Racine Railroad Products 910115 User manual
910115
Loading Arm
3.2023 Rev 2.1
Original Instructions
Page ii
Loading Arm
910115
Record of Changes
Rev No.
Date
Description of Changes
Rev 1
4.2007
Initial release.
Rev 2
10.2019
Branding update, new format, updated parts list
Rev 2.1
3.2023
Add environmental section, add hose, and recommended hydraulic fluids,
Add PPE section
910115
Loading Arm
3.2023 Rev 2.1
Original Instructions
Page iii
Table of Contents
Section 1: Overview and Safety....................................................................................................................5
Loading Arm Overview..................................................................................................................................5
Environmental Protection..............................................................................................................................5
Safety Information.........................................................................................................................................6
Safety Terms .............................................................................................................................................6
Machine Use and Safety Precautions .......................................................................................................6
Section 2: Specifications and Installation......................................................................................................7
Specifications................................................................................................................................................7
Installation.....................................................................................................................................................7
Hose Requirements ......................................................................................................................................8
Hose Types ...............................................................................................................................................8
Hydraulic Hose Recommendation.............................................................................................................8
Hydraulic Fluid Recommendation .............................................................................................................9
Tool Connecting Procedures.....................................................................................................................9
Disconnecting Hoses...............................................................................................................................10
Section 3: Tool Operation ...........................................................................................................................11
Personal Protective Equipment ...........................................................................................................11
Storage Preparation ................................................................................................................................14
Section 4: Maintenance...............................................................................................................................14
Troubleshooting.......................................................................................................................................14
Section 5: Parts and Service Support.........................................................................................................15
Loading Arm Drawings and Parts List.........................................................................................................16
Service Parts List.....................................................................................................................................16
Assist Arm Drawing .................................................................................................................................17
Assist Arm Parts List............................................................................................................................19
Loading Arm Drawing..............................................................................................................................20
Loading Arm Parts List.........................................................................................................................22
Section 6: Warranty Terms and Conditions ................................................................................................23
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Section 1: Overview and Safety
Loading Arm Overview
Racine Railroad Products designs and manufactures equipment primarily for the repair and new
construction of rail and railroad tie track maintenance.
The Loading Arm is used on rail already fixed to ties. It allows a load to be applied to the rail to assure
proper distance between the rails when under pressure. The loading arm can also be used as an Assist
Arm.
The Assist Arm is designed to quickly position the rail for fastening to the tie. It is often used on curves to
maintain the proper distance between rails.
The arms can be adjusted to different lengths to accommodate different rail positions. Isolated ends allow
for use near crossing and switches. The arms feature a rotary control valve for operating in a pushing or
pulling function.
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.
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.
Do not throw the discarded equipment in trash cans.
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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.
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 use this machine for other than its intended purpose.
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.
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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.
Always 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
Specifications
Length ...........................66.00-78.00 in [167.6-191.1 cm]
Width.............................4.75 in [12.0 cm]
Height............................9.00 in [22.8 cm]
Weight...........................38.0-lbs [17.2 kg]
Max push.......................6.13 tons [5561 kg]
Max pull.........................5.15 tons [4675 kg]
Installation
Unpacking Instructions
Upon receiving your Loader Arm,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.
Testing
1. Using the pump, extend the arm completely.
2. The loading arm is equipped with a pressure gauge.
3. Pump the pressure up to 2500 psi on this model for testing.
4. Return the arm to the fully retracted position.
If the tool fails to function properly see the trouble shooting section of this manual.
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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).
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
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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 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 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.
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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.
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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
6. Steel Toed Safety Shoes
Never get fingers or other extremities under or between the rails
being adjusted. Failure to follow these instructions may lead to
severe personal injury.
Note: The loading arm has a psi to lbs of force conversion chart located next to the system pressure
gauge. The gauge only reads pressure in the push direction not in the pull direction.
Before Operating
Check the hydraulic fluid level in the reservoir.
Fully retract the arm before placing between the rails.
Loading Arm
1. Position the loading arm between the rails
being adjusted.
The arm should be in the fully retracted
position to assure maximum travel when
pushing the rail apart.
2. Open the clamp ends located at each end of
the arm. (Arrow A.)
3. Adjust the length of the arm by pinning the
arm extension in the hole closest to fitting
between the rail without going over.
(Arrow B.)
You may need to extend the arm using the pump to position the clamping mechanism over the
rail properly.
4. Close the clamping arm and insert the pin at each end or the tool.
5. Remove the jack handle from the storage position inside the transport handle. (Arrow C.)
6. Insert the handle into the receiver for the pump valve. (Arrow D.)
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Proper Positioning on the Rail
Proper Positioning on the Rail
7. Position the control valve into the required
position and pump the valve to position the rail
as needed. (Arrow F.)
