Racine Railroad Products 910161 Operating instructions
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 3
Table of Contents
Section 1: Overview and Safety....................................................................................................................5
Hydraulic Rail Drill Overview.........................................................................................................................5
Environmental Protection..............................................................................................................................5
Safety Information.........................................................................................................................................5
Safety Terms .............................................................................................................................................6
Machine Use and Safety Precautions .......................................................................................................6
Section 2: Specifications and Installation......................................................................................................8
Specifications................................................................................................................................................8
Recommended Hydraulic Fluid .................................................................................................................8
Rail Drill Components ...................................................................................................................................9
Hose Requirements ....................................................................................................................................10
Hose Types .............................................................................................................................................10
Hydraulic Hose Recommendation...........................................................................................................11
Hydraulic Fluid Recommendation ...........................................................................................................11
Tool Connecting Procedures...................................................................................................................11
Connecting Hoses................................................................................................................................12
Disconnecting Hoses...........................................................................................................................12
Setting for Open-Center or Closed-Center................................................................................................13
Open-Center Systems.............................................................................................................................13
Closed-Center Systems...........................................................................................................................14
Section 3: Tool Operation ...........................................................................................................................16
Personal Protective Equipment ...........................................................................................................16
Pre-Operation..............................................................................................................................................16
Operation: Drill Socket / Bit.........................................................................................................................17
Handle Grip Hydraulic Flow Indicators....................................................................................................18
Inlet and Outlet Adaptors ............................................................................................................................19
Common Hook-Ups –Couplers ..............................................................................................................20
Common Hook-Ups –Plumbed w/ Hose Set..............................................................................................20
Section 4: Maintenance...............................................................................................................................21
Troubleshooting ..........................................................................................................................................22
Determining the Problem Area................................................................................................................22
Troubleshooting Guide............................................................................................................................23
Section 5: Parts and Service Support.........................................................................................................25
Technical Support & Service...................................................................................................................25
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 4
Parts............................................................................................................................................................26
Section 6: Warranty Terms and Conditions ................................................................................................31
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 5
Section 1: Overview and Safety
Hydraulic Rail Drill Overview
RRP designs and manufactures equipment primarily for the repair and new construction of rail and
railroad tie track maintenance.
Hydraulic Rail Drill is a low pressure hydraulic rail drill MAG Series (Machined Aluminum, Gerotor)
designed for drilling holes and fastening hardware.
The drill balances well in a gloved hand while the handle, grip and trigger have been ergonomically
designed for ease of operation. The drill incorporates proven gerotor motor for long life and greater
efficiency over gear type motors.
Do not use this machine for other than its intended purpose.
Please read these instructions when using this tool, which can only be used for the specified purpose.
This instruction manual should be kept throughout the life of the tool.
The operator of this tool should:
•Have access to this operation instruction.
•Read and understand this operation instruction.
Environmental Protection
Comply with relevant national waste disposal laws and regulations. Waste electronic
devices cannot be treated as household waste.
Equipment, accessories, and packaging shall be recyclable.
Don't throw the discarded equipment in trash cans.
Safety Information
For safe installation and operation of this equipment, carefully read and understand the contents of this
manual. Improper operation, handling, or maintenance can result in equipment damage and personal
injury.
Only trained and authorized personnel should be allowed to operate this machine. In addition, all
personnel at the worksite should be aware of the safety concerns and their individual responsibilities prior
to working this machine.
Please read and comply with all the safety precautions in this manual before operating this machine.
Your safety is at risk.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 6
Safety Terms
DANGER indicates a hazardous operating procedure, practice, or
condition. If the hazardous situation is not avoided death or serious
injury will occur.
WARNING indicates a hazardous operating procedure, practice, or
condition. If the hazardous situation is not avoided death or serious
injury could occur.
CAUTION indicates a potentially hazardous operating procedure,
practice, or condition. If the hazardous situation is not avoided
moderate or minor injury could occur.
Machine Use and Safety Precautions
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. Observe the following precautions whenever you are operating,
working on or near this equipment.
Do not make any modifications without authorization or written approval from Racine Railroad Products.
Replace all Racine Railroad Products and OEM parts with genuine Racine Railroad Products and OEM
parts. Using non-OEM parts may compromise the safety of the machine.
Do not wear loose clothing, jewelry, radio belts, etc., when operating, working on or near this equipment.
They can be caught in moving parts and may result in severe injury.
Always wear appropriate personal protective clothing when operating this equipment: e.g., orange safety
vest, hard hat, safety glasses with side shields, hearing protection, steel-toed safety boots, leather gloves,
dust respirator, etc.
Always lift heavy objects with the knees and legs, not the arms and back.
Always keep hands, arms, feet, head, clothing, etc., out of the operating area and away from all rotating
or moving components when operating, working on or near this machine.
