Racine Railroad Products 910169 User manual
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page iii
Original Instructions
Table of Contents
Section 1: Overview and Safety....................................................................................................................5
Hydraulic Spike Driver Overview...................................................................................................................5
Environmental Protection..............................................................................................................................5
Safety Information.........................................................................................................................................5
Safety Terms .............................................................................................................................................6
Machine Use and Safety Precautions .......................................................................................................6
Section 2: Specifications and Installation......................................................................................................7
Unpacking Instructions..................................................................................................................................8
Tool Preparations..........................................................................................................................................8
Hose Requirements ......................................................................................................................................8
Hose Types ...............................................................................................................................................8
Hydraulic Hose Recommendation.............................................................................................................9
Hydraulic Fluid Recommendation .............................................................................................................9
Tool Connecting Procedures...................................................................................................................10
Disconnecting Hoses...............................................................................................................................10
Section 3: Tool Operation ...........................................................................................................................11
Personal Protective Equipment ...........................................................................................................11
Operation.....................................................................................................................................................11
Shut-Down Procedures ...........................................................................................................................11
Section 4: Maintenance...............................................................................................................................12
Trouble Shooting .....................................................................................................................................13
Section 5: Parts and Service Support.........................................................................................................14
Hydraulic Spike Driver Assembly and Parts List.........................................................................................15
Section 6: Warranty Terms and Conditions................................................................................................20
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 5
Original Instructions
Section 1: Overview and Safety
Hydraulic Spike Driver Overview
Racine Railroad Products designs and manufactures equipment primarily for the repair and new
construction of rail and railroad tie track maintenance.
The Racine Railroad Products Hydraulic Spike Driver is a portable, remotely powered, handheld power
tool designed for track rail fastening. The Racine Hydraulic Spike Driver accommodates rail and tie plate
spikes uses a high impact reciprocating ram to finish inserting steel spikes into wooden cross-ties after
spikes are manually started.
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.
Failure to do so could result in personal injury or equipment damage. 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.
Note: Information in this document is subject to change without notice.
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.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 6
Original Instructions
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 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.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 7
Original Instructions
Always shut disconnect 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
Section 2: Specifications and Installation
Hydraulic System:................................Open Center
Length:.................................................30.50 in. (~77.0 cm)
Width:...................................................18.00 in. (~75.7 cm)
Height, Work Mode:.............................6.00 in. (~15.24 cm)
Weight:.................................................88 lbs. (~39.8kg)
Mechanical Data
Hydraulic Motor:
Maximum Flow:....................................10 gpm (~38 lpm)
Maximum Pressure:.............................2000 psi (~140 bar)
Full Bypass Setting:.............................2250 psi (~157 bar)
Hydraulic fluid requirements:
Viscosity (Fluid Thickness)
U.S.A.
METRIC
50° F 450 SSU Max.
10° C 95 Centistokes
100° F 130-200 SSU
38° C 27-42 C.S
140° F 85 SSU Min.
60° C 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 & B) Pass
Oxidation (ASTM D943) 1000 Hours Minimum
Pump Wear Test (ASTM D2882) 60 mg Maximum
Recommended hose size: .500 inch/12mm I.D. up to 50 ft./15m long
Recommended hose size: .625 inch/16 mm I>D> up to 100 ft/30 m long
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 8
Original Instructions
Unpacking Instructions
Upon receiving your Hydraulic Spike Driver promptly remove it from the shipping container. Always
keep top side of container up. Inspect unit for damage which may have incurred during shipping and
report it to carrier for claim.
Tool Preparations
The Hydraulic Spike Driver may require some assembly before use. The machine should receive an
in-service inspection before initial operation. If the tool is used in cold weather, preheat the hydraulic
fluid by running power source at low engine speed.
Fluid temperature should be at or above 50° F/10° C (400-ssu / 82 centistroke) before use, when
using recommended fluids. Using too thick of fluid may result in tool damage.
Never stick foreign objects, fingers, or other extremities into
moving mechanism. Failure to follow these instructions may lead
to severe personal injury or tool damage.
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 Hydraulic Spike Driver 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).
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 9
Original Instructions
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
Chevron
Clarity AW 15032
Exxon
Univis J 32
Mobil
D.T.E. 13M
Gulf
Harmony AW-HVI-150-32
Shell
Tellus T 32
Texaco
Rando HDZ 32
Union
Unax AW-WR-32
Amsoil
AWH 15032
Sunvis
Low Pour H/032-product code 19300
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 10
Original Instructions
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.
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.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 11
Original Instructions
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
Spring Loaded Handles
The Hydraulic Spike Driver is equipped with spring loaded handles for operator comfort when operating
thus dampening vibration and decreasing fatigue. This handle also controls operation of the control valve
cartridge.
•Press down on the handles to open the control valve and begins operation.
•Pull up to close the hydraulic control valve, stopping operation.
