Marta 10924A User manual

Track and Structures
Track Maintenance Training
Module - Tools
Rail Drill
Metropolitan Atlanta Rapid Transit Authority
Infrastructure Training

Course –Basic Track Technology
Module -- Tools –Rail Drill
Metropolitan Atlanta Rapid Transit Authority Infrastructure Training HRTF-5112
Rev. 1 (12-2014)
2
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Track Maintenance
Training

Course –Basic Track Technology
Module -- Tools –Rail Drill
Metropolitan Atlanta Rapid Transit Authority Infrastructure Training HRTF-5112
Rev. 1 (12-2014)
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THIS IS THE MOST IMPORTANT INFORMATION IN THIS MANUAL FOR
SUCCESSFUL HOLE CUTTING
1. Make sure cutter is properly installed. (See instructions for installing
Rotabroach® Cutter in arbor.)
2. The #1 cause of premature cutter failure is improper clamping. Read,
understand and follow clamping procedures on the next page.
3. Always use caution in contacting the rail with the cutting tool. Allow the
cutter to completely enter the rail before applying full feed pressure.
4. Do not force tool at the end of cut. Reduce manual feed pressure prior to
break-through on the rail and allow the cutter to work.
The Hougen 10923A and 10924A Electric Rail Drill in conjunction with the
Rotabroach® cutting tool provides you with the most efficient lightweight
rail drilling system available. This new cutting technology will be most successful
when the operator understands the above mentioned instructions.
ATTENTION: NEW CLAMPING PROCEDURE
WARNING: IMPROPER CLAMPING WILL
CAUSE PREMATURE CUTTER FAILURE!
WITH CLAMP IN OPEN POSITION, REST
UNIT ON RAIL BASE. BOTTOM OF SHOES
SHOULD CONTACT TAPER ON RAIL BASE.
(SEE FIG. A)

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PERFORMANCE TIP: CLOSE CLAMP UNTIL CLAMP PAD CONTACTS
WEB OF RAIL.
STEP #2:
RAISE REAR OF RAIL DRILL TO LOCATE
SHOES IN PROPER POSITION.
STEP #3:
WHILE MAINTAINING CONTACT BETWEEN
SHOES AND RAIL, TIGHTEN CLAMP.
STEP #4:
WHEN UNIT IS FIRMLY CLAMPED, CHECK
FOR PROPER SHOE AND PAD CONTACT ON
BOTH SIDES.

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IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, basic safety precautions should always be
followed to reduce the risk of lire, electric shock, and personal injury, including the
following:
1. READ ALL INSTRUCTIONS
2. Grounding Instructions
This tool should be grounded while in use to protect the operator from electric
shock.
•The tool is equipped with a 3-conductor cord and 3-prong grounding type
plug to fit the proper grounding type receptacle. The green (or green and
yellow) conductor in the cord is the grounding wire.
Never connect the green (or green and yellow) wire to a live terminal. Your unit is
for use on 115 it has a plug that looks like that shown in sketch. An adapter see
sketches, is available for connecting sketch type plugs to 2-prong receptacles.
•The green-colored rigid ear, lug, or the like, extending from the adapter
must be connected to a permanent ground, such as a properly grounded
outlet box.
Use only 3-wire extension cords that have 3-prong grounding type plugs and 3-
pole receptacles that accept the tool’s plug. Replace or repair damaged cords.
•Make sure the conductor size is large enough to prevent excessive voltage
drop which will cause loss of power and possible
motor damage.
Keep Work Area Clean
Cluttered areas and benches invite injuries. Keep dirt
and chips from under Rotabroach Gutter area and drill
shoe.

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Consider Work Area Environment
Do not expose tool to rain.
Do not use tool in damp or wet locations.
Keep work area well lit.
Do not use tool in presence of flammable liquids or gases.
Guard Against Electric Shock
Prevent body contact with grounded surfaces. For example: pipes, radiators, ranges,
refrigerator enclosures.
Keep Others Away
Do not let visitors contact tool or extension cord. All visitors should be kept away
from work area.
Store Idle Tools
When not in use tools should be stored in a dry, and high Or locked-up piece out
of reach of children.
Do Not Force Tool
It will do the job better and safer at the rate for which it was intended.
Use Right Tool
Do not force small tool or attachment to do the job of a heavy-duty tool.
Do not use tool for purpose not intended —for example - do not use circular saw
for cutting tree limbs or logs.
Dress Properly
Do not wear loose clothing or jewelry. They might entangle with spinning chips
or get caught in moving parts. Rubber gloves and non-skid footwear are
recommended when working outdoors. Wear sturdy leather work gloves when
working indoors.