Always make sure that all guards, covers, belts, hoses, and operating components are in good working
order and that all controls are in the appropriate position before starting the engine.
Always make sure that all safety equipment installed properly and are in good working order. Do not
operate the machine until unsafe conditions have been corrected.
Always operate in a well-ventilated area and make sure that the air filters, air filter covers, and muffler
are in good condition.
Always keep the machine clean and free of debris. Operate the machine in a safe and responsible
manner. Exercise caution when fueling, working on or near rotating or moving components, hot
components, and fuel systems. Be aware of potential fire hazards and prevent sparks, exhaust, etc., from
starting fires on the machine and/or work area.
Always 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.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 7
Always shut disconnect the drill from the power source and make sure that all controls are in a safe
position and install all appropriate locking and safety devices before doing any of the following:
•Lubricating
•Adjusting
•Installing Tooling
•Making Repairs
•Performing Service
Tools are not insulated for use on or near energized conductors. Use of
these tools near energized conductors may lead to electrical shock, causing
severe injury or death.
Do not use these tools near energized conductors without adequately insulating
operator and surroundings.
Tool parts rotate at high speeds and can cause severe personal injury. Keep all
body parts away from moving parts of the tool when connected to a hydraulic
power source or during operation.
Operator must clear all bystanders from the work area when handling, starting,
and operating a tool to avoid injury to bystanders.
Do not over-reach while using a tool. Loss of balance can cause serious
personal injury or death. Move closer to work area and securely support yourself
and your work. Always keep proper footing and balance.
Hydraulic fluid is under pressure.
Always depressurize the hydraulic system before connecting or disconnecting a
tool to avoid serious injury from escaping fluid. If injury results from escaping
hydraulic fluid, seek immediate medical attention to avoid serious bodily injury.
Hot hydraulic fluid.
Exposure to hot hydraulic fluid can cause severe burns. Do NOT connect or
disconnect a tool while the hydraulic power source is running and/or the
hydraulic fluid is hot.
Never lock a tool trigger in the power ON position. A tool locked ON can lead
to serious injury or death
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 8
Section 2: Specifications and Installation
Specifications
Weight:..........................7.6 lbs (3.5 kg)
Length: ..........................9.0 in (229 mm)
Height:...........................9.6 in (243 mm)
Width:............................3.6 in (91 mm)
Chuck Type:..................7/16" Quick Chuck
Optimal Pressure: .........1000 - 2000 PSI
Flow Range:..................4-12 GPM
Optimal flow Range:......4-8 GPM
Operation:......................Open/Closed option
Motor:............................Gerotor
Torque:..........................550 ft-lbs
Tool Ports:.....................#6 SAE O-ring (F)
System fluid temperature must not exceed 140º F (60º C) regardless of operating conditions and/or
system.
Sufficient oil cooling is recommended to limit the system fluid temperature.
Maximum flow must not exceed the recommended rate as noted on the tool specification label. Install a
flow meter in the return line to test the rate of all flow in the system before working the tool.
Operating pressure at the tool must not exceed 2000 lbs/in2 (18.8 MPa). The system relief valve must be
located in the supply circuit between the hydraulic power source and the tool to limit pressure to the tool.
Recommended Hydraulic Fluid
Any non-detergent hydraulic fluid which meets the following specifications may be used:
S.U.S.............................@ 100º F (38º C) 140 to 225
@ 210º F (99º C) 40 minimum
Flash Point ....................340º F (170º C) min.
Pour Point......................-30º F (-34º C) min.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 10
Hose Requirements
It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface
and an abrasion resistant outer surface. Each hose must have male pipe ends for most application.
Longer hoses can be used when necessary but can affect the operation of the tool due to resistance in
the hose.
If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return
ports, the pressure required to push the fluid through the system and back to the tank will be higher. This
will reduce tool power.
Important: Oil should always flow from the male coupler through the female coupler.
Note: The pressure increases in uncoupled hoses left in the sun. This may make them difficult to
connect. When possible after use, connect the free ends of the operating hoses together.
Hose Types
Hydraulic hose types authorized for use with the tool are:
1. Labeled and certified non-conductive.
•This is the only hose authorized for use near electrical conductors.
•Constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement,
and weather resistant thermoplastic or synthetic rubber cover.
2. Wire braided (conductive)
•This hose is conductive and must never be used near electrical conductors.
•Constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and
weather resistant synthetic rubber cover
3. Fiber braided (not certified or labeled non-conductive)
•This hose is conductive and must never be used near electrical conductors.
•Constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement,
and weather resistant thermoplastic or synthetic rubber cover.
The rated working pressure of the hydraulic hose must be at least 175 bar (2500 psi).
