maintenance, and repair manual - hydraulic … · 1 model rp-10-86-1 rail puller operation,...

1

MODEL

RP-10-86-1

RAIL PULLER

OPERATION,

MAINTENANCE,

AND REPAIR MANUAL

1805 2nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310PHONE (218) 236-0223 * FAX (218) 233-5281

E-MAIL ADDRESS; [email protected] * INTERNET ADDRESS: www.portaco.com

2

TABLE OF CONTENTS

1.0 Introduction1.1 General Information1.2 Features1.3 Safety Summary1.4 General Safety Precautions1.5 Warning and Caution Statements1.6 Training Requirements

2.0 Installation Instructions2.1 Unpacking Instructions2.2 Rail Pull Preparation2.3 Testing2.4 Adjustments2.5 Power Source Requirements2.6 Hydraulic Hose Requirements2.7 Hydraulic Fluid Recommendations2.8 Tool Connecting Procedures2.9 Work Area Safety Precautions

3.0 Operating Instructions3.1 Description of Rail Puller3.2 Controls and Graphics3.3 Before Operation3.4 Positioning on Rail3.5 Connecting hoses3.6 Operating Instructions3.7 Disconnecting Hoses3.8 Cold Weather Operation3.9 Storage Instructions

4.0 Maintenance Instructions4.1 Assembly View and Parts List4.2 Graphic Set Complete4.3 Tool Maintenance4.4 Trouble Shooting4.5 Technical Specification

3

1.0 INTRODUCTION

1.1 General Information

This manual presents installation,operation, and maintenance information forthe RP-10-86-1 Rail Puller. The RailPuller’s function is to pull two lengths of railtogether in preparation for thermite, orboutet welds. PortaCo’s RP-10-86-1 RailPuller operates at low pressure. Thesystem is designed to operate at 2000psi/138 bar. A pressure intensifying systemis NOT used with this tool.

Shields and guards protect all mechanicaland hydraulic components; this will alsoprovide protection to the operator. Alloperations are self-contained andautomatic. No manual clamping or wedgesare used with the PortaCo Rail Puller.

The RP-10-86-1 Rail Puller operates onHTMA type RR hydraulic tool circuit, whichis an open center system providing a flow of9-10.5 gpm/34-40 lpm at an operatingpressure of 2000 psi/138 bar.

PortaCo, Inc. reserves the right to makechanges at anytime without notice andwithout incurring any obligation.

1.2 FEATURES

The main features of the PortaCo, Inc. RP-10-86-1 Rail Puller is as follows:

Length 110 in (279.4 cm)Width 29.38 in (74.6 cm)Height 21 in (53.3 cm)Weight (operating) 1130 lbs. (512.5 kg)

Upper ambient operating temperature 110°F (43° C), lower ambient operatingtemperature –20° F (-28° C).

The Rail Puller is supplied with a 3-Pointlifting sling for positioning the unit on the railand also positioning for transport andstorage. The lifting eyes and the sling arecolor coded to provide level positing. (SeeFig. 1.2A and 1.2B)

Fig. 1.2A This picture is showing a red donutdecal located on the stationary end of the RailPuller. This end gets the red hook on the sling.

Fig. 1.2B This picture is showing a blue donutdecal located on the working end of the RailPuller. This end gets the blue hooks on thesling. There are two lifting eyes on the working

end of the Rail Puller.

This unit operates at 2000 psi/138 bar,eliminating a pressure intensifier and therisks associated with a high-pressuresystem.

WARNINGNever stand under Rail Puller whensuspended. Injury or death may occur ifRail Puller is lowered or dropped onpersonnel.

4

Cylinder travel gauge indicates cylinderposition to maximize cylinder stroke, usage.(Fig. 1.2C)

Fig. 1.2C

Center decals on frame indicate center ofwork area for full utilization of the 66.12 in(167.9 cm) long 24” in (61 cm) wide workingarea. (Fig. 1.2D)

Fig. 1.2D

All operating functions and gauges arelocated in a single control panel that ismonitored by a single operator. Thecontrols and gauges are labeled as to theirfunction and operating instructions includinga comprehensive operating instructiondecal also placed on the control panel.(Fig. 1.2E)See 3.2 controls and graphics part ofmanual for a brief description of each decalfound on this tool.

