTE: DRAWING IS FOR ILLUSTRATIVE PURPOSES, ITEM NO. PART NUMBER DESCRIPTION QTY.
YOUR PARTS MAY NOT BE EXACTLY AS PICTURED
1 11660 RW1019HD FRONT AXLE,ICF,08 F-4/550 1
2 11472 LARM WLDMT,1019,08DODGE/STER4/5,DS OUTER 1
3 11493 LARM WLDMT,1019,08DODGE/STER4/5,DS INNER,LPO 1
4 11474 LARM WLDMT,1019,08DODGE/STER4/5,PS OUTER 1
5 11477 LARM WLDMT,1019,08DODGE/STER4/5,PS INNER,LPO 1
6 240800 HYD.CYL.ASSY.,FRONT LH (3-1/2")(3500HD) 1
7 240801 HYD.CYL.ASSY.,FRONT RH (3-1/2")(3500HD) 1
8 11494 FRONT FRAME BRACKET 1
9 818328 FRONT CROSS TUBE DETAIL 1
10 11485 DET,FRAME BKT,FORMED,1019 STER/DGD 4/5500 1
11 11488 DET.AXLE BKT TUBE,08STER/DGD 4/5500 4
12 11484 AXLE BRACKET SIDE PLATE 1
13 11492 WLDMT,LOWER SWING LINK,STERLING/DODGE 4/5500 2
14 11495 WMT,PIN,SWG LNK,08STR/DGD 4/5500 1
16 11124 RW-1019 PIN ASSY.,FRONT (1-1/4"DIAX10-1/4"L) 2
17 818136 RW-1630 FRONT WASHER, FLAT (FW-1-1/2") 8
18 818134 RW-1630 FRONT HEX NUT, SLOTTED (SLHN; 1-1/2"-6) 4
19 HHCS1/2-13X8GR8 HEX HD CAP SCREW 1/2-13 X 8" GRADE 8 2
20 HN1/2-13 1/2-13 HEX NUT 2
21 11079 RW-1019 TIE PIN SPACER TUBE 2
NS 818137 RW-1630 FRONT COTTER PIN (1/4"X2-1/2") 4
NOTE: ITEMS 10-15 ARE INCLUDED NS 818128 RW-1630 FRONT COTTER PIN (3/16"X2") 8
8 IN SWINGLINK KIT PART #:11480 NOTE: NS = NOT SHOWN ON DRAWING
9 15 11 10 12 13 14
18 17 *MUST HAVE SERIAL # WHEN ORDERING PARTS*
DEPENDING ON OPTIONS, PART #'S MAY VARY;
15 SEE LONG ARM VARIATIONS IN SECTION 5.5
15
4 5
7
16
6
17 18 2
DODGE/STERLING 45/5500
FRONT ASSY. PARTS DIAGRAM
B
A - - -
1 TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
MANUAL, '08 DODGE/STER 4/5500 FRONT ASSY

FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" - PARTS DIAGRAM, RW-1019
.X ± .063
.XXX ± .005
DRILL SIZES: + .015
19 21 20 ANGULAR:
SURF FINISH:
± 1°
125 MICRO
THREADS: 2A AND 2B
NEH 4/27/11 M1019120 #
LABEL PART NO. DESCRIPTION QTY.
RW-1019HD FRONT AXLE,IDF,4500 W/
1 11663 1
1212 PIVOT ARMS
2 12124 RW-1212 FRONT LONG ARM DETAIL 2
RW-1212/1420 LONG ARM WLDMT,
3 12178 1
FRONT INNER LH, REM P/O'S
RW-1212/1420 LONG ARM WLDMT,
4 12179 1
FRONT INNER RH, REM P/O'S
5 240100 HYD.CYL.ASSY.,FRONT RH (4-1/2" X 9-1/2" 1
7 STROKE)
HYD.CYL.ASSY.,FRONT RH (4-1/2" X 9-1/2"
6 240099 1
STROKE)
7 810236 '03 KODIAK FRAME EXTENSION FOR RW- 1
1019 (DRIVER'S SIDE)
8 810234 '03 KODIAK FRAME EXTENSION FOR RW- 1
9 15 1019 (PASS. SIDE)
9 810154 CROSS TUBE MOUNTING BLOCK (3") 2
18
10 818155 4" SPRING HANGER BRACKET w/NUTS 2
11 13
? RW-1630 SPRING BRACKET SPACER
18 11 818160 (1"X2") 6
12 RW-1630 SPRING BRACKET SPACER
12 818158 2
2 (1/2"X2")
13 818153 RW-1630 SPRING BRACKET RUBBER 2
MOUNTING STRIP
4 RW-1212/1420 PIVOT ARM TIE PIN SPACER
3 14 12044 2
TUBE
15 15 10124 RW-1212/1420 PIN ASSY.,FRONT 4
17 21 16 12052 RW-1212/1420 FRONT CYL.SPACER 4
21 RW-1630 FRONT HEX NUT, SLOTTED (1-
1 17 818134 1/2"-6) 4
17 18 818127 RW-1630 FRONT HEX NUT, SLOTTED (1"-8) 4