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 11
Hydraulic Hose Recommendation
Hydraulic Hose Recommendation
Flow Per Circuit
Length Each Hose
Use
Inside Diameter
SAE Spec Hose
(Wire Braid)
SAE Spec Hose
(Fiber Braid)
GPM
LPM
Feet
Meter
Inch
MM
5 to 8
19 to 30
To 50
To 15
Both
1/2
13
SAE 100R1-8
100R7-8
5 to 8
19 to 30
51 to 100
15 to 30
Both
5/8
16
SAE 100R2-10
SAE 100R8-10
5 to 8
19 to 30
100 to 300
30 to 90
Pressure
Return
5/8
3/4
16
19
SAE 100R2-10
SAE 100R1-12
SAE 100R8-10
SAE 100R7-12
9 to 12
34 to 45
To 50
To 15
Both
5/8
16
SAE 100R2-10
SAE 100R8-10
9 v 12
34 to 45
51 to 100
15 to 30
Pressure
Return
5/8
3/4
16
19
SAE 100R2-10
SAE 100R3-12
SAE 100R8-10
SAE 100R7-12
9 to 12
24 to 45
100 to 200
30 to 60
Pressure
Return
3/4
1
19
25.4
SAE 100R2-12
SAE 100R1-16
SAE 100R8-12
SAE100R7-16
The rated working pressure of the hydraulic hose must be at least 2500 psi / 173 bar.
Hydraulic Fluid Recommendation
Inspect hoses for cuts, crushing, leaks, or abrasion,
which may be a safety hazard or reduce fluid flows.
The following fluids work well over a wide temperature
range at startup, allow moisture to settle out, and resist
biological growth likely in cool operating hydraulic
circuits.
Others that meet or exceeds the specifications of these
fluids may also be used.
Type
Hydraulic fluid
Amsoil
AWH ISO 32
Chevron
Rando HD Premium Oil MV ISO VG 32
Rando HDZ ISO 32
Gulf
Harmony AW ISO Multi-Grade 32
Mobil
DTE Oil Excel 32
Schaeffer
Dilex Supreme Hydraulic Fluid w/
Dynavis ISO 46.
Shell
Shell Tellus S2 VX 32
Sunoco
Sunvis 1032 HVI Hydraulic Oil
Tool Connecting Procedures
1. Stop the engine before connecting the tool and or hoses to the OFF power unit, and when switching
hoses or tools.
2. 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 where vehicles can run over the hoses. Do not lay hose over sharp objects.
Pressurized fluid escaping from a damaged hose can penetrate the
skin and be injected in the body causing injury or death.
Do not pull on hoses to drag the power unit or tool.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 12
Connecting Hoses
1. Wipe quick couplers with a clean lint free cloth before connecting them.
2. Depressurize the system.
3. Allow system and hydraulic fluid to cool if too hot to handle.
4. Securely connect the return (tank “R”) hose from the power source to the tool.
5. Securely connect the supply (pressure “P”) hose from the 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.
When connecting the quick couplers, the flow should run from male coupler to the female coupler.
The female coupler on the tool is the inlet. Quick couplers are marked with a flow direction arrow.
Pressurized fluid escaping from a damaged hose can penetrate the
skin and be injected in the body causing injury or death.
Do not pull on hoses to drag the power unit or tool.
Note: When possible, connect the free ends of uncoupled hoses to prevent build up in the hoses. The
sun can also increase pressure in the hoses and make connecting them difficult.
Disconnecting Hoses
1. Stop the hydraulic power source.
2. Depressurize 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 (IN port).
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.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 13
Setting for Open-Center or
Closed-Center
The Rail Drill is equipped to allow the tool to be used with either Open or Closed Center hydraulic power
systems. To change between open and closed center remove the bolt holding the trigger to the spool and
flip the trigger up.
1. For open center operation, turn trigger spool so that the red dot on the front of the trigger points
towards the letters 0/C on trigger.
2. For closed center, turn trigger spool so that the red dot on the front of the trigger points toward the
letters C/C on trigger.
3. Reattach the trigger.
Open-Center Systems
An Open-Center System is a hydraulic system in which
the oil circulates at all times.
•When a tool is in the circuit and not activated, the oil
bypasses the tool motor returning to tank.
•When the trigger is activated, oil is diverted by an
activation spool into the gerotor motor.
•These systems do not provide as much instant power
as their closed-center counterparts.
The Rail Drill is factory set at Open-
Center.
This is indicated by the position of the dot
to the right of the slot.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 14
The green represents the hydraulic fluid flow path through the drill.
The trigger is not activated. Activation spool closed
and returns hydraulic fluid back to tank.
The trigger is activated. Activation spool now
open and porting directs fluid to gerotor motor to
turn shaft.
Closed-Center Systems
A Closed-Center System is hydraulic system in which the oil
flows from the pump source to the tool (in its off position) and
stops. It does not return to the tank
•When the trigger is actuated the pressure and flow is
instantaneously released into the tool.
•These systems provide great amounts of instant power.