*IMPORTANT*

READ AND UNDERSTAND EACH DECALAND OR TAGS THAT ARE ON ORATTACHED TO THE RAIL PULLERBEFORE OPERATING THE TOOL.The Puller is also equipped with a trappedpressure valve to release any pressure,which may accrue do to ambienttemperature changes. This feature aids inhose connection. (Arrow A Fig. 1.2E)

*IMPORTANT*ALWAYS CLOSE TRAPPED PRESSUREVALVE PRIOR TO OPERATING PULLERTO PREVENT OIL LEAKAGE.

The Rail Puller hydraulic system pressure ismonitored by a pressure gauge located inthe control panel. A pressure to tons of pullchart is located below the pressure gaugefor quick reference. (Arrow B Fig. 1.2E)

The Rail Puller’s controls are located on theleft side of the control panel. (Arrow C Fig.1.2E) When the control is released thepressure is maintained.

A rail holding valve is also located andmarked with an instructional decal on thecontrol panel (Arrow D Fig. 1.2E). Whenthe valve is turned to the hold directioncompletely, the hoses can be removed fromthe Rail Puller, and used on another tool.See 3.0 operating instructions for moreinformation.

C

B

DA

5

Fig. 1.2E

1.3 Safety Summary

Tool operators and maintenance personnelmust always comply with the safetyprecautions given in this manual and on thestickers and tags attached to the tool andhoses.

These safety precautions are given for yoursafety. Review them carefully beforeoperating the power unit and beforeperforming maintenance or repairs.Supervising personnel should developadditional precautions relating to thespecific work area and local safetyregulations.

1.4 General Safety Precautions

The PortaCo, Inc. Rail Puller is designed toprovide safe and dependable service ifoperated according to the instructionsprovided in this manual. Read andunderstand this manual and any stickersattached to the tool before operating.Failure to do so could result in personalinjury or equipment damage. Check therules and regulations at your location. Therules may include an employer’s worksafety program. Regulations may identifyhazards such as working around utilitysupply lines or hazardous slopes.

1.5 Warning and Caution Precautions

Warning and Caution statements havebeen strategically placed throughout thetext prior to operating or maintenanceprocedures, practices, or conditionsconsidered essential to protection ofpersonnel or equipment and property.

CAUTIONHIGHLIGHTS AN ESSENTIALOPERATING OR MAINTENANCEPROCEDURE, PRACTICE, CONDITIONSTATEMENT, ETC. WHICH IF NOTSTRICTLY OBSERVED, COULD RESULTIN DAMAGE TO, OR DESTRUCTION OF,EQUIPMENT OR LOSS OF MISSIONEFFECTIVENESS.

1.6 Training Requirements

Operator training for the Rail Puller shouldconsist of information found in this manual.In addition the operator must receiveinstructions, both verbally and throughdemonstrations for applications in which thetool is going to be used. The new operatormust start in an area without by standersand use the tool until able to fully operatethe tool under the conditions for the workarea.

2.0 Installation Instructions

2.1 Unpacking Instructions

Upon receiving your Rail Puller promptlyinspect it for damage which may haveincurred during shipping and report it tocarrier for claims.

2.2 Rail Puller Preparation

The PortaCo G-18D55-53-W power unit isrecommended for hydraulic supply. Thisunit is equipped with two 5-gpm/20 lpm

WARNINGHighlights an essential operating ormaintenance procedure, practice,condition statement, etc. Which if notstrictly observed, could result in injuryto, or death of, personnel or long termhealth hazards.

6

circuits that can be combined for on 10-gpm/40 lpm circuit.

If the Rail Puller is used in cold weather,preheat the hydraulic fluid by running thepower source at a low engine speed. Fluidtemperature should be at or above 50°F/10° C (400-ssu/82 centistroke) beforeuse, when using recommended fluids.Using too thick of fluid may result in tooldamage.

There is no assembly required upon arrivalof the new tool. The PortaCo Rail Puller isready to use after unpacking. Attach theprovided sling (Fig. 1.2A and 1.2B) byhooking the colored hook to the matchingcolored lifting eyes on the Rail Puller framefor proper lifting. Sling points are alsomarked with a “sling point” decal. (Fig.2.2A)

Fig. 2.2A

2.3 Testing

The Rail Puller has been tested prior toshipment, and meets all PortaCo’srequirements. Only qualified personnelshould do testing of this tool. If testing isrequired contact PortaCo, Inc. for propertesting procedures.

2.4 Adjustments

All adjustable components have been set atPortaCo, Inc. before shipping and do notrequire any adjusting upon receiving this

unit. The Rail Puller is ready for use afterunpacking.

2.5 Power Source Requirements

PortaCo, Inc. has preset all adjustable

components before shipment. Adjustmentsof these components are not required. TheRail Puller is ready for use after unpacking.