5
19 12042 RW-1212 PIVOT ARM TIE PIN DETAIL 2
HN3/4-
20 HEX NUT 3/4-10 GRADE 8 2
10GR8
21 818136 RW-1630 FRONT WASHER, FLAT (FW1-1/2) 4
NS 818137 RW-1630 FRONT COTTER PIN (1/4"X2-1/2") 4
NS 818128 RW-1630 FRONT COTTER PIN (3/16"X2") 4
NOTE: NS = NOT SHOWN ON DRAWING
1 16
GM/CHEVY 45/5500 FRONT
20 14 19 ASSY. PARTS DIAGRAM
B
A - - -
6 TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
FRAC, MACH: ± 1/32" MANUAL, '08 C4/5500 FRONT ASSY PARTS

FRAC, OTHER: ± 1/16" - DIAGRAM, RW-1019
.X ± .063
.XXX ± .005
DRILL SIZES: + .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
NEH 4/18/11 M1019110 #
9 97
2 8.
12178 - DRIVER SIDE INNER 11441 - DRIVER SIDE OUTER

12179 - PASSENGER SIDE INNER 11442 - DRIVER SIDE INNER
12124 - EITHER OUTER 11443 - PASSENGER SIDE OUTER
11444 - PASSENGER SIDE INNER 11472 - DRIVER SIDE OUTER
11493 - DRIVER SIDE INNER
11474 - PASSENGER SIDE OUTER
11477 - PASSENGER SIDE INNER
11494 - FRONT FRAME BRKT
D C 1019 LONG ARM, '02-'09 GM/CHEVY 45/5500 1019 LONG ARM, '06 F4/550
1019 LONG ARM, 2008 - 2012 RAM/STERLING 45/5500 A D
AND 2013+ RAM 45/5500 W/ GASOLINE ENGINE
11310 - DRIVER SIDE OUTER

6 17
5 30 2 3.
2 3. 11446 - DRIVER SIDE INNER
11498 - FRONT FRAME BRKT
1019 LONG ARM , 2013+ RAM 45/5500 W/ DIESEL ENGINE C D

1019 SUPER-DUTY OUTER LONG ARM, '98 TO '04 1019 LONG ARM, '08 F4/550
NOTE: GIVEN PART #'S HAVE VARYING RETENTION OPTIONS.

WHEN ORDERING PARTS, PLEASE INFORM THE DMF PARTS DEPARTMENT
OF WHAT STYLE OF LONG ARM AND RETENTION OPTIONS YOU REQUIRE.
REFER TO DRAWING M1019124 FOR MORE INFORMATION.
11314 - DRIVER SIDE INNER NOTE:

5 30
2 3.
11316 - PASSENGER SIDE INNER IF ORDERING DRIVER'S SIDE OUTER ARM, MUST HAVE SERIAL #
63
18. 0
10099 - PASSENGER SIDE OUTER FOR A REPLACEMENT SERIAL TAG. (LONG ARM WILL SHIP WITH
10121 - PASSENGER SIDE INNER TAG ATTACHED)
D 9/1/17 REMOVED 2001 AND OLDER GM; ADDED 2013+ RAM DIESEL BJF
C 5/27/11 ADDED GM/CHEVY LONG ARM, ADDED YEAR MODEL NEH
B 5/3/11 ADDED RETENTION NOTE NEH
A 4/18/11 ADDED DODGE/STERLING LONG ARM, ADDED YEAR MODEL NEH
1019 SUPER-DUTY INNER LONG ARM, '98 TO '04 REV DATE DESCRIPTION BY APP
1019 SUPER-DUTY INNER LONG ARM, PRE-'98 A TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
RW-1019 VARIOUS LONG ARMS
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019
.X ± .063
.XX ± .030
.XXX ± .005
DRILL SIZES: + .015
ANGULAR: ± 1°
THREADS: 2A AND 2B
JBG 4/22/10 M1019116 D
ITEM PART
PARTS: (MUST HAVE SERIAL # WHEN ORDERING) DESCRIPTION QTY.
NO. #
COMOPLETE FRONT AXLE ASSEMBLY OPTIONS (AXLE, AXLE TUBES, 1 10603 RW-1019-HD AXLE 1
WHEELS, AND PIVOT ARMS) 2 10660 RW-1019-HD AXLE TUBE ASSY., FRONTLH 1
('05-CURRENT F-4/550, '08-CURRENT DODGE/STERLING 45/5500 ONLY) 3 10658 RW-1019-HD AXLE TUBE ASSY., FRONT RH 1
NON-INSULATED, WITH BRAKES - 11676 4 11111 RW-1019 PIVOT ASSY., FRONT RH (3500 & F-550) OUTBOARD 1
NON-INSULATED, NO BRAKES - 11678 5 11105 RW-1019 PIVOT ARM ASSY., FT RH INBOARD 1
INSULATED, WITH BRAKES - 11668 6 11104 RW-1019 PIVOT ARM ASS'Y, FRONT DRIVER INBOARD 1
INSULATED, NO BRAKES - 11662 7 11110 RW-1019 PIVOT ARM ASSY., FRONT LH (3500 & F-550) OUTBOARD 1
FRONT AXLE TUBE OPTIONS: 8 10570 RW-1019-HD WHEEL,NON-INS., W/RACES 1
DRIVER'S SIDE, W/BRAKE SADDLES: 10660 9 10580 RW-1019-HD WHEEL,INSULATED,w/RACES 1
PASSENGER'S SIDE, W/BRAKE SADDLES: 10658 10 10591 RW-1019-HD BEARING CONE 4
DRIVER'S SIDE, NO BRAKE SADDLES: 10662 11 10592 RW-1019-HD SEAL, STANDARD 2
PASSENGER'S SIDE, NO BRAKE SADDLES: 10664 12 10595 NUT, AXLE (TIMKEN TN-08) 2
13 10596 WASHER,TONGUE (TIMKEN K-91508) 2
4 5 14 10598 WASHER, AXLE TAB (TIMKEN WH-08) 2
15 10516 RW-1019 HUBCAP, H.D. STYLE 2
16 16 12564 ANTI-ROTATION PIN 1
6 7 17 800108 HUBCAP BOLTS, (HHCS 5/16-18X3/4") 8
18 12566 ANTI-ROTATION PIN LOCK WASHER 1
18 19 800109 HUBCAP LOCK WASHERS, (LW-5/16) 8
20 10586 RW-1019-HD INSULATOR RING 1
21 10590 RW-1019-HD BEARING RACE -
22 10588 10" HD WHL INSULATOR DETAIL -
23 10587 10" HD WHL STEEL SLEEVE DETAIL -
24 10584 10" HD WHL: INSUL MACHINE DETAIL -
8 9 NOTE: ITEMS 21-24 ARE COMPONENTS OF
ITEM 9
3
20
15
2 1
11
10
A- PACK ALL BEARINGS ENSURING COMPLETE COVERAGE (INSIDE AND OUT) 21 10 13 14
B- INSERT BEARING IN INBOARD SIDE OF WHEEL (FLANGE SIDE) 24 22 23 21 12 19 17
