Operating and Service Manual Rail Puller
Contents
1. 22 2 0 0 0020002000 5 2 1 2 1 Inspection and Warranty Registration 2 1 22 Initial Assembly and In Service 2 1 2 3 rati esed e 2 3 Sectuonss Operating ada 3 4 31 Safety Precautions and Devices T 3 4 32 TWAS A AR A 3 4 33 Normal Operating Parameters toto i estes e Da reae ae eoa add 3 5 o4 Emergency PrOCEOUTE S KN ananas R s 3 6 Section 4 Maimtenance 3 6 35 Safety Precautions and DEMCES obere edite 3 6 30 Dail Inspection and la Lo 3 7 PP Eren les 66009 2522 W 3 8 Secon Parts Lists and Ek OG P ot 4 1 4 1 Recommended Spare Parts booties 4 1 42 Standard Parts List 43 Customer Options Lists by Serial Number 2 2 2 4 2 Section 5 Parts and Service Support EA 5 1 51 iNonsVVarranty Parts Sales2. ACE OE 5 1 52 Technical SUDDOFt amp SENICE u L u u 5 1 5i Warranty arts amp S NI66u u l DIC LRL LUE 5 2 SEGUGNO ADPENAICES uu 6 1 6 1 Sales 5 6 1 E RNC 6 1 1910093 Rev1 Draft 21 Jan 03 doc This list identifies where photos tables and other figures are located within the text of this manual All parts lists and drawings are provided in Section 5 Figure 1 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Table 1 Figures Rail Rail Puller Left Frontal View Es Rail Puller Right Frontal View 5 cR E Rail Puller Rail Frame Showing Center Datum uv Rail Puller Manufacturer s Data Plate POTENS Rail Puller Hydraulic Controls ssec 26 Rail Puller Hydraulic Quick Couplers Rail Puller Hydraulic pressure Gauge cT TRENT Y Rail Puller Rail Gripper Cams On Working End Rail Puller Rail Gripper Cams On Stationary 52 8 Rail Puller Synchronized gt Rail Puller Caution Decal RN Rail Puller Lifting Chain CETERIS Rail Puller Operating instructions Decal
3. m Jm mM lt lt RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY EXPLODED VIEW OF HYDRAULIC FITTINGS CONNECTIONS RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY HYDRAULIC HOSE ASSEMBLIES BILL OF MATERIAL ITEM No PART No DESCRIPTION QUANTITY HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD HOSE ASSY HYD 10 HOSE ASSY HYD 11 HOSE ASSY HYD 12 HOSE ASSY HYD 13 HOSE ASSY HYD 14 HOSE ASSY HYD eS a Om bs Du s 2 JD R
4. inane Rail Puller Hydraulic Oil Drain Hose Rail Puller Hydraulic Hose Recommendation ZZ 1 1 Purpose This manual provides general instructions for operating and maintaining the Racine Railroad Products Rail Puller 1 2 Cancellation Not Applicable Initial Release Record subsequent changes made to this manual on page i 1 3 Scope This Bulletin applies to all Racine Railroad Products Rail Puller power tool Reference Serial Number Decal 1 4 Definitions This manual uses the following standard terms for clarity 1 4 1 1 4 2 143 1 4 4 DANGER An operating procedure practice or condition etc which WILL RESULT IN INJURY OR DEATH if not carefully observed or followed WARNING n operating procedure practice or condition etc which may result in injury or death if not carefully observed or followed Caution An operating procedure practice or condition etc which may result in damage to equipment if not carefully observed or followed Note An essential operating procedure practice or condition etc 1 5 General Safety Precautions and Devices 2 1 1910093 Rev1 Draft 21 Jan 03 doc uro 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 1 5 10 WARNING Failure to follow safety precautions when operating this equipment can result in serious injury or death to the operator or other persons in the area Obser
5. Non Warranty Parts and Technical Service policies and procedures are provided in Section 6 of this manual 2 10 Section 2 Initial Set up and Adjustment 2 1 2 2 2 2 1 2 2 2 Inspection and Warranty Registration The Rail Puller is normally shipped via common carrier in a crate or pallet The warranty period begins on the date of shipment from our factory Upon delivery by the carrier inspect the Rail Puller and shipping materials for damage Ensure that all items indicated on the packing list have been received Address items lost or damaged in shipment with the freight carrier Removing Packing Materials Delivery Inspection Remove the packing materials and inventory the contents of the packing list Ensure that Operating and Service Manuals tool kits and any other materials sent with the machine are in good condition Product Registration Card Please fil out and return the Product Registration Card to help us better serve you Your feedback on the Product Registration Card helps us improve our products and service Note Unless otherwise indicated the address and contact name provided on the Product Registration Card will be the mailing address for future Service Bulletins and Customer Service Information Note Please contact our Service Department at the address provided in Section 6 of this manual if you have any problems with or questions about your new machine Initial Assembly and In Service Maintenance T