PortaCo, Inc. RP-10-86-1 Rail Pullerrequires the flow and pressurerequirements of the HTMA type RRhydraulic circuit. The HTMA defines thetype RR circuit as one nominally rated at 10gpm / 38 lpm. The hydraulic system mustprovide a flow range of 9-10.5 gpm/34-40lpm at 2000 psi/138 bar measured at thepower supply, this is an open centersystem.

The relief valves should be adjusted for acracking pressure of 2200-2300 psi/152-159 bar with full flow pressure notexceeding 2500 psi/173 bar measured atthe power supply outlet.

The total system back pressure measuredat the tool end of the return hose should notexceed 250 psi/17 bar when operating atthe maximum system flow, systemconditions for measurements are atmaximum fluid viscosity of 400 ssu (82centistokes) i.e. at minimum expectedoperating temperature.

WARNINGAll adjustments made to the Rail Pullermust be preformed by trained personnelbut only after consulting PortaCo, Inc. forproper procedures. Improper adjustmentsmay result in severe personal injury, death,or damage to the Rail Puller.

WARNINGThe Rail Puller is equipped withadjustable valves for regulating thespeed of the hydraulic cylinders andsequence in which they act. A reliefvalve also limits the maximum pressureallowed in the system. Adjustments tothese controls are to be preformed by aqualified technician only.

7

The hydraulic system should have sufficientheat rejection capacity to limit the maximumoil temperature to 140° F (60° C) at themaximum expected ambient temperature.The recommended minimum coolingcapacity to dissipate tool generated heat ata 40° F (22° C) difference between ambienttemperature and oil temperature is 6 H.P./4.8 K.W. (210 BTU/min).

Hydraulic systems should have an idealfilter of 10 micron to a max of 25-micronnominal filtration. Filter elements should besized for two to three times system flow toprevent filter by pass under lowtemperature start up and to providemaximum dirt holding capacity.

The PortaCo, Inc. G-18D55-53-W Powerunit is recommended for the hydraulicsupply. This power source meets orexceeds all HTMA requirements. PortaCo’sG-18 is equipped with two 5 gpm/20 lpmcircuits that can be combined for one 10gpm/40 lpm circuit.

2.6 Hydraulic Hose and FluidRequirements

Hoses and hose fittings used with this toolmust comply with SAE standard J1273 (seeAppendix A) recommended practice for“selection, installation, and maintenance ofhose and hose assemblies.

It is not often necessary or advisable to uselong hoses. All hoses must have an oilresistant inner surface and an abrasionresistant outer surface. Each hose musthave male pipe ends for most application.Longer hoses can be used when

necessary, but can affect the operation ofthe tool due to resistance in the hose.If small diameter or long hoses are used, orif restrictive fittings are connected to thesupply and return ports, the pressure isrequired to push the fluid through thesystem and back to the tank will be higher.This will reduce tool power.

*Important* – Oil should always flow fromthe male coupler through the femalecoupler.

NOTE: The pressure increase inuncoupled hoses left in the sun may makethem difficult to connect. When possibleafter use, connect the free ends of theoperating hoses together.

HOSE TYPES

Hydraulic hose types authorized for use byPortaCo, Inc. is as follows:

1. Labeled and certified non-conductive.

2. Wire braided (conductive)

3. Fabric braided (not certified or labelednon-conductive)

Hose 1: Listed above is the only hoseauthorized for use near electricalconductors. Hoses 2 and 3: Listed aboveare conductive and must never be usednear electrical conductors.

HOSE PRESSURE RATING

The rated working pressure of the hydraulichose must be at least 2500 psi/173 bar.

8

HYDRAULIC HOSE RECOMMENDATIONTable 2.6

FLOW PER CIRCUIT LENGTH EACH HOSE USE INSIDE DIAMETER SAE SPEC HOSE(WIRE DRAID)

SAE SPECHOSE (FIBERBRAID)

GPM LPM FEET METERS INCH MM5 to 8 19 to 30 To 50 To 15 Both ½ 13 SAE 100R1-8 100R7-85 to 8 19 to 30 51-100 15 to 30 Both 5/8 16 SAE 100R2-10 SAE 100R8-105 to 8 19 to 30 100-300 30 to 90 Pressure

Return5/8¾

1619

SAE 100R2-10SAE 100R1-12

SAE 100R8-10SAE 100R7-12

9 to 12 34 to 45 To 50 To 15 Both 5/8 16 SAE 100R2-10 SAE 100R8-109 to 12 34 to 45 51-100 15 to 30 Pressure