C- PACK GREASE ON INBOARD SIDE OF BEARING, COVERING BACK SIDE OF BEARING
FORD/DODGE/STER. FRONT WHEEL
& AXLE ASSY. PARTS DIAGRAM
J- ADJUST BEARING END-PLAY B 1/23/17 REVISED BEARING SETTING PROCEDURE BJF
1- TIGHTEN AXLE NUT TO 200 FT-LBS WHILE ROTATING WHEEL
A 7/5/11 UPDATED TO SHOW INSULATED ASSEMBLY NEH
2- BACK OFF AXLE NUT ONE FULL TURN
B 3- TIGHTEN AXLE NUT TO 50 FT-LBS WHILE ROTATING WHEEL REV DATE DESCRIPTION BY APP
TOLERANCES:
4- BACK OFF AXLE NUT (ITEM 12) BY ONE NOTCH OF THE TAB WASHER (ITEM 14) TITLE:
(UNLESS SPECIFIED)
K- SELECT TABS ON TAB WASHER THAT MOST NEARLY LINE UP WITH THE SLOTS IN THE AXLE NUT FRONT WHEEL & AXLE ASSY PARTS DIAGRAM,
AND BEND THEM UP TO SECURE THE NUT FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 '08 F-550, RW-1019
L- VERIFY BEARING END-PLAY IS 0.001”-0.005” WITH A DIAL INDICATOR .X ± .063
M- FILL OUTBOARD CAVITY WITH GREASE .XXX ± .005
N- RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE (OUTBOARD FACE OF HUB) ANGULAR: ± 1°
O- INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK WASHERS SURF FINISH: 125 MICRO
THREADS: 2A AND 2B
NEH 4/19/11 M1019112 B
PARTS: (MUST HAVE SERIAL # WHEN ORDERING) 1 10603 1 RW-1019-HD AXLE
COMPLETE FRONT AXLE ASSEMBLY OPTIONS (AXLE, AXLE TUBE, 2 10660 1 RW-1019-HD AXLE TUBE ASSY., FRONTLH
WHEELS, AND PIVOT ARMS) ('08-CURRENT C4/5500 ONLY)
NON-INSULATED, WITH BRAKES - 11680 3 10658 1 RW-1019-HD AXLE TUBE ASSY., FRONT RH
NON-INSULATED, NO BRAKES - 11679 4 12108 2 1212 PIVOT ARM ASSY. FOR 1019 TUBE, LH
INSULATED, WITH BRAKES - 11663 5 12109 2 1212 PIVOT ARM ASSY. FOR 1019 TUBE, RH
INSULATED, NO BRAKES - 11667
6 10570 1 RW-1019-HD WHEEL,NON-INS., W/RACES
FRONT AXLE TUBE OPTIONS:
DRIVER'S SIDE, W/ BRAKE SADDLES: 10660 7 10580 1 RW-1019-HD WHEEL,INSULATED,w/RACES
PASSENGER'S SIDE, W/ BRAKE SADDLES: 10658 8 10591 4 RW-1019-HD BEARING CONE
DRIVER'S SIDE, NO BRAKE SADDLES: 10662 9 10592 2 RW-1019-HD SEAL, STANDARD
PASSENGER'S SIDE, NO BRAKE SADDLES: 10664
10 10596 2 WASHER,TONGUE (TIMKEN K-91508)
1019 WHEEL (W/RACES) OPTIONS:
INSULATED: 10580 11 10598 2 WASHER, AXLE TAB (TIMKEN WH-08)
NON-INSULATED: 10570 12 10595 2 NUT, AXLE (TIMKEN TN-08)
13 10516 2 RW-1019 HUBCAP, H.D. STYLE
14 800108 8 HUBCAP BOLTS (HHCS 5/16"-18 X 3/4")
15 800109 8 HUBCAP LOCK WASHERS, (LW-5/16)
16 12564 1 ANTI-ROTATION PIN
17 12566 1 ANTI-ROTATION PIN LOCK WASHER, (LW-3/8GR8)
6 4 18 10586 1 RW-1019-HD INSULATOR RING
19 10590 - RW-1019-HD BEARING RACE
20 10588 - 10" HD WHL INSULATOR DETAIL
21 10587 - 10" HD WHL STEEL SLEEVE DETAIL
16 22 10584 - 10" HD WHL: INSUL MACHINE DETAIL
17 NOTE: ITEMS 19-22 ARE