6. The lifting chain sling s three point system levels and stabilizes the unit for easy positioning on the rail Figure 12 Rail Puller Lifting Chain Sling 3 3 Normal Operating Parameters Performance Data The Racine Railroad Products Rail Puller is designed to pull two lengths of rail together in preparation for thermite and boutet welds It will pull 120 tons and 6 inches of travel and will accommodate rail size ranging from 115 to 141 Ibs The unit operates on low pressure 2 000 psi 138 bar so a pressure intensifier is not used on this Rail Puller Production Rate The Racine Railroad Products Rail Puller production rate is predicated on a need to use basis in railway maintenance activity Cautioni REMOVE RAIL SPIKES AND ANCHORS AT A MINUMUM CLEARANCE OF 60 INCHES ON EACH SIDE OF THE CUT RAIL JOINT TO BE WELDED BEFORE SETTING RAIL PULLER ONTO RAIL Caution DO NOT OPERATE RAIL PULLER WHEN BYSTANDERS ARE NEAR THE WORK AREA Caution DO NOT OPERATE RAIL PULLER NEAR FLAMMABLE MATERIALS ENERGIZED TRANSMISSION LINES Caution AVOID ENVIRONMENTAL OIL SPILLAGE DISPOSE OIL DRAINED FROM TRAPPED PRESSURE VALVE IN A SUITABLE CONTAINER Caution DO NOT USE HOSES COUPLERS OR FITTINGS WHICH ARE DAMAGED REPLACE IMMEDIATELY Caution DO NOT DISENGAGE TENSION DURING RAIL JOINT WELDING OPERATION ALLOW WELD TO COOL DOWN BELOW 700 F BEFORE RELEASING Securely connect the return tank hose first from the power source port
7. ASSEMBLY RIGHT BASE CYLINDER ASSEMBLY BILL OF MATERIAL ITEM No PART No DESCRIPTION QUANTITY 1 GLAND CYL END COMPLETE 1 2 PISTON CYLINDER 1 3 ROD CYLINDER COMPLETE 1 4 RING RETAINING 1 5 O RING 1 6 O RING 7 4 8 1 9 WIPER SEAL ROD 1 10 O RING 1 11 BACKUP RING 2 12 RING BACKUP 2 13 HYDRAULIC CYLINDER R 1 14 BOLT 25 X 1 50 FSC 4 15 BOLT 32 NC X 1 25 SHCS 4 16 RETAINING RING 1 17 O RING 1 ITEM No PART No 3 RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY HYDRAULIC FITTINGS BILL OF MATERIAL DESCRIPTION 25 HH PLATED LOCK WASHER 25 NUT 32 NC X 2 SHCS WASHER FLAT 25 PLATED BOLT 32 NC X 2 SHCS LOCKWASHER 32 PLATED BOLT 25 NC X 1 75 HH PL GR 5 FITTING FITTING FITTING FITTING COVER COUPLER COVER COUPLER FITTING FITTING FITTING FITTING COVER COUPLER COVER COUPLER FITTING FITTING FITTING FITTING VALVE NEEDLE FITTING TEE MANIFOLD HYD RETURN FITTING 90 MANIFOLD HYDRAULIC GAUGE PRESSURE VALVE CONTROL VALVE HOLDING SPACER NEEDLE VALVE FITTING 90 FITTING TEE Elbow QUANTITY RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY EXPLODED VIEW OF RAIL PULLER ANO LP SERIALE 021426012
8. T M S NG 1977 MUN NE MIT MADE 19 Sy JU AU jJ 121 INTOROPENING ONS PAGHEENOSORBRLUELE v uit ERIT S VAL TERRESE URE TRIRAREBDAE AURE AUSTA RETON DSEOAWHENSORERATINGARU EENE JEGHANISMBANU BRULEE RAIN G 08110 ii GBYALYB 11 805110 AE MOBAISECOMBLETE MORET MING VALUE STANDERUSHKADOWNEONAJNE ATROUVA VERHAND 51 11 HAY SIN i emend COMPLETE en HES BULLING DISTANCE ES u i Im ONE TING RHE HOSESSESHUTSTHESE DWERSSQUERGESORRAANDEORE DP M VN Ii OTT ADR MR TORRE WT d BRESSUME aN 10 ST Figure 13 Rail Puller Operating Instructions Decal Daily Inspection and Lubrication At a minimum perform the following routine daily maintenance on the Rail Puller to keep it in good working condition Daily Inspection Before operating the Rail Puller inspect the following and correct any problems as necessary e General Condition of the Assembly e All Guards and Safety Devices are Installed and Operable e Controls are Operable e Hose Condition Routine Adjustments and Maintenance This section outlines basic adjustments and maintenance required for daily operation
9. and are in good condition Inspect for any hydraulic oil leaks and repair as required Do not operate the Rail Puller if a leak is present since the ability to hold the rail in position maybe lost if a leak reduces oil pressure Close the trapped pressure valve completely Turn the rail holding counterclockwise release rail direction to open the hydraulic circuit 315 910093 M Rev1 Draft 21 Jan 03 doc 3 4 3 4 3 Inspect the gripper pads for wear or damage Replace excessive worn or damaged pads before use Gripper pads that are in poor condition can slip on rail Inspect hoses which connect the Rail Puller to power source for wear cracking fatigue or leaks before using DANGER NEVER INSPECT PRESSURIZED HOSES COUPLERS OR FITTINGS WITH HANDS OR AT CLOSE DISTANCES PRESSURIZED FLUID CAN PUNCTURE THE SKIN AND INJECT OIL INTO THE BODY WHICH WILL RESULT IN INJURY OR DEATH TO SAFELY TRANSPORT AND STORE THE RAIL PULLER PERFORM A NORMAL SHUT DOWN AS FOLLOWS 1 Stop the hydraulic power source 2 Depressurized the system 3 Allow system and hydraulic fluid to cool 4 Disconnect the supply pressure hose to the power source pressure port from the tool 5 Disconnect the return tank hose to the hydraulic power source Return port from the tool Out port 6 To prevent contamination always install dust caps over the hydraulic ports of the tool when disconnected Prepare the unit for transport