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Always Wear Safety Glasses or Goggles
Do Not Abuse Cord
Never carry tool by cord or yank it to disconnect from - receptacle. Keep cord from
heat, oil and sharp edges.
Secure Work
Clamp work securely using appropriate shoe size and shape. Tighten clamp by
using two hands with handle placed in central position and tighten securely.
Do Not Overreach
Keep proper looting and balance at all times.
Maintain Tools with Care
Keep tools sharp and clean for better and safer performance. Do not use dull or
broken Rotabroach Cutters.
Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and, if damaged, have repaired by authorized
service facility.
Inspect extension cords periodically and replace if damaged.
Keep handles dry, clean, and free from oil and grease.
Disconnect Tools
When not in use, before servicing, and when changing Rotabroach Cutters or
accessories.
Remove Adjusting Keys and Wrenches
Form habit of checking to see that keys and wrenches are removed from tool
before turning it on.

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Outdoor Use Extension Cords
When tool is used outdoors; use only extension cords intended for use outdoors
and so marked.
Stay Alert
Watch what you are doing. Use common sense. Do not operate tool when you
are tired.
Check Damaged Parts
Before further use of the tool, a part that is damaged should be carefully checked
to determine that it will operate properly and perform its intended function.
•Check for alignment of moving parts, binding of moving parts, breakage of
parts, mounting, and any other conditions that may affect its operation.
A part that is damaged should be properly repaired or replaced by an authorized
service center unless -otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by authorized service center.
Do not use tool if switch does not turn it on and off.
Additional Safety Precautions
Arbor and cutter should never be used as a hand-hold.
Keep hands and clothing away from all moving parts.
Do not use Rotabroach Cutters where ejected slug might cause injury (slug ejected
at end of cut).
Be sure that all safety devices are properly adjusted and in use. Also, adhere to
all operating instructions.

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Do not drill through any surface that may contain live electrical wiring. Drilling into
a live wire could cause exposed metal parts of the drill to be made live.
Do not attach Rail Drill to live 3rd rail track
Remove chips wrapped around Rotabroach Cutter and arbor after each hole. With
motor off and power disconnected, grasp chips with leather gloved hand and pull
and rotate counterclockwise.
Should the cutter become jammed in the work, stop the unit immediately to
prevent personal injury.
Disconnect the tool from the power supply and loosen jammed cutter by turning
the arbor counterclockwise. Never attempt to free the jammed cutter by starting
the motor.
Never operate the tool without culling fluid being applied to the inducer 0-rings or
without the inducer ring retaining finger in place.
Operating Near Welding Equipment
When operating your Rail Drill near an arc welder, it is important that they are
connected to the same Earth Ground. If they are not, severe damage to the unit,
particularly the power cord, could occur. This could also result in personal injury to
the operator.
Safe Electrical Connection
Wet electrical connections are shock hazards. To
prevent the cutting fluid from traveling along the cord
and contacting the plug or power outlet, tie a drip loop
as shown.
•Also elevate extension cords or gang box
connections.

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RECOMMENDED EXTENSION CORD GAUGES
Length of Cord in Feet 115V 25 Ft.- 50 Ft. - 100 Ft. - 150 Ft. - 200 Ft. - 250
Ft. - 300 Ft. - 400 Ft. - 500 Ft.
CHECK OUT CONTROLS BEFORE INSTALLING CUTTER
IMPORTANT: Before turning on the machine, it Is imperative that the operator
know and understand instructions for safe operation, correct operation
procedures and the location and interaction of control panel components and
other related features.
MOTOR START SWITCH - Starts the motor. (This is a relay operated motor
control. The unit will not restart after a power interruption without depressing
the start switch again.)
MOTOR STOP SWITCH - Deactivates Motor
LINE ON - Light indicates unit has power.
CIRCUIT BREAKER - Provides motor overloads protection with reset button
capabilities. Plug unit into proper 115 volt AC power source. ‘Line On’ light
should come on. DO NOT use with DC power.
CHECK OUT OPERATION OF CONTROLS BEFORE
INSTALLING A ROTABROACH CUTTER
IMPORTANT: Before turning on the machine, It Is
imperative that the operator know and understand
instructions for safe operation, correct operation
procedures and the location and interaction of control
panel components and other related features.
MOTOR START SWITCH - Starts the motor. (This is a relay operated motor
control. The unit will not restart after a power interruption without depressing
the start switch again.)