Return5/8¾

1619

SAE 100R2-10SAE 100R3-12

SAE 100R8-10SAE 100R7-12

9 to 12 24 to 45 100-200 30 to 60 PressureReturn

¾1

1925.4

SAE 100R2-12SAE 100R1-16

SAE 100R8-12SAE 100R7-16

2.7 Hydraulic Fluid Recommendation

Inspect hose for cuts, crushing, leaks, orabrasion, which may be a safety hazard orreduce fluid flows. The following fluids workwell over a wide temperature range atstartup, allow moisture to settle out, andresist biological growth likely in cooloperating hydraulic circuits.

PortaCo, Inc recommends these fluids.Others that meet or exceeds thespecifications of these fluids may also beused.

Type Hydraulic fluidChevron “Clarity” AW 15032Exxon “Univis” J 32Mobil D.T.E. 13MGulf “Harmony” AW-HVI-150-32Shell “Tellus” T” 32Texaco “Rando” HDZ 32Union “Unax” AW-WR-32Amsoil AWH 15032Sunvis Low Pour H/032-product code 19300

Hydraulic fluid requirements:

a) Viscosity (fluid Thickness)

USA METRIC

50° F 4450 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 Minimum

Demulsibility (ASTM D-1401) 30 Minutes Maximum

Flash Point (ASTM D-92) 340° F/170° C Minimum

Rust Inhibition (ASTM D-665 A & B) Pass

Oxidation (ASTM D943) 1000 Hours Minimum

Pump Wear Test (ASTM D2882) 60 mg

Maximum

2.8 Tool Connecting Procedures

The power unit should be off beforeconnecting, or switching a tool and, orhoses. Turn the hydraulic on/off valve tothe off position before starting the engine.Make sure all hoses are connected forcorrect flow direction to and from the toolbeing used. When routing hose in the workarea, position them where personnel willnot be at risk of tripping over them, orwhere vehicles can run them over. Also donot lay hose over sharp objects.

CAUTION:DO NOT PULL ON HOSES TO DRAGTHE POWER UNIT.

2.9 Work Area Safety Precautions

9

- Do not operate the tool unlessthoroughly trained or under thesupervision of an instructor.

- Establish a training program for alloperators to ensure safe operation.

- Operator must clear all bystanders fromthe work area when handling, startingand operating a tool, to avoid potentialinjury to bystanders.

- Pinch hazard: Tool parts move at highspeed and force and can cause severepersonal injury. Keep all body partsaway from moving tool parts to avoidinjury when the tool is connected to thehydraulic power source or duringoperation.

- Do not over-reach while operating thistool. Loss of balance can cause seriouspersonal injury or death. Securelysupport yourself and the tool beforeoperating the tool. Always keep properfooting and balance.

- Never operate the tool when you aretired, angry, emotionally disturbed, orunder the influence of alcohol, drugs,medications, or anything that couldaffect your vision, alertness,coordination or judgement.

- Hydraulic fluid under pressure: Do notuse any part of your body to locate ahydraulic leak. Escaping fluid underpressure can cause severe injury ordeath. If injury results from escapinghydraulic fluid, seek immediate medicalattention to avoid serious bodily injury.

- Disconnect tool from hydraulic sourcebefore inspection or cleaning.

- Only a properly trained person shouldperform any maintenance, service, andor repairs to a tool.

- Never operate a tool that is damagedimproperly adjusted, or not completelyand securely assembled.

Use all appropriate personal safetyequipment when handling, operating, andservicing this tool such as safety shoes,hard hat, eye and ear protection, weargloves and back support.

To help ensure safe operation of this tool,keep all safety labels clean and legible.Replace labels when necessary with newlabels. See section 4.2 Graphic SetComplete.

10

SAFETY REGULATION

Enter below any local or other safety regulations required for the operator to follow. Make surethe operator and maintenance personnel have knowledge of these regulations.___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

11

3.0 OPERATING INSTRUCTIONS

3.1 Description of Rail Puller

PortaCo, Inc. RP-10-86-1 Rail Puller isdesigned to pull two lengths of rail togetherin preparation for thermite or boutet welds.It will pull 120 tons and 6 inches of travel.The unit operates on low-pressure 2,000psi/138 bar so a pressure intensifier is notused on this Rail Puller.

All mechanical and hydraulic componentsare protected by shields or guards toassure long life of components and provideprotection to the operator. All operationsare self-contained and automatic. Nomanual clamping or wedges are used withthe PortaCo Rail Puller.