10. as outlined in above section Emergency Procedures In the event of any malfunction IMMEDIATELY SHUT OFF THE HYDRAULIC POWER SOURCE and correct the problem DO NOT PERFORM MAINTENANCE ON THE RAIL PULLER WHILE THE HYDRAULIC POWER SOURCE MOTOR IS RUNNING OR HOSES ARE CONNECTED Maintenance Procedures Safety Precautions and Devices Normal maintenance of the Rail Puller can be performed without any special maintenance related safety devices Before operating the Rail Puller perform a daily inspection as described in Section 4 2 Ensure that all general safety precautions are observed and that proper personal protective clothing is worn as described in Sections 1 5 and 3 1 WARNING DO NOT PERFORM MAINTENANCE ON THE RAIL PULLER WHILE THE HYDRAULIC POWER SOURCE MOTOR IS RUNNING OR HOSES ARE CONNECTED Safety Devices Upon completion of maintenance ensure that the following Safety Devices are installed on the Rail Puller The hydraulic control valves are operable The hydraulic quick couplers and hoses are safe to use Weekly lubrication of the gripper cams and gripper arms The gripper pads are in good condition 3 4 4 Annually Remove the cover from the opposite end as well as the control panel backside cover Peform a detailed inspection of the systems hoses and fittings for damage and leaks 3 6 345 Special Procedures Required See Local Requirements 3 5 3 5 1 2 1 E
11. cum a 3 2235 3 0 EAR EYE HEAD Figure 6 Rail Puller Hydraulic Quick Couplers 42272342 Figure 7 Rail Puller Hydraulic Pressure Gauge 2 7 910093 Rev1 Draft 21 Jan 03 doc Figure 8 Figure 9 Rail Puller Rail Gripper Cams On Working End Rail Puller Gripper Cams On Stationary End INSPECT GRIPPER PADS FOR WEAR OR DAMAGE DAILY REPLACE REQ D Figure 10 Rail Puller Synchronized Rail Gripper Cams 1 10 Service Manuals and Tools 1 10 1 1 19 2 Operating and Service Manuals One Operating and Service Manual is provided with each machine Manuals are shipped with each machine Operating and Service Manual Changes The Operating and Service Manual may be updated to reflect product development and or revised operating and maintenance procedures If appropriate Service Bulletins may be released to provide additional operational maintenance and or safety information Record all changes made to this Manual in the Record of Changes on page i Submit recommendations and requests for Operating and Service Manual Changes to Racine Railroad Products Inc Attn Technical Service Manager 1524 Frederick Street P O Box 044577 Racine WI 53404 7577 Phone 262 637 9681 E mail techserv racinerailroad com Website _http www racinerailroad com 29 910093 M 1 Draft 21 Jan 03 doc 1 1
12. gpm 20 circuits that can be combined for one 10 gpm 40 lpm circuit e Ifthe tool is used in cold weather preheat the hydraulic fluid by running power sourc at low engine speed Fluid temperature should be at or above 50 F 10 400 ssu 82 centistokes before use when using recommended fluids Using too thick of fluid may result in tool damage e Check that the power is open center system Do not use the Rail Puller with closed center system or tool damage may occur e Check hydraulic hosed for cracks leakage and damage If the hoses or couplers show any of these wear characteristics replace them before operating the tool NEVER attempt to locate leaks with your hands personal injury may occur from pressure system Gripper Pads e Check gripper pads for wear or damage Replace excessively worn or damaged pads before use Gripper pads that are in poor condition can slip on rail e Check for loose or missing fasteners and roll pins Replace or tighten any missing hardware before using Rail Puller Hose Connecting e Wipe quick couplers with a clean lint free cloth before connecting them e Connect hoses from power source to the tool It is recommended that you connect the return hoses first and disconnect last to minimize or avoid trapping pressure within the tool e When connecting the quick couplers the flow should run from male coupler to female coupler The female coupler on the tool is the inlet Quick couplers are marke
13. 1 1 11 1 1 11 2 1 11 4 Warranty Terms and Conditions Warranty Period Each new machine and new parts of our manufacture are warranted against defects in material and workmanship for one year from the date of shipment from our factory When contacting the factory for parts service or warranty support please provide the Racine Railroad Products Model and Serial Number and any locally assigned identification number to our customer service personnel to help them identify your machine and better serve you Vendor Parts Warranty Period Other equipment and parts used but not manufactured by Racine Railroad Products are covered directly by the manufacturer s warranty for their products Warranty Parts and Service We will repair or replace without charge F O B factory Racine Wisconsin USA any part of our manufacture which is proven to be defective during the warranty period Material claimed defective must be returned if requested to the factory within 30 days from the date of the claim for replacement Ordinary wear and tear abuse misuse and neglect are not covered by this warranty Depending upon the circumstances we may provide technical assistance and or technical service support without charge to assist in the correction of warranty related problem Non Warranty Parts and Service Material damaged through normal wear and tear abuse misuse and or neglect are not covered by this warranty