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MOTOR STOP SWITCH - Deactivates motor.
LINE ON - Light indicates unit has power. Also has secondary feature working in
conjunction with Automatic Shut-off to indicate tripping point of shut-off?
CIRCUIT BREAKER - Provides motor overloads protection with reset button
capabilities.
POWER FEED DIAL - Allows two feed rate settings for alloy or carbon rail
materials. To change setting, lift spring loaded retainer and rotate dial to desired
notched position.
AUTOMATIC SHUT-OFF - Deactivates drill and feed motors at end of cutting cycle.
Also, shuts-off “Line On” lamp, a feature for ease of drill stroke adjustment.
POWER FEED ACTUATOR - In” position
disengages feed mechanism. Out’ position
engages power feed. Actuator must be
positioned ‘In” to manually operate slide.
DEPTH SCALE & POINTER - Used in
conjunction with Automatic Shut-off to
determine depth of cut. Control panel switch
plate and power feed actuator Depth scale and
pointer.
Plug unit into proper 115 volt AC power source. Line On’ light should come on.
DO NOT use with DC power.

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Quick Connect
PRE-OPERATION INSTRUCTIONS
(Drill and Pressurized Coolant System)
Perform the following procedure with power source disconnected.
1. Install correct shoes for rail type being drilled.
2. Install correct size Rotabroach cutter with pilot pin and secure to drill arbor
with sot screw(s). See Installation instructions
3. Fill coolant bottle with Rotabroach cutting fluid (a water soluble and
biode9radable product) or equivalent. Conventional fill access is achieved by
removing the pump handle.
Caution! Contents are under pressure. Partially open container to slowly release
pressure before removing. A quick-fill access is also provided at the quick
disconnect auxiliary hose port. This feature is intended for use when dispensing
coolant from large drums with a hand pump.
4. Attach coolant bottle quick connect
hose filling to drill arbor at inducer fitting.
5. Pressurize coolant bottle
(approximately 20 pumps).
6. Partially open shut-oil valve.
7. Depress pilot pin approximately 1/4”
and watch for coolant flow from side of
pilot pin point. Note: Coolant is under
pressure —stay out of path of spray. If
coolant does not flow, rotate valve further
to open or unclog coolant system.
8. Shut-off coolant valve.
Quick-disconnect auxiliary tilling

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OPERATING INSTRUCTIONS
Perform procedures outlined in PRE-OPERATION INSTRUCTIONS
1. Make sure workplace, caller and shoe surfaces are free of chips, etc.
2. Place locator template on rail head.
3. Align drill on locator.
4. Lightly clamp drill to rail and insure proper (3) point contact on each shoe.
Unit must be snug to prevent movement during cut, failure to do so will result in
fractured cutters when contacting workplace. Do not over tighten.
5. Pump to re-pressurize system as required. Then turn on coolant feed.
6. Start machine by depressing motor “Start” switch. Manually feed tool to rail
and very gently start cut.
Feed tool through workplace at an even feed rate. Do not over-load unit to induce
a motor stalling situation. Do not pause during cut nor release teed pressure it
changing hand grip on feed handles. This will result in premature cutter wear and
drilling problems while in the cut. At end of cut (is audible as motor load
diminishes), press motor “Stop” button.
Engage power feed by pivoting “Out” handle located on hub. Power feed
mechanism will feed cutter through work piece. Drill and feed motors will
automatically stop with proper depth control adjustment. Disengage load
mechanism by pivoting handle “In” using palm of gloved hand.
1. Turn feed handles to retract arbor.
2. Remove or loosen clamp. Slug should eject from spring loaded pilot pin
pressure. Drill cycle is complete and you are ready to go on to next hole. Shutting
off coolant after use is suggested, if use is intermittent.

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IF SLUG HAS NOT FALLEN FREE. Disconnect power source and shut off
coolant supply. Use a screwdriver to carefully flip out sloe by inserting it
between slug flange and cutter gullet. It generally will remove easily while
discharging a squirt of coolant. Avoid prying with force, damage to cutter and
cutting edge may result.
•Listen for signs of motor over-loading or stalling during drill cycle. Reduce
feed if necessary.
A slow-blow circuit breaker - will react under gross overloading conditions. If
the circuit \breaker POPS-OUT’ follow this procedure:
1. Turn motor “OFF” by pressing motor “STOP” button.
2. Press circuit breaker ‘‘IN.’’
3. Turn motor “ON” by pressing motor “START” button.
4. Resume operation.
Listen for signs of motor over-loading r stalling during drill cycle. Reduce feed
setting If necessary. A slow-blow circuit breaker will react under gross overloading
conditions. If the circuit breaker “POPS-OUT” follow this procedure:
1. Turn motor “OFF” by pressing motor ‘Shoe” button.
2. Pivot power feed actuator handle “IN” to “DISENGAGED” position.
3. Reduce feed selling.
4. Press circuit breaker ‘IN.”
5. Turn motor “ON” by pressing motor “START” button.
6. Pivot power teed actuator handle “OUT” to feed engaged position.