The Rail Puller will accommodate rail sizeranging from 115 lb to 141 lb rail.

Single control panel houses all the controlsand monitoring devices required tooperated the unit. A single control is usedto clamp the rail and pull the rail. A holdingvalve maintains the rail position and allowsthe hoses to be disconnected from the RailPuller and used to operate other tools whilewelding.

System pressure gauges and tonsconversion legend along with the cylinderpositioning gauge allows the operator tomonitor system functions while making apull.

The Rail Puller has three lifting eyeslocations color coded to match the liftingsling, which is supplied with the Rail Puller.The three point system levels and stabilizesthe unit for easy positioning on the rail.PortaCo’s Rail Puller rated at 10 gpm/40lpm at 2,000 psi/140 bar, and operates onan open center hydraulic system.

3.2 Controls and Graphics

The following decals are placed on the toolto aid in its operation and maintenance.The operator should locate and understandthem before using the Rail Puller.

Located on the control panel are thefollowing decals for operating the RailPuller.

The Caution decal which specifies the ratedflow of 10 gpm/40 lpm and pressure of2000 psi/138 bar. (Fig 3.2A) the decal alsoadvises the following safety tips. (Arrow AFig 3.2 Q)

Fig. 3.2A

- Keep all guards in place.

- During operation always wear approvedsafety protection for (following bysymbols for ear, eye, and headprotection).

The control lever is labeled with a decal,which indicates the “PULL” and “RELEASERETURN” direction for operating the RailPuller. (Fig. 3.2B) (Arrow B Fig. 3.2Q)

12

Fig. 3.2B

The rail holding valve decal indicates thedirection to rotate the handle to hold the railin place or release the rail after completingthe job. It also notes the importance ofhaving the hoses connected between theRail Puller and power source beforereleasing the rail. (Fig. 3.2C) (Arrow C Fig.3.2Q). The pressure gauge is labeled witha “Hydraulic System Pressure Gauge”decal. (Fig. 3.2D ) (Arrow D Fig. 3.2Q)

Fig. 3.2C

Fig. 3.2D

Directly below the gauge is located the“Tons Conversion Legend” decal. Thischart converts the pressure reading on thegauge to tons of pull on the rail. (Fig. 3.2E)(Arrow E Fig. 3.2Q)

The “Trapped Pressure Valve” decalindicates the direction in which to turn thevalve for releasing trapped pressure in the

Fig. 3.2E

hydraulic system when connecting to thehydraulic hoses. It also notes theimportance of having this valve closedtightly before operating the Rail Puller. (Fig3.2F) If left open while attempting to use theRail Puller, oil will drain out the drain hoseon the opposite side of the control panel,and the Rail Puller will not functioncorrectly. (Arrow F Fig. 3.2Q)

Fig. 3.2F

Also located on the control panel isPortaCo, Inc. serial number and modelnumber tag. (Fig. 3.2G) Keep this tag intactand legible. It is recommended that theserial number and model number be writtenin the operator’s manual as a back up, inthe event that the serial tag becomesdamaged. The model number and serialnumber are also required when orderingreplacement parts for the Rail Puller.(Arrow G Fig. 3.2Q)

13

Fig. 3.2G

An “Operating Instructions” decal is locatedon the lower right hand side of the controlpanel. (Fig. 3.2H) This decal presents stepby step instructions on how to operate theRail Puller. (Arrow H Fig. 3.2Q)

Fig. 3.2H

Above the control panel is located anindicator button inside a slot. A decal with“Fully Retracted” printed at the left end and“Maximum Extension” on the right endindicates the Rail Puller’s cylinder position.(Fig 3.2I) (Arrow I Fig. 3.2Q)

Fig. 3.2I

On both ends of the Rail Puller a “ClearSpikes and Rail Anchors a minimum of 60”both sides of cut” decal has been placed.(Fig 3.2J) (Arrow J Fig. 3.2R). This decalrecommends the removal of rail fastenersfor a smooth even pull on the rail.

The hydraulic hose connection ports arelocated in the control panel and are labeledrespectively as to their function. The leftport is pressure (Fig 3.2K) (Arrow K Fig.3.2Q) and is equipped with a femalecoupler. The right port is return (Fig 3.2L)(Arrow L Fig. 3.2Q) and is equipped with amale coupler.