14. 375 14 39 FLAT WASHER SAE No 6 14 40 NUT 32 NC NYLOCK 4 41 BOLT 32 X 4 CYL MOUNT 4 RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY RAIL PULLER ASSEMBLY BILL OF MATERIAL ITEM PART DESCRIPTION QUANTITY 42 PIN COTTER 125 X 1 25 3 43 BOLT 375 NC X 2 5 SHCS PLATED 8 44 BOLT 375 X 1 0 HH PL GR 5 6 45 BOLT 375 NC X 12 CARRIAGE 1 46 BOLT 25 NC X 50 SSBHCS 13 47 SCREW SOCKET SET 25 20 375 1 48 NUT JAM 12 49 BOLT 50 NC X 2 0 HH PL GR 5 1 50 51 WASHER 25 FLAT PLATED 1 52 25 X 75 STAINLESS STEEL 8 53 WEAR PAD CYLINDER 1 54 SCREW SET10 32 x 375 12 DM MN MEN 56 CAP 1 5T WASHER FLAT 187 BLK ZINC 1 58 HU 1058 SPRING CAM RETURN 2 59 Mt 1094 GRIPPER PAD 4 RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY CAM ARMS ACTUATOR CYLINDER ASSEMBLY BILL OF MATERIAL ITEM No PART DESCRIPTION QUANTITY 1 PISTON CYLINDER 1 2 BACKUP PISTON 3 O RING PISTON 4 BOLT 375 X 1 00 SHCS 5 O RING 6 O RING 7 END CAP ROD 8 SEAL WIPER 9 WIPER SEAL ROD 10 SEAL ROD 11 BACKUP ROD 12 TUBE CYLINDER 13 ROD CYLINDER RACINE RAILROAD PRODUCTS 1524 FREDERICK STREET RACINE 53404 262 637 9681 910093 RAIL PULLER
15. 4 FREDERICK STREET RACINE WI 53404 262 637 9681 910093 M RAIL PULLER ASSEMBLY RAIL PULLER ASSEMBLY BILL OF MATERIAL CAUTION USE ONLY GENUINE RACINE RAILROAD PRODUCTS INC PARTS THE SUBSTITUTION OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE HYDRAULIC RAIL PULLER No X PART No DESCRIPTION QUANTITY 1 375 NC HH PLATED 3 2 NUT 25 NC HH PLATED 4 3 LOCK WASHER 375 11 4 LOCK WASHER 25 2 5 WASHER FLAT 50 PLATED 4 6 WINGNUT 25 NC 2 7 NUT 50 NC HH SELF LOCKING 2 8 BOLT 50 NC X 2 75 PL HH GR 5 2 9 BOLT 32 NC X 1 25 SHCS 6 10 BOLT 50 NC X 1 25 HH PL GR 5 4 11 BOLT 25 NC X 1 0 HH PL GR 5 2 12 BOLT 25 NC X 5 0 GRADE 8 4 13 FRAME COMPLETE 1 14 CARRIER CAM COMPLETE 1 15 CAM COMPLETE R 1 16 CAM COMPLETE L 1 11 ARM GRIPPER R COMPLETE 1 18 ARM GRIPPER L COMPLETE 1 19 HYD CYLINDER WELDMENT R 1 20 HYD CYLINDER WELDMENT L 1 21 GUIDE CYLINDER END COMPLETE 2 22 PANEL STATIONARY END COMP 2 29 PANEL CONTROL COMPLETE 1 24 PANEL COVER CONTROL COMP 1 25 CYLINDER SLAVE COMPLETE 2 26 GEAR TIMING COMPLETE R 1 27 GEAR TIMING COMPLETE L 1 28 PLATE RETAINING 2 29 GUARD CYLINDER BOLT 2 30 GUARD GAUGE 1 31 FLAP SPARK 1 32 LINK GRIPPER ARM 2 33 ADAPTER LINK CYLINDER 1 34 PIN GRIPPER ARM 2 35 ZERK GREASE 2 36 TUBE CYLINDER 1 37 16105 ROD CYLINDER 1 38 RIVET POP SD46BS 25 X
16. DIAMETER SAE SPEC HOSE SAE SPEC HOSE WIRE BRAID FIBER BRAID 1 2 13 SAE 100R1 8 100R7 8 5 8 16 SAE 100R2 10 SAE 100R8 10 5 8 16 SAE 100R2 10 SAE 100R8 10 3 4 19 SAE 100R1 12 SAE 100R7 12 5 8 16 SAE 100R2 10 SAE 100R8 10 5 8 16 SAE 100R2 10 SAE 100R8 10 3 4 19 SAE 100R3 12 SAE 100R7 12 3 4 19 SAE 100R2 12 SAE 100R8 12 1 25 4 SAE 100R1 16 SAE100R7 16 1 LABELED AND CERTIFIED NON CONDUCTIVE TO BE USED NEAR ELECTRICAL CONDUCTORS 2 WIRE BRAIDED CONDUCTIVE DO NOT USE NEAR ELECTRICAL CONDUCTORS 3 FABRIC BRAIDED NOT CERTIFIED OR LABELED NON CONDUCTIVE DO NOT USE NEAR ELECTRICAL CONDUCTORS 4 HYDRAULIC HOSE RATED WORKING PRESSURE MUST BE AT LEAST 2500 PSI 173 BAR 5 RECOMMENDED HOSE SIZE 500 INCH 12mm I D UP 50 FT 15 M LONG 6 RECOMMENDED HOSE SIZE 625 INCH 16 mm I D UP TO 100 FT 30 M LONG U S A 50 F 450 SSU Max 100 F 130 200 SSU 140 F 85 SSU Min VISCOSITY FLUID THICKNESS METRIC 10 C 95 Centistokes 38 27 42 C S 60 16 5 C S Min Pour Point 10 F 23 C Minimum for cold startup Viscosity Index ASTM D 2220 140 F Minimum Demulsibility ASTM D 1401 30 Minutes Maximum Flash Point ASTM D 92 340 F 171 C Minimum Rust Inhibition ASTM D 665 A amp B Pass Oxidation ASTM D943 1000 Hours Minimum Pump Wear Test ASTM D2882 60 mg Maximum 2 2 The Racine Hydraulic 910098 power unit is recommended for hydraulic supply This unit is equipped with two 5
17. Operating and Service Manual Reference Serial Number Decal Racine Railroad Products 1524 Frederick Street Racine WI 53404 7577 Phone 262 637 9681 Fax 262 637 9069 910093 M Rev1 Draft 21 Jan 03 doc Table of Contents Cover Page Record OF Tabea R Ai nte 9 Listo Figures S TaDieS IV Section 1 General Information and eel 1 1 Purpose HE 152 A 1 1 gt 10 0 RETURN 1 1 14 Definitions EPEE 1 1 15 General Safety Precautions Devices OLA ees ede eee hee 1 1 16 Machine Description and 1 2 iT Machine WE GA CA 1 6 18 Machine Components and Major 1 6 19 Operator 1 7 Service Manuals and TOONS eo 1 10 TO Waranty Terms and e 1 10 Section 2 Initial Set up and
18. Rail Puller Open trapped pressure valve hoses to Rail Puller hydraulic systems and lift control lever up while connecting hoses Damaged couplers Inspect couplers replace if required Wrong size rail Rail Puller designed to fit 115 141 Ib rail Cams or gripper arm are Inspect cams and or gripper closed arms fully retract Rail Puller so clamping systems opens Rail Puller will not set down on rail 3 8 Rail Puller clamping system does not move Rail Puller clamps Rail but to pull rail Problem Rail Puller will not unclamp from rail Gap in rail does not close enough Rail Puller slips on rail does not have enough power Rail holding valve is closed Trapped pressure valve open Hydraulic Flow not turned at power source Damaged hose in hydraulic system Contaminated relief valve on Rail Puller Trapped pressure valve open Damaged hose in hydraulic system Low setting or contaminated relief valve on power source Contaminated relief valve on Rail Puller Possible Cause Rail holding valve is closed Excess pressure on Rail Puller from Rail Rail Puller is at max pull Maximum pulling pressure has been achieved Relief valve set too low at power source Relief valve defective in Rail Puller Irregular surface on rail where grippers grab Worn or damaged gripper pads Open rail holding valve Close