If operating the loading arm, continue pumping
until the pressure gauge reaches the force
required for measuring the rail movement.
Removing Arm
1. To remove the arm from the rail, open the clamping ends.
If the rail was pulled, extend the arm until the clamp ends will open freely.
2. Retract the arm to the fully retracted position.
3. Close the end clamps.
4. Insert the pins to prevent them from being lost.
Assist Arm
1. Position the assist arm between the rails.
2. Open the clamping end and set it over the fixed rail.
3. Close the clamp and pin it in place. Make sure the arm is full retracted.
4. Remove the shoe from the end of the arm and position it under the rail.
5. It may be necessary to crib out under the rail if there is not enough room for the shoe.
6. Extend the arm until a set of holes in the arm align with a set of holes in the shoe.
7. Insert the connector pin. (See images below for proper position on the rail.)
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Assist Arm
1. Remove the jack handle from the storage position inside the transport handle. (Arrow C.)
2. Insert the handle into the receiver for the pump valve. (Arrow D.)
3. Position the control valve into the required position and pump the valve to position the rail as
needed. (Arrow F.)
Removing the Assist Arm
1. To remove the assist arm from the rail, relieve the pressure using the jacking system to move the arm
until it set loosely on the rail.
2. Remove the pin connecting the shoe to the arm.
3. Open the clamping end and lift the main unit out of the work area.
4. Slide the shoe out from under the rail and connect it to the assist arm.
5. Fully retract the arm to make the unit as compact as possible.
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Storage Preparation
The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes.
1. Fully retract the arm and insert all pins.
2. Pin the adjustable portion of the arm at the shortest overall position to conserve space.
3. Insert the jack handle into the carrying handle.
4. Position the control valve in the blocked position.
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.
Wipe all external surfaces after each use with a clean, lint free cloth to remove surface contaminants from
the tool.
If the arm fails to extend completely or fails
to build pressure check the fluid level in the
hydraulic oil reservoir.
1. Retract the arm completely.
2. Remove the fill plug and fill the reservoir
to the bottom of the neck in the tank.
3. Insert the plug.
Troubleshooting
The following chart can be used as a guide to correct any problem you may experience with the tool.
Problem
Cause
Resolution
Arm will not extend completely.
Control valve in wrong position.
Check control valve position.
Low fluid level.
Check fluid level in hydraulic oil
reservoir.
Arm will not extend or retract,
and pumps hard.
Control valve in blocked position.
Check control valve position.
Loading arm will not build
pressure.
Control valve not in extend
position.
Set valve in extend position if
pushing rail apart.
Low fluid level.
Check fluid level in hydraulic oil
reservoir.
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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.
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Assist Arm Parts List
Item No.
Description
Qty
Item No.
Description
Qty
1
NUT, 3/8
3
24
CLAMP ARM
1
2
3/8 LOCK WASHER
5
25
TANK HYD
1
3
NUT, 3/8
3
26
BUSHING PLASTIC
1
4
BOLT, 3/8 NC X 2 ½ HH
3
27
PIN
4
5
BOLT, 3/8 NC X 2 ¾ HH
1
28
PUMP HAND
1
6
BOLT, ¼ NC X 2 ¼ HH
1
29
BALVE HYD
1
7
¼ NYLOCK NUT
4
30
SPACER
2
8
¼ LOCK WASHER
2
31
HOSE HYD
1
9
¼ WASHER FLAT
1
32
HANDLE COMPLETE
1
10
BOLT, ¼ NC X ½ HH
1
33
TUBE SHOURT
1
11
NUT, ½
1
34
HOSE HYD
1
12
FITTING
1
35
FITTING 90°
4
13
BOLT ½ NC X 2 ¾ HH
2
36
HOSE HYD
1
14
FITTING
2
37
HOSE HYD
1
15
BOLT, ¼ NC X 2 ½ HH
2
38
HOSE HYD
1
16
FITTING
3
39
HOSE HYD
1
17
CLAMP HOSE
2
40
GUARD CHECK
1
18
FITTING
2
41
BOLT
2
19
3/8 FLAT WASHER
3
42
BOLT
2
20
FITTING
1
43
PLUG/CAP
21
FRAME COMPLETE
1
44
PLATE RETAINING
1
22
FITTING
1
45
MOUNT PLATE (CHECK)
1
23
FOOT RAIL COMPLETE
1
46
STRAP
1
47
VALVE CHECK HYD
1
48
INSULATOR LARGE
1
49
FOOT RAIL INSULATED
1
50
¼ NYLOCK NUT
2
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