Fig. 3.2J

Fig. 3.2K

Fig. 3.2L

The trapped pressure drain hose is locatedon the side opposite the control panel andis labeled with a “Hydraulic Drain” decal.(Fig. 3.2M) (Arrow M Fig. 3.2R)

Fig. 3.2M

A “Center” decal indicates the center of thework area for ideal positioning whenwelding. (Fig 3.2N) (Arrow N Fig 3.2R)

Fig. 3.2N

14

Located on the pressure gauge is a 120 tondecal. This decal clearly illustrated whenthe Rail Puller has reached 120 tons of pull(Fig. 3.2O).

Fig. 3.2O

The “Grease Zerk Decal” makes it quickand easy for the operator to locate thegrease zerk. See section 4.3 ToolMaintenance in this manual for Zerklocations and lubrication intervals.

Fig. 3.2P

Fig. 3.2Q

B

I

G

H

AK L

C

F

E

D

15

Fig. 3.2R

J

M

N

16

3.3 Before Operating

Check that all guards are in position andsecurely fastened, and are in goodcondition. Inspect Rail Puller for anyhydraulic oil leaks and repair as required donot operate Rail Puller if a leak is present,the ability to hold the rail in position maybelost if a leak reduces oil pressure. Closethe trapped pressure valve completely.Turn the rail holding valve counterclockwise(release rail direction) to open the hydrauliccircuit.

Inspect the gripper pads (Fig 3.3A) for wearor damage. Replace excessive worn ordamaged pads before use. Gripper padsthat are in poor condition can slip on rail.

Fig. 3.3A

Inspect hoses, which connect Rail Puller topower source for wear, cracking, fatigue, orleaks before using. Also check thatcouplers are in good condition.Fig. 3.3B

Do not use hoses, couplers, or fittingswhich are damaged, replace immediately.

Remove and clean the protective lenscovering the pressure gauge as required.(Fig. 3.3B) Two wing nuts hold lens in placeand are easily removed for servicing.Fasten lens in position before operating theRail Puller.

3.4 Position on Rail

Use truck crane to lift and position RailPuller on rail to be welded. Rail must setinto openings on each end of the RailPuller. (Fig 3.4A)Fig. 3.4A

WARNINGNever inspect pressurized hoses,coupler, or fittings with hands or atclose distances. Pressurized fluid canpuncture the skin and inject oil into thebody resulting in death.

WARNINGNever stand under the Rail Pullerwhen suspended. Injury or death mayoccur if Rail Puller is lowered ordropped on personnel. Always standclear and always maintain firm footingwhen guiding Rail Puller in place.

Good BadBad Good

17

Fig. 3.2B shows a picture of both ends ofthe Rail Puller showing how the Rail Pullerfits on the rail.

Fig. 3.2B

Align center of opening in the rail with the“Center” decals on the Rail Puller frame.This position will best utilize the work areaprovided within the Rail Puller’s frame.

When the Rail Puller is properly positioned,unhook the lifting sling form the Rail Pullerand remove the sling from the work area.

3.5 Connecting Hoses

Return (tank) hose connection shouldalways be connected before supply(pressure) hose connection to preventpressure build-up inside the tool, whichcould result in severe bodily injury.

1. Stop the hydraulic power source.

2. Depressurize the system.

3. Allow system and hydraulic fluid to cool.

- It is recommended that the return hosebe connected first and disconnect last tominimize or avoid trapping pressurewithin the tool.

4. Securely connect the return (tank) hosefrom the power source (port “T”) to thetool (“Return” port).

5. Securely connect the supply (pressure)hose from the power source (port “P”) tothe tool (“Pressure” port). Make surefittings are tight.

- When connecting the quick couplers,the flow should run from male coupler tothe female coupler. The female coupleron the tool is the inlet. Quick couplersare marked with a flow direction arrow.

- When possible, connect the free ends ofuncoupled hoses to prevent build up inthe hoses. The sun can also increasepressure in the hoses and makeconnecting them difficult.

3.6 Operating Instructions

1. Position Rail Puller on rail. See section3.4 for proper placement on rail.

2. Connect the hoses to the Rail Puller.See section 3.5 for proper connectingprocedure. If hoses are difficult toconnect, open the trapped pressurevalve to relieve systems pressure.Place a suitable container under thedrain hose, located opposite the control

WARNINGPinching hazard, tool parts move athigh speed and force and can causesevere personal injury. Keep all bodyparts away from moving parts of thetool when connected to the hydraulicpower source or during operation.

WARNING- Always stop the hydraulic power

source flow and depressurize thesystem before connecting a tool.Failure to comply could result insevere bodily injury.