19. d through our Technical Service Department Our warranty terms and procedures are provided in Section 1 11 ofthis manual 5 3 1 Warranty Parts Claims Material claimed to be defective must be returned to our factory for evaluation Defective materials will be replaced or your account will be credited if replacement materials have already been purchased Please contact our Technical Service Department at the address provided below if you have any questions or problems 5 952 Warranty Service Support Depending upon the circumstances and availability of technical service personnel we may provide technical assistance and or field service support at no charge to the customer to assist in the correction of warranty related problems Contact our Technical Service Department at the address provided below to coordinate Warranty Technical Field Service Support Racine Railroad Products Inc Attn Technical Service Manager 1524 Frederick Street P O Box 044577 Racine WI 53404 7577 Phone 262 637 9681 Extension 111 E mail techserv racinerailroad com Website http Wwww racinerailroad com 9 2 Section 6 Appendices 6 1 Sales Representatives For more information about this or any of our other products please contact the nearest Representative shown on our Sales Representatives List 6 2 The Owners Manuals provided was current at the time of printing 910093 M Rev1 Draft 21 Jan 03 doc RACINE RAILROAD PRODUCTS 152
20. d trapped pressure valve Turn flow ON at power source Check for leaks and replace damaged hose Have relief valve checked by qualified technicians Close trapped pressure valve Check for leaks and replace damaged hose Test power source and make repairs as required Have relief valve checked by a qualified technician Open rail holding valve Quickly switch control lever between pull and release Release rail and retract Rail Puller to Fully retracted position Try pulling rail again Check the hydraulic system pressure gauge and determine the ton rate from legend If reading indicates 120 tons rail has achieved maximum pulling pressure Check pressure gauge reading on Rail Puller Test Rail Puller relief valve and repair as required Inspect rail and reposition Rail Puller if required Inspect gripper pads and replce as required 39 910093 Rev1 Draft 21 Jan 03 doc 3 10 Special Tools None specified 3 10 Section 4 Parts Lists and Illustrations The following parts lists are sorted by description in alphabetical order and grouped by the assembly that the individual parts are used on The lists provide the part description quantity used required and part number for each part as well as the part number of the assembly that the part is used on A List in the Dwg column indicates that a parts list for the assembly is included in Sections 4 2 4 3 of this manual A Dwg in t
21. d with an arrow to show flow direction e sure the pressure hose is connected to the pressure port and the return hose connected to the return port Note When possible connect the free ends of uncoupled hoses to prevent pressure build up in the hoses The sun can also increase pressure in the hoses and make connecting difficult e Turn on the hydraulic circuit at your power source e Note Depending on temperature let the power source and hydraulic oil warm up before applying full load 2 3 Setup and Adjustments Tool Connecting Procedures The power unit should be off before connecting or switching a tool and or hoses Turn the hydraulic on off valve to the off position before starting the engine Make sure all hoses are connected for correct flow direction to and from the tool being used When routing hose in the work area position them where personnel will not be at risk of tripping over them or where vehicles can run over them Also do not lay hose over sharp objects Caution DO NOT PULL ON HOSES TO DRAG THE POWER UNIT All mechanical and hydraulic components are protected by shields or guards to assure long life of components and provide protection to the operator All operations are self contained and automatic No manual clamping or wedges are used with the Racine Railroad Products Rail Puller oingle control panel houses all controls and monitoring devices required to operate the unit A single control is used to clam
22. designed for rail welding joint tensioning The Racine Rail Puller accommodates 115 Ib to 141 Ib rail and is positioned on work site using the 3 Point Lifting Sling and truck crane or hoist AFTER SETTING RAIL SAFELY REMOVE 5 LIFTING SLING AND HYDRAULIC CONTROL STORE OUT OF THE _ PANEL AT WORKING WORK AREA UNTIL gt gt 55 k Figure 1 Rail Puller Left Frontal View E LIFTING SLING 2 Puller Right Frontal View 213 910093 M Rev1 Draft 21 Jan 03 4 EN ZUGE CLEAR SPIKES AND ANCHORS 60 IN MIN 2 FROM RAIL JOINT Figure 3 Rail Puller Showing Center Datum 1 6 1 Manufacturer Racine Railroad Products Inc 1524 Frederick Street P O Box 044577 Racine WI 53404 7577 Phone 262 637 9681 E mail custserv racinerailroad com Website http lwww racinerailroad com 6 2 Physical Data Tool Specifications Hydraulic System Open Center Length 108 00 in 274 3 cm Width 28 00 in 71 1 cm Height Work Mode 19 94 in 50 6 cm Weight less tools 1130 Ib 512 5 kg Temperature Upper ambient operating 110 F 43 C Lower ambient operating 20 F 28 C 1 7 Lower ambient operating 20 F 28 C Options and Accessories Contact Racine Railroad Products 1524 Frederick Street P O Box 044577 Racine WI 53404 7577 Phone 262 637 9681 262 637 9669 Mechanical Data Hydraulic Motor Open c