7 COMPONENTS OF ITEM 7
3 2

A- PACK ALL BEARINGS ENSURING COMPLETE COVERAGE (INSIDE AND OUT) 11
B- INSERT BEARING IN INBOARD SIDE OF WHEEL (FLANGE SIDE)
C- PACK GREASE ON INBOARD SIDE OF BEARING, COVERING BACK SIDE OF BEARING 1 9 8 19 22 20 21 19 10 12 18 13 15 14
GM/CHEVY 45/5500 FRONT WHEEL
J- ADJUST BEARING END-PLAY
& AXLE ASSY. PARTS DIAGRAM
1- TIGHTEN AXLE NUT TO 200 FT-LBS WHILE ROTATING WHEEL
B 1/24/17 REVISED BEARING SETTING PROCEDURE BJF
2- BACK OFF AXLE NUT ONE FULL TURN
B 3- TIGHTEN AXLE NUT TO 50 FT-LBS WHILE ROTATING WHEEL A 7/5/11 UPDATED TO SHOW INSULATED ASSEMBLY NEH
4- BACK OFF AXLE NUT (ITEM 12) BY ONE NOTCH OF THE TAB WASHER (ITEM 11) REV DATE DESCRIPTION BY APP
K- SELECT TABS ON TAB WASHER THAT MOST NEARLY LINE UP WITH THE SLOTS IN THE AXLE NUT TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
AND BEND THEM UP TO SECURE THE NUT
FRONT WHEEL & AXLE ASSY PARTS DIAGRAM,
L- VERIFY BEARING END-PLAY IS 0.001”-0.005” WITH A DIAL INDICATOR FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" RW-1019 '08 C4/5500, RW-1019
M- FILL OUTBOARD CAVITY WITH GREASE .X ± .063
N- RUN A BEAD OF SILICONE ON HUBCAP MOUNTING SURFACE (OUTBOARD FACE OF HUB) .XXX ± .005
O- INSTALL HUBCAP WITH PROVIDED HEX SCREWS AND LOCK WASHERS DRILL SIZES:
ANGULAR:
± 1°
THREADS: 2A AND 2B
NEH 4/19/11 M1019114 B
1/2" CROSS TUBE - P/N #810349 3.00" CROSS TUBE - P/N #810154 5.00" HIGH 3-PC. CROSS TUBE - P/N #810107
4.00
.50 5.00
1.50
3.00
4.00
6.00" HIGH 3-PC. CROSS TUBE - P/N #810328
1.00" CROSS TUBE - P/N #810261
5.00
4.00" CROSS TUBE - P/N #810267 6.00
1.00
2.00
VOLVO CROSS TUBE - P/N #809999
1-1/4" CROSS TUBE - P/N #810258

3.5
4.00 4.50
5.00
1.25 VOLVO OFFSET CROSS TUBE - P/N'S BELOW

2.25
5.00" CROSS TUBE - P/N #810270
5.00
2.00" CROSS TUBE - P/N #810264
7.96
DRIVER SIDE (SHOWN) - P/N #810388

PASSENGER SIDE (OPPOSITE HAND) - P/N #810389
B - - -
A - - -
5.00
6.00 REV DATE DESCRIPTION BY APP
2.00 TOLERANCES:
(UNLESS SPECIFIED)
TITLE:
3.00 VARIOUS CROSS TUBE DETAILS
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" -
.X ± .063
.XX ± .030 DIVERSIFIED METAL FABRICATORS, INC. (404) 875-1512
.XXX ± .005
ANGULAR: ± 1°
THREADS: 2A AND 2B
JBG 8/11/2010 MGENN101 #
2.875
4.000
5.500
6.625
8.000
4" SPRING HANGER - P/N #818155
10.000
6-5/8" OFFSET SPRING HANGER - P/N #818172
5.500
6.625
8.000
6-5/8" SPRING HANGER - P/N #818170
8.375
9.500
10.000
9-1/2" OFFSET SPRING HANGER - P/N #810136
7.875 B
9.000 A - - -
TOLERANCES:
TITLE:
(UNLESS SPECIFIED)
VARIOUS SPRING HANGER BRACKETS
FRAC, MACH:
FRAC, OTHER:
± 1/32"
± 1/16" -
.X ± .063
8.000 .XXX
DRILL SIZES:
± .005
ANGULAR: ± 1°
9" SPRING HANGER - P/N #818142 THREADS: 2A AND 2B