- Pressurized fluid escaping from adamaged hose can penetrate theskin and be injected in the bodycausing injury or death.

18

panel, to catch any oil drained.Dispose of oil in a responsible manor inaccordance with local or companyregulations.

CAUTIONOIL DRAINED FROM TRAPPEDPRESSURE VALVE COULD LEAK ONTHE GROUND IF NOT CAPTURED BY ASUITABLE CONTAINER. DISPOSE OFOIL IN A RESPONSIBLE MANOR.

After connecting the hoses, make sure thetrapped pressure valve is closed tightly.Remove drained oil from work area afterhose has stopped dripping. Clean anyspills before continuing.

*IMPORTANT*Trapped pressure valve must be closedwhen operating Rail Puller.

3. Lift control valve handles to closeclamping mechanism and pull rail to therequired location.

4. Close the holding valve to maintain railposition. After the holding valve isclosed tight the hydraulic fluid flow tothe Rail Puller can be turned off, andthe power source shut down. Ifrequired the power source can bedisconnected from the Rail Puller andused to operate other tools while therail is being welded. With the hydraulicflow turned off and the holding valveclosed tightly, operate the control leverin both directions to relieve pressuretrapped in the hoses. Disconnect thehoses from the Rail Puller and usepower source as required.

5. The Rail Puller must be connected tothe power source before opening the“Holding Valve”. If the power sourcehas been disconnected, reconnect it to

the Rail Puller following the procedurein section 3.5 of this manual. Start thepower source and turn the hydraulicflow “On”. When the welding process iscomplete open the holding valve andpush down on the control valve handleto release the rail and retract the RailPuller. The Rail Puller may jumpslightly when the rail is released this isnormal. Retract the Rail Puller until theindicator is in the “Fully Retracted”position on the gauge decal.

*IMPORTANT*If the Rail Puller is not retracted completelythe pulling distance will be reduced.

6. Before disconnecting the hoses, shutthe power source “Off” and operate thecontrol valve in both directions torelease any trapped pressure.

7. Disconnect the hoses from the RailPuller following the procedure given insection 3.7 of this manual.

8. Attach the lifting sling to the lifting eyesof the Rail Puller. NOTE: the ends ofthe sling are color coded to match thecolors on the lifting eyes. Attach hooksto alike colored lifting eye. The twoshort legs of the sling are painted blueand attach to the lifting eyes on thecontrol panel end of the Rail Puller.The long leg of the sling is painted redand connects to the end opposite of thecontrol panel.

9. Remove Rail Puller from rail and returnit to its storage position.

WARNINGNever stand under Rail Puller whensuspended. Injury or death may occurif Rail Puller is lowered or dropped onpersonnel.

19

3.7Disconnecting Hoses

1. Stop the hydraulic power source.

2. Depressurize the system.

3. Allow system and hydraulic fluid tocool.

4. Disconnect the supply (pressure) hoseto the power source (pressure port)from the tool (“IN” port).

5. Disconnect the return (tank) hose to thehydraulic power source (“Return” port)from the tool (“OUT” port).

6. To prevent contamination, alwaysinstall dust caps over the hydraulicports of the tool when disconnected.

3.8 Cold Weather Operation

Hydraulic fluids are thicker in cold weather;therefore, run the engine at low idle longenough to bring the fluid temperature up tominimum of 10° C/50° F or until the top ofthe hydraulic tank feels warm, beforeoperating tool.

3.9 Storage Instructions

Cover male and female couplers with thecoupler dust caps. Properly secure the toolto prevent it from moving around. For longterm storage place in a horizontal positionin a cool dry environment which is notsubjected to rapid temperature changes.

WARNINGIf injury results from escaping hydraulicfluid, seek immediate medical attention.Serious bodily injury may occur if propermedical attention is not administeredimmediately.

Do not attempt to locate hydraulic leaks byfeeling around hoses and fittings withhands. “Pin-hole” leaks can penetrate theskin.

20

CAUTION: USE ONLY GENUINE PORTACO INC PARTS OR EQUIVALENT.THE USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENTQUALITY MAY DAMAGE THE HYDRAULIC TOOL.