23. enter Maximum Flow 10 40 Maximum Pressure 2000 psi 138 bar Maximum Back Pressure 250 psi 14 bar Performance Data Production Rate Machine Identification The Manufacturer s data plate is located on the control panel of the assembly Please provide the Racine Railroad Products Model and Serial Number and any locally assigned identification number to our customer service personnel when contacting the factory for parts service or warranty support ZA B MADE IN USA HYDRAULICS MODEL 4 910093 SERIAL 4 031436501 tta tn ht d 8 t MM Figure 4 Manufacturer s Data Plate 245 910093 M Rev1 Draft 21 Jan 03 doc 1 8 Machine Components and Major Assemblies 1 8 The Racine Railroad Products Rail Puller is comprised of a unitized main frame with the required components fastened onto 1 9 Operator Controls Refer to Figures 5 through 10 to identify and locate the controls and major components of the Rail Puller TOGGLI VALVE LAT ze RU AJ 3 m nt lt RZA 2 3 A Figure 5 Rail Puller Hydraulic Controls E v A amp i gt Cm 5 7 ak FLOW 10 PRA LEM m er MAX PRESSURE 2000 MP PS r zz MANO it PRESSURE To RETURN lt farau
24. evices are installed properly and are in good working order DO NOT OPERATE the machine until unsafe conditions have been corrected Operate the POWER SOURCE ENGINE only in a well ventilated area and ensure that the air filter s air filter cover s muffler are in good condition DO NOT crank the engine with the spark plug removed Keep the machine clean and free of debris Operate the machine in a safe and responsible manner Exercise caution when working on or near rotating or moving components hot components and fuel systems Be aware of potential fire hazards and prevent sparks etc from starting fires on right of way Comply with all instructions provided on any decals or placards installed on the machine and with any relevant amplifying information provided in this manual or other general operating procedures When you leave this equipment even for a short time shut off the hydraulic power source and disengage the hydraulic supply hoses shut off the power source engine ensure that all controls are in a safe position and install all appropriate locking and safety devices before doing any of the following Lubricating Adjusting Making Repairs Performing Service 2 2 1 5 11 1 6 Comply with all Lock Out Tag Out Procedures and other safety procedures established for your work environment Machine Description and Specifications The Racine Railroad Products Rail Puller is a transportable remotely powered tool
25. exceeding 2500 psi 173 bar measured at the power supply outlet The hydraulic system s back pressure measured at the tool end of the return hose should not exceed 250 psi 17 bar when operating at the maximum system flow 2 1 i910093 M Rev1 Draft 21 Jan 03 doc FLOW PER CIRCUIT GPM 5 5 8 5 TO 8 9 TO 12 9 12 9 12 NOTE HYDRAULIC HOSE TYPES LPM 19 TO 30 19 TO 30 719 30 7347045 34 TO 45 24 45 system conditions for measurements at maximum fluid viscosity of 400 ssu 82 centistokes i e at minimum expected operating temperature The recommended minimum cooling capacity to dissipate tool generated heat at a 40 F 22 C difference between ambient temperature and oil temperature is 6 H P 4 8 K W 210 BTU min Hydraulic systems should have an ideal filter of 10 micron to a maximum of 25 micron nominal filtration Filter elements should be sized for two to three times system flow to prevent filter by pass under low temperature start up and to provide maximum dirt holding capacity Hydraulic Hose and Fluid Requirements FEET TO 50 HYDRAULIC HOSE RECOMMENDATION LENGTH EACH HOSE METERS TO 15 51 100 15 TO 30 100 TO 300 TO50 51 TO 100 100 TO 200 30 TO 90 TO 15 15 TO 30 30 TO 60 USE BOTH BOTH PRESSURE RETURN BOTH PRESSURE RETURN PRESSURE RETURN INCH MM INSIDE
26. he Dwg column indicates that a drawing of the part with parts list is included in Section 5 4 of this manual Section 4 1 Recommended Spare Parts List Section 4 2 Standard Parts List Section 4 3 Customer Options Parts List Section 4 4 List of Illustrations 4 1 Recommended Spare Parts List The following parts are commonly used consumable wear and or routine maintenance items We recommend that these parts be stocked in the quantities indicated below to maintain your machine at peak performance Puller Recommended Spare Parts List IL Standard Parts List This list includes all serviceable parts used on a standard model machine that has no customer options installed See Section 4 3 for parts used on optional features that added to the standard model Rail Puller PIN 910093 71 F rnm 4 1 910093 Rev1 Draft 21 Jan 03 doc Placard List Rail Puller ________ List Rail Puller LN 910093 PLATE SERIAL Description DECAL LOGO 4 3 Customer Options Lists by Serial Number These lists include all parts that are specified as customer options and not included in a base model These lists are sorted by customer option RRP Ser No RRP Part No ______ RP 001 03 91009 22 _ O WAR EZ Options Parts List Section 5 Parts and Service Support 5 1 5 2 5 2 1 Non Warra