JBG 4/01/10 MGENN100 #
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 parts@dmfatlanta.com
Service Department (404) 879-7882 service@dmfatlanta.com
Phone (404) 875-1512  Fax (404) 875-4835 info@dmfatlanta.com

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DIVERSIFIED METAL FABRICATORS, INC.

Parts & Service Manual

SERIAL NUMBER (FRONT) ________________________

SERIAL NUMBER (REAR) ________________________

DMF  665 Pylant Street  Atlanta, Georgia 30306

Message from DMF

© 2017 DMF, Inc. All Rights Reserved.

SECTION 1.0 GENERAL INFORMATION

© 2017 DMF, Inc. All Rights Reserved. 1-1

1.1 GENERAL DESCRIPTION

1-2 © 2017 DMF, Inc. All Rights Reserved.

1.2 CURRENTLY APPROVED CHASSIS

2008-2016 Ford F-4/550 08-Present Ram 45/5500

© 2017 DMF, Inc. All Rights Reserved. 1-3

1.3 FRONT RAILGEAR

1.3.1.A ’08-‘16 Ford F-4/550 Front Railgear Components

1-4 © 2017 DMF, Inc. All Rights Reserved.

1 FRONT MOUNTING PIN

7 COBRA BRAKE (IF EQUIPPED)

4 8 REAR MOUNTING PIN

1.3.1.C ’08 GM 4/5500 Front Railgear Components

© 2017 DMF, Inc. All Rights Reserved. 1-5

1.4 REAR RAILGEAR

Figure 1.4.1 Rear Railgear Components

1-6 © 2017 DMF, Inc. All Rights Reserved.

1.5 ANTI-LOCK BRAKE (ABS), TRACTION CONTROL & ELECTRONIC

Please refer to the following note relevant to your chassis:

Ford F4/550 ABS/Traction/ESC Notes:

Dodge 4/5500 ABS Notes:

GM 4/5500 ABS Notes:

© 2017 DMF, Inc. All Rights Reserved. 1-7

SECTION 2.0 OPERATIONS

© 2017 DMF, Inc. All Rights Reserved. 2-1

2.1 BEFORE YOU OPERATE THE RAILGEAR

Railgear Retention Systems and Locations

2.1.2 Daily Inspection

2-2 © 2017 DMF, Inc. All Rights Reserved.

2.2 HIGHWAY OPERATION

2.3 GETTING ON THE RAIL

2.3.1 Getting onto the Rail

© 2017 DMF, Inc. All Rights Reserved. 2-3

2.3.4 On the Tracks

2.4 GETTING OFF OF THE RAIL

2-4 © 2017 DMF, Inc. All Rights Reserved.

SECTION 3.0 ROUTINE MAINTENANCE

© 2017 DMF, Inc. All Rights Reserved. 3-1

3.1 INSPECTION AND MAINTENANCE

3.1.1 DAILY MAINTENANCE

 Visually inspect for hydraulic fluid leaks.

 Check level of hydraulic oil and all other fluids.

3-2 © 2017 DMF, Inc. All Rights Reserved.

3.1.3 BI-ANNUAL MAINTENANCE OR AS REQUIRED

3.1.4 ANNUAL MAINTENANCE OR AS REQUIRED

3.2 LUBRICATION SPECIFICATION

Wheel Bearing Grease / Grease Fittings:

© 2017 DMF, Inc. All Rights Reserved. 3-3

*AS A WEEKLY PREVENTITIVE MAINTENANCE PROCEDURE:

• Warm Climates: Mystik JT-6 Hi-Temp Multi-Purpose .XX

3.3 WHEEL WEAR GAUGE