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Positioning of Optional Hole Template
Template placement on head of rail with tapered tip
flush with end of rail and side locking screws
fastened to rail head. Notches in template give
precise location of hole centerlines to be drilled.
The rail clamp assembly has a locating screw which
rests in the template notch. The locating screw is
adjustable to accommodate the full range of rail
sizes.
The locating screw must contact the sides of the matching notch and can lightly
touch the bottom of the notch or by 1/16”clearance. To adjust locating screw turn
knob and raise or lower locating screw as required.
Hole location templates are offered as optional equipment. Three of these
templates are provided with established hole spacing. The fourth template is
produced to customer specified hole spacing.
POWER FEED CLUTCH DISENGAGE TRAVEL ADJUSTMENT Model 10924A
Manufacturing tolerance variations combined with wear factors requires the need
for variable clutch lift-off adjustment. Stepped washer facilitates fixed adjustments
in .015 increments when used in conjunction with thrust washer located at the end
of the shaft at the gear box.
The disengaging lever mechanism provides over-travel to accommodate the
appropriate lift-off. Insufficient lift-off (not enough stepped washer thickness) will not
completely disengage the clutch. A binding/clicking movement will be noticed with
manual movement of the slide with clutch disengaged. Too much lilt-off will
disengage the clutch too far allowing the clutch balls to fall out of the clutch plate
raceway.

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Proper lubrication between the hub and segmented ring will reduce or eliminate
the need for readjustment from original factory settings by lubricating the unit
periodically at grease fitting.
The term “Lift-Off’ is used to signify the travel of the engagement rod to lift-off the
clutch not including the free-play movement
The proper lift-off is between .060 and .085 the combined stack heights will allow
adjustments in .015” increments to obtain the correct measurements. If the lift-off
is inadequate move to the next thicker stack increment! The reverse is true with
the opposite case.
SLIP CLUTCH
The power feed actuator handle operates a
mechanical engaging/disengaging slip clutch.
The clutch is factory preset to provide positive
drive of the feed mechanism under normal
conditions. If the clutch responds, a noticeable
cycling noise can be heard. A slight hesitation will be noted before it re-engages
itself. Major reasons for clutch slippage are: hard spots in workplace, over
feeding of clutter or a dull tool. Consult remedies for hole making problems if
problem persists. Power feed clutch assembly showing stepped washer
combinations
CLUTCH DISENGAGE OVER-TRAVEL CORRECTION
If over-travel results in excessive clutch disengagement and failure to re-engage
disassemble clutch housing subassembly. Loosen clutch tension adjusting nut.
Remove (6) screws and cover, place balls in their proper cavities in clutch plate.
Reassemble clutch, then tighten nut. Final setting can be obtained after unit
assembly. Clutch should respond at 60-65 ft-lbs. torque when utilizing a torque
wrench setting fixture, lithe setting was not changed during disassembly, torque
setting should remain constant.

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POWER FEED CLUTCH TORQUE ADJUSTMENT
1. Disconnect power
2. Move lever to “Engaged” position.
3. Remove front cover plate by-removing 4 screws with 1116 Hex Key.
4. To adjust clutch tighter, advance nut by using screw driver notches on nut
periphery. Rotate nut in opposite direction to reduce clutch out-put torque.
5. Proper torque setting for clutch assembly is 60-65 ft-lbs. when utilizing a
torque wrench setting fixture.
AUTOMATIC SHUT-OFF FEATURE
Model 10924A Rail Drills
An adjustable automatic shut-off feature is provided which will deactivate the drill
and teed motors at the end of the cutting cycle. Two methods for setting the
tripping point are listed and should be followed according to user preference.
Shut-off Adjusting Procedure: METHOD #1
1. Disconnect power.
2. Clamp unit to rail with proper cutter and shoes securely mounted.
3. Manually move slide toward workplace and gently touch cutter to rail.
4. Loosen Thumb Screw at Depth Pointer and relocate pointer to read “0” on
depth scale.
5. Fully retract slide.
6. Unclamp unit and remove from rail and set on flat surface.
7. Connect to power source —“Line On” light should be illuminated.
8. Measure Rail Web thickness (example 115 lb. AREA. equals 5/8”) and add
an additional 1/16” to 118’.
9. Manually move slide 11/16”to 3/4” pointer position on scale and watch if the
Line On’ light goes out or blinks before reaching desired position.
10. Rotate depth adjusting knob until the ‘Line On’ light goes out while at the
desired stroke position.
a) if light signaled off during slide advance rotate knob clockwise.
b) if light did not signal during advance rotate knob counter-clockwise.