27. he Rail Puller was tested after assembly at our factory Flammable liquids were removed for shipping and must be reinstalled After assembly the machine should receive a thorough In Service inspection before initial operation If you do not feel qualified to perform this Service work yourself contact a competent mechanic or the Racine Railroad Products Service Department for technical support Uncrating a new machine Support the Rail Puller and cut the banding if any to release the machine from the shipping crate Use the included 3 point lifting sling and a truck crane or hoist to lift the Rail Puller The lifting sling points and the lifting sling chain assembly with 3 hooks are color coded with a red donut decal sling point located on the stationary end of the Rail Puller is for the red colored single sling hook and two blue donut decal sling points on the work end of the Rail Puller accommodate the two blue colored sling hooks Remove Rail Puller options and accessories separately clear of the crate and place on a safe surface Initial Assembly After unpacking and inspecting the Rail Puller options and accessories prepare the unit for service by doing the following Hydraulic Systems Use a calibrated flow meter and pressure gauge to check the hydraulic power source for 5 10 gpm 20 38 Ipm at 1500 2000 psi 100 138 bar e Relief valves should be adjusted for a cracking pressure 2200 2300psi 152 159 bar with full flow pressure not
28. nty Parts Sales Material damaged through normal wear and tear abuse misuse and or neglect are not covered by our warranty and should be ordered directly from our Customer Service Department Parts for models that are no longer in production may not be available Parts amp Customer Service Address Please contact us at the following address for parts and customer service support Racine Railroad Products Inc Attn Customer Service 1524 Frederick Street P O Box 044577 Racine WI 53404 7577 Phone 262 637 9681 Extension 105 E mail custserv racinerailroad com Website http www racinerailroad com Non Warranty Parts Orders When placing a parts order please provide the following information e Company Name and Billing Address e Purchase Order Number and Issuing Authority e Shipping Address e Special Handling Instructions e Contact Phone Number e Machine Model and Serial Number Part Numbers and Quantities Being Ordered Note Please use Racine Railroad Products part numbers when ordering parts Racine Railroad Products part numbers are shown on the parts lists and drawings in Section 5 of this manual and have only six 6 numbers Any part number with other than six numbers e g contains alpha numeric characters is a Vendor Part Number and NOT a Racine Railroad Products part number Technical Support amp Service Telephone and web based technical support is available for current production models through
29. of the Rail Puller These instructions are intended for operator level field maintenance and not repair shop or overhaul level procedures Lubricant Type and Locations Use lithium complex NLGI 2 grease and apply 3 5 strokes to the gripper arms on a weekly basis 317 910093 Rev1 Draft 21 Jan 03 doc VALVE REQUIRES PROPER POM Figure 14 Rail Puller poeni Oil L Drain Hose 3 6 Trouble Shooting The following chart can be used as guide to correct any problems you may be experiencing with the Rail Puller To determine the problem in operation of the Rail Puller always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as required in the Pre operation section of this manual Be sure you are using an accurate flow meter Check the flow with the hydraulic fluid temperature at least 80 F 27 C Always thoroughly check the power source and hoses before disassembling the Rail Puller To determine the problem in operation of the Rail Puller always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as required in the Pre operation section of this manual Be sure you are using an accurate flow meter Check the flow with hydraulic fluid temperature at least 80 F 27 Always Inoroughiy check the power source and hoses before disassembling the Rail Puller Possible Cause Unable to connect hydraulic Pressure trapped in