Spring loaded handles reduce vibration and operator fatigue.
The spring-loaded handle extends the control valve spool to the OFF position thus prevents accidental
starting of the tool.
Operation
1. Connect the pressure and return hoses to the hydraulic power source and start power motor.
2. Grasp both handles firmly, place the ram end on the spike head and press the handle toward the
spike driver, activating the tool.
Always hold the tool with both hands to maintain control.
3. To stop the Hydraulic Spike Driver, pull up on the handles.
When the fastener contacts the surface of the material being fastened, impact time is predicated by
the number of strokes required to drive a spike into a wooden tie
Shut-Down Procedures
1. Stop the Hydraulic Spike Driver with the spring loaded handle to close the valve.
2. Shut down the hydraulic power source.
3. Disconnect the hydraulic hoses from the spike driver.
4. Remove the tool from work area.
5. Prepare the unit for transport as outlined in transportation and handling.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 12
Original Instructions
Section 4: Maintenance
It is highly recommended to practice regular check-ups and maintenance in accordance with the
usage
frequency to keep your tool in better condition and reduces total
run
ning
costs.
Do not perform maintenance on the machine while the hydraulic
power source motor is running or when hoses are connected.
All maintenance must be done with the tool disconnected from the
power source.
Cleaning and Maintenance Recommendations
•
Wipe
all external surfaces after each use with a clean, lint free cloth to remove surface
contaminants from the tool.
•
Store all
tools in an enclosed area to prevent weather from contaminating their systems.
Safety Devices
When maintenance is complete, make sure the following:
•
The hydraulic
control valves are operable.
•
The hydraulic quick couplers and hoses are safe to use.
Storage Preparation
•Cover male and female hose whips.
•Store in the upright position. Secure tool to prevent it from being knocked over.
•Store the machine on a smooth level surface.
•The tool should be stored in a cool, dry environment which is not subjected to rapid temperature
changes.
Daily
Do not attempt to locate hydraulic leaks by feeling around hoses
and fitting with hand. Pin-Hole leaks can penetrate the skin.
•Wipe all tool surfaces, fittings, and couplings free of grease, dirt, and foreign materials.
•Inspect the tool, hydraulic system, hoses, and fittings for signs of leaks, cracks, wear, and/or damage.
Replace if necessary.
•To prevent contamination, always install dust caps over the hydraulic ports when disconnected.
•Inspect machine for damage and wear, replace as required.
Monthly
•Perform a detailed inspection of the systems hoses and fittings according to the hydraulic hose
operator’s manual and as stated in SAE standard j1273, May 1989 or latest revision.
Replace the hoses and/or fittings if necessary.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
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Original Instructions
Trouble Shooting
The following chart can be used as guide to correct any problem you may be experience with the
Hydraulic Spike Driver:
To determine the problem in operation of the spike driver, always check that the hydraulic power source
is supplying the correct hydraulic flow and pressure to the tool as listed in the table.
•Be sure you are using an accurate flowmeter.
•Check the flow with the hydraulic fluid temperature at least 80F/27C.
•Always check the power source and hoses before disassembling the spike driver.
Problem
Possible Cause
Solution
Tool will not run.
Power source.
Check power source flows and
pressure (5-10 gpm/20-38 lpm
@ 1500-2000 psi 100-400 bar).
Coupler or hoses.
Check for /remove obstruction.
Flow control spool not fully
shifted.
Shift spool to on or off position.
Mechanical failure.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 14
Original Instructions
Section 5: Parts and Service Support
Telephone and web-based technical support is available for current production models through our
Technical Service Department. Service Manuals and limited technical support may be available for
models that are no longer in production.
Telephone and E-mail Technical Support
Telephone and E-mail technical support is 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
E-mail: techserv@racinerailroad.com
Non-Warranty Technical or 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 customer's expense, to assist in the correction of
non-warranty related problems. Contact our Technical Service Department to coordinate Non-Warranty
Technical or Field Service Support.
Warranty Technical or 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 or Field Service Support.
Warranty Parts & Service
Warranty parts and service are coordinated through our Technical Service Department.
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.
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 or Field Service Support.
910169 –Hydraulic Spike Driver
1.2023 Rev 2.1
Page 20
Original Instructions
Section 6: 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 customer service for factory parts, service or warranty support please provide the:
•Racine Railroad Products Model
•Serial Number
•Any locally assigned identification
Vendor Parts Warranty Period
Other equipment and parts used, but not manufactured by Racine Railroad Products, Inc., 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 Racine
Railroad Products manufactures 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 problems.
Non-Warranty Parts and Service
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.
Note: Parts for models that are no longer in production may not be available.
Non-Warranty Parts Orders
When placing a parts order please provide the following information:
•Company Name and Billing Address
•Purchase Order Number and Issuing Authority
•Shipping Address
•Special Handling Instructions
•Contact Phone Number
•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 in the parts lists and drawings 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
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