Because of the surges created, the system must contain
an accumulator to limit any potential damage these
spikes might cause.
The Rail Drill is at Closed-Center.
This is indicated by the position of the
dot to the right of the slot.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 15
The green represents the hydraulic fluid flow path through the drill.
The trigger is not activated. Activation spool
closed with no return path.
The trigger is activated. Activation spool now open
and porting directs fluid to gerotor motor to turn
shaft.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 16
Section 3: Tool Operation
Personal Protective Equipment
Before operating this machine, make sure that all general safety precautions are observed,
and that proper personal protective clothing is worn as described below.
At a minimum, operators should wear the following Personal Protective Equipment:
1. Safety Glasses
2. Hearing Protection
3. Hard Hat
4. High Visibility Safety Vest
5. Leather Work Gloves (outside the cab)
6. Steel Toed Safety Shoes
Pre-Operation
Accidental tool start can cause serious personal
injury
.
Do not
install or remove tool attachments on a tool that
is
connected to
a hydraulic power source.
Tooland attachment may be hot. Hot surfaces can
cause
serious
bodily burns. Use caution when working
around
these
components.
Worn or damaged attachments may fail during use
and
cause
severe personal injury. Discard tool attachment
if
any cracks,
chips, or gouges are
present.
Bit may fail during use, potentially causing
severe
personal injury. Some bits with a long spiral
or
wide
flute spacing may not be acceptable for use with
this
tool.
Drill test holes to determine if bit whips, bends
under
side-load, or lunges forward at breakthrough. Do
not
use
a bit that behaves as
above.
1. Inspect the quick change chuck. Remove any dirt
or
other contamination that may have
accumulated
in
the
chuck.
2. Slide and hold quick change chuck away from
tool
and remove drive
shank
3. Insert desired bit into hex socket of tool and
release
chuck
.
4. To remove drill bit, slide and hold quick change chuck away from tool and remove bit.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 17
Operation: Drill Socket / Bit
The Rail Drill operates by automatically supplying fluid in such a way that it turns the drive shaft of the
assembly. As the trigger is depressed, it moves the spool to close off the flow of oil to the return port and
directs the flow of oil through the tool circuit.
The flow of oil through the directional spools causes the shaft to turn and rotate the drive assembly. With
no or minimal resistance, the anvil and hammer turn in unison.
As greater resistance is encountered during use of the drill, the force of the resistance causes the
hammer to slip and strike the anvil resulting in the impact action. The impact action continues until the
resistance is reduced or the work completed.
Rotating parts. Keep all body parts away from rotating parts of the
tool to avoid personal injury.
1. Inspect the square drive. Remove any dirt or other contamination that may have accumulated in
the chuck.
2. Slide desired square drive socket onto drive on the tool or insert the desired bit in quick-change
chuck.
3. Connect the hydraulic hoses from the hydraulic power source to the tool.
4. Start the hydraulic power source. Allow power source to run (idle) for a few minutes to warm
hydraulic reservoir fluid.
5. Set the directional spool to the desired position (forward or reverse).
The torque values listed under specifications are approximate and
dependent on hydraulic oil temperature, fluid condition, pump flow
and many other variables present while using these tools.
To achieve a specified torque, use a calibrated torque wrench.
Failure to follow this instruction may cause an incorrect torque
value in situations requiring a specific torque.
Never change spool direction while the tool is operating. Shifting the spool while the tool is
operating may cause internal tool damage. Always allow the tool to come to a complete stop
before changing direction.
6. Grasp the tool handle. Place your opposite hand on the top of the tool. This will allow leverage to be
applied while operating.
7. To start the tool, squeeze the trigger.
8. To stop the tool, release the trigger.
9. After the tool has stopped rotating completely, lay the tool on a flat stable surface.
10. When the tool is not in use, stop the hydraulic power source flow to reduce excess heat build-up
and unnecessary wear on tool components.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 19
Inlet and Outlet Adaptors
The steel adaptors serve to protect the forged
aluminum threads from being damaged from other
adaptors or couplers, especially tapered NPT pipe
thread.
The adaptors are polarized; the output adaptor is
larger (SAE 8) because its internal feature
interfaces with a reverse flow check ball.
Note: Removal of these adaptors by a customer
voids the warranty.
910161
Hydraulic Rail Drill
1.2023 Rev 3.1
Original Instructions
Page 20
Common Hook-Ups –Couplers
Common Hook-Ups –Plumbed w/ Hose Set
Non-Conductive Rubber (NCR) Hoses
•8-foot hose
•10-foot hose
Swivels
•2 required
•Located between the Inlet/Outlet adaptors and the hose assembly
•Used for ease of assembly when attaching the hose to the drill at the
factory prior to shipment.
Note: NCR hoses are banded at various intervals for ease of
maneuverability when in use.
Swivels
Hose Bands
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