30. our Technical Service Department Service Manuals and limited technical support may be available for models that are no longer in production In the future Technical Support features will be expanded on our home page on the world wide web Telephone and E mail Technical Support Telephone and E mail technical support 15 available on normal U S business days from 8 00 AM to 5 00 PM U S Central Time Zone GMT 6 5 Daylight Savings Time Contact us at Phone 262 637 9681 Extension 111 E mail techserv racinerailroad com Website http llwww racinerailroad com 5 1 i910093 M Rev1 Draft 21 Jan 03 doc 3 22 Non Warranty Technical Field Service Support Depending upon the circumstances and availability of technical service personnel we may provide technical assistance and or field service support at the customers expense to assist in the correction of non warranty related problems Contact our Technical Service Department to coordinate Non Warranty Technical Field Service Support 5 2 3 Warranty Technical Field Service Support Depending upon the circumstances and availability of technical service personnel we may provide technical assistance and or field service support at no charge to the customer to assist in the correction of warranty related problems Contact our Technical Service Department to coordinate Warranty Technical Field Service Support 5 3 Warranty Parts amp Service Warranty parts and service are coordinate
31. p the rail and pull the rail A holding valve maintains the rail position and allows the hoses to be disconnected from the Rail Puller and used to operate other tools while welding 213 910093 M Rev1 Draft 21 Jan 03 doc Section 3 Operating Procedures 3 1 Safety Precautions and Devices Before operating the Rail Puller perform a daily inspection of the tool as described in Section 4 2 Ensure that all general safety precautions are observed and that proper personal protective clothing is worn as described below Personal Protective Equipment The following Personal Protective Equipment should be worn by the operator Figure 11 Rail Puller Caution Decal 3 2 Safety Glasses Hearing Protection 7 A CAUTION Safety Helmet SDA MAX FLOW 10 GPM 40 LPM R PRESSURE 2000 psi 150 W ZE suum Leather Work Gloves OPERATING TOOL Steel Toed Safety Shoes Transportation amp Handling NEVER ALLOW PERSONNEL BENEATH THE RAIL PULLER WHEN SUSPENDED INJURY OR DEATH WILL RESULT IF RAIL PULLER IS LOWERED OR DROPPED ON PERSONNEL ALWAYS STAND CLEAR AND MAINTAIN FIRM FOOTING WHEN GUIDING RAIL PULLER IN PLACE The Rail Puller is typically transported by truck or rail At job or storage site the Rail Puller is lifted into position with the aid of a hoist or truck crane using the supplied three hook lifting chain sling vs sling point locations color coded to match the lifting sling hooks
32. to the tool Return port and disconnect last to minimize or avoid trapping pressure within the tool Securely connect the supply pressure hose secondly from the power source port P to the tool Pressure port All mechanical and hydraulic components are protected by shields or guards to assure sane life of components and provide protection to the operator All operations are self contained and automatic No manual clamping or wedges are used with the Racine Railroad Products Rail Puller Single control panel houses all the controls and monitoring devices required to operate the unit A single control is used to clamp and pull the rail A holding maintains the rail position and allows the hoses to be disconnected from the Rail Puller and used to operate other tools while welding system pressure gauges and tons conversion legend along with cylinder positioning gauge allows the operator to monitor system functions while making a pull Clear rail of spikes and anchors 60 inches on each side of joint cut Use truck crane to lift and position Rail Puller on rail to be welded Rail must set into opening on each end of the Rail Puller Align center of opening in the rail with the Center decals on the Rail Puller frame When the Rail Puller is properly positioned unhook the lifting sling and remove sling from the work area Operation Before operating the Rail Puller check that all guards are in position and securely fastened
33. ve the following precautions whenever you are operating working on or near this equipment Always wear appropriate work clothing when operating this equipment DO NOT WEAR loose clothing jewelry radio belts etc when you are operating working on or near this equipment Always wear appropriate personal protective clothing when operating this equipment e g Orange safety vest hard hat safety glasses with side shields full face shield hearing protection steel toed safety boots leather gloves dust respirator leggings etc Always lift the Rail Puller with the 3 Point Lifting Sling and a truck crane or on rail hoist Always use care when transporting the Rail Puller and ensure proper footing and crew coordination when moving or positioning the Rail Puller This equipment may be operated from either side of the rail Remove all spikes and anchors a minimum of 60 inches on both sides from the cut rail including ballast that may hinder the proper placing of the Rail Puller on the rail Keep your hands arms feet head clothing etc out of the operating area and away from all rotating or moving components when you are operating working on or near this equipment Ensure that all guards covers hoses and operating components are in good working order and that all controls are in the appropriate position before starting the engine Ensure that installed safety equipment e g fire extinguishers first aid kits locking and safety d
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