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11. Move slide in and out several times to insure tripping point is correct.
12. Make a cut following operational procedures. If unit stopped short of cutting
through, rotate knob slightly clockwise and restart motor and repeat it
necessary until reaching correct depth. Cutter should pass just through material
with a slight over travel amount to insure that the Automatic shut off and depth
scale components work. If unit is through (is audible as motor load diminishes)
and continues, press motor “Stop” switch.
NO ALLOW UNIT TO CONTINUE TO ADVANCE OR CLAMP ARM WILL BE
CUT AND CUTTER MAY FRACTURE.
Retract slide to proper through position and turn depth adjust knob counter-
clockwise until light goes out.
Shut-off Adjusting Procedure: METHOD #2
1. Clamp unit to rail with proper cutter and shoes securely mounted.
2. Make a cut following operational procedures. As unit cuts through (is audible as
motor load diminishes) press motor ‘Stop’ switch. Cutter should pass just through
material with a slight over travel amount to insure it is through.
DO NOT ALLOW UNIT TO CONTINUE TO ADVANCE OR CLAMP ARM
WILL BE CUT AND CUTTER MAY FRACTURE.
Position slide to proper through position and turn depth adjust knob until light
goes out. Clockwise rotation of automatic shut-off adjustment knob will
lengthen cutting stroke before shut-off.
Installing/Replacing Rotabroach Cutter in Arbor
1. Disconnect from power source. Turn off coolant at shutoff in the case of
replacing a cutter. The spring seat system located within arbor was not designed
to be 100% leak proof.

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2. Lay down on its side with feed handles up.
3. Position side so the side looking screw on arbor is visible between base plate
and front support bracket.
Loosen and remove screw. Remove cutter in case of 41049 Set Screw
replacement.
Do not depress pilot pin during procedure to release spring seat. Doing so will
result in releasing pressured contents of arbor cavity and coolant loss; some loss,
however, is normal due to cavity 40222 Set Screw between cutter shank and
spring seat.
4. Insert proper pilot in shank end of Rotabroach Cutter. 75.000-Seriet Cutter
5. Insert Rotabroach Cutter until a flat on cutter shank is aligned with set screw
hole and is exactly perpendicular to axis of setscrew hole of removed screw.
6. Insert set screw and tighten. Make sure cutter is secure.
For Proper Clamping Instructions, Refer to Color Insert Located at Front of
This Operator’s Manual
FRONT SUPPORT BRACKET ADJUSTMENT
(Adjust gibs before adjusting arbor support bracket)
(Disconnect Power Source)
1. Loosen Side Locking Screws.
2. Loosen the Support Bracket Bolts.
3. Be sure top of arbor is flush with the shoulder on
motor out-put shaft. Also make certain arbor is
securely fastened.
4. Turn feed handle until motor and spindle are at the bottom of their (ravel.
5. Tighten Front Support Bolts (use 242 Loctite if possible).
6. Feed slide in and out a few times, checking for free and uniform movement.
7. Tighten Side Locking Screws. Do not over tighten.

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NOTE: Check front support bolts regularly to make certain they are tight. Tighten
as required.
ADJUSTMENT OF GIBS
(Disconnect Power Source)
1. Loosen all Gib Screws (4O237.
2. Feed the drill in and out a few times and then, with top of molar slide flush with
top of housing, tighten the Gib Screws until you feel them touch the Steel Gib
(40225). Feed the drill in and out again.
3. Adjust Gib Screws so that there is uniform pressure from top to bottom. (fop of
motor slide flush with top of housing.)
4. Turn each Gib Screw In about 118-114 turn, depending upon your preference.
5. Gibs should be tight enough so that slide moves in and out smoothly with no
wobble or shaking. (Looseness will cause cutter breakage.)
NOTE: GlBS SHOULD BE WBRICATED REGULARLY.
Super Concentrate Cuffing Fluid
A good flow of cutting fluid to the tool is important. It cools and lubricates the
cutting edge! helps evacuate the chips, keeps the slug from expanding, and
helps eject the slug. Various mineral and sulfur base oils are quite popular,
however water base solutions have better cooling qualities.
Listed is our own recommended Concentrated Cutting Fluid for Rotabroach
Cutters and similar cutting tools. It is a water soluble, biodegradable product.
This cutting fluid contains no ingredients that are on the U.S. Government
Hazardous Materials list. It is in a super concentrated form that will require a
10:1 mixture of water.
Measure amount of concentrate which comes in 4 full 1-gallons units. Then
and will make 44 gallons