4.0 Maintenance Instruction

4.1 Assembly View and Parts List

ITEM # PART # DESCRIPTION QTY

1 4243-00P BOLT ½” X 1” GRADE 8 2

2 1062-00P NUT, ¼” NC HH PL 2

3 1063-00P LOCK WASHER 3/8 30

4 1064-00P LOCK WASHER ¼” 10

5 1350-00P WASHER, FLAT ½” PLATED 4

6 N/A

7 1612-00P NUT ½” NC HH SELF LOCKING 2

8 1777-00P BOLT ½” NC X 2 ¾” PL HH #5 2

9 3893-00P BOLT 3/8” X 1” SHCS 7

10 2303-00P BOLT ½” NC X 1 ¼” HH PL #5 4

11 N/A

12 3758-00P BOLT ¼” NC X 5 ½” GRADE 8 4

13 4235-00W FRAME COMPLETE 1

14 4216-00W CARRIER CAM COMPLETE 1

15 3994-00W CAM COMPLETE (R) 1

16 3995-00W CAM COMPLETE (L) 1

17 3996-00W ARM GRIPPER (R) COMPLETE 1

18 3997-00W ARM GRIPPER (L) COMPLETE 1

19 HYD. CYLINDER RIGHT (see exploded view)

20 HYD. CYLINDER LEFT (see exploded view)

21 4234-00D GUIDE CYLINDER LEFT 1

22 4239-00W PANEL STATIONARY END COMPLETE 2

23 4237-00W PANEL CONTROL COMPLETE 1

24 4238-00W PANEL COVER (CONTROL) COMPLETE 1

25 4011-00W CYLINDER SLAVE COMPLETE 2

21

26 4012-00W GEAR TIMING COMPLETE (R) 1

27 4013-00W GEAR TIMING COMPLETE (L) 1

28 4014-00D PLATE RETAINING 2

29 4236-00D GUARD CYLINDER BOLT 2

30 N/A

31 4240-00D FLAP SPARK 1

32 4044-00D LINK GRIPPER ARM 2

33 4045-00W ADAPTOR LINK/CYL. 1

34 4047-00W PIN GRIPPER ARM 2

35 4120-00P ZERC GREESE 2

36 4121-00D TUBE CYLINDER 1

37 4122-00D ROD CYLINDER 1

38 1742-00P RIVET, POP SD46BS ¼ X 3/8 14

39 4174-00P #6 SAE FLAT WASHER 14

40 1899-00P NUT 5/16nc NYLOCK 4

41 3908-00P BOLT 5/16” X 4” (CYLINDER MOUNT) 4

42 1080-00P PIN, COTTER 1/8 X 1 ¼ 3

43 3453-00P BOLT 3/8 NC X 2.5 SHCS PL 12

44 1324-00P BOLT, 3/8 NC X 1 HH PL #5 6

45 4244-00D ROD INDICATOR 1

46 3270-00P BOLT ¼ NC X ½ SSBHCS 13

47 2752-00P SCREW SOCK SET ¼-20 X 3/8 1

48 1041-00P NUT JAM 12

49 4433-00P BOLT ½ NC X 2 ½ HH PL #5 2

51 1099-00P WASHER, ¼ FLAT PLATED 1

52 4176-00P ¼ X ¾ STAINLESS STEEL 8

53 4124-00D WEAR PAD @ CYLINDER 1

56 4178-00P CAP 1

57 1656-00P WASHER FL 3/16 BLK ZINK 1

22

58 4030-00P SPRING CAM RETURN 2

59 3998-00D GRIPPER PAD 4

60 2925-00P GREASE ZERK 4

61 1882-03P COUPLING 1/8” NPT 2

62 4242-00P NIPPLE 1/8” NPT X 2” 2

63 4233-00D GUIDE CARRIER RIGHT 1

64 1351-00P NUT ½” NC 4

65 1349-00P WASHER LOCK ½” 2

66 4211-00D RETAINER GRIPPER PAD 4

SER # 031463604 AND UP

67 4474-00D STOP RAIL 2

68 1093-00P WASHER FLAT 3/8 4

69 3956-00P WASHER ¾ 2

25


1 1062-OOP NUT, ¼ nc HH PL 2

2 1064-OOP LOCK WASHER ¼ 2

3 1094-OOP NUT, 5/16 nc X 2 SHCS 2

4 1099-OOP WASHER, ¼ FLAT PLATED 2

5 1148-OOP BOLT, 5/16nc X 2 SHCS 2

6 1175-OOP WASHER, LOCK 5/16 PLATED 2

7 1220-OOP BOLT ¼ nc X 1 ¾ HH PL #5 2

8 1237-OOP FITTING 6




12 2241-OOP COVER COUPLER 1

13 2512-OOP COVER COUPLER 1





18 2701-OOP COUPLER HYD. 1

19 2702-OOP COUPLER HYD. 1




24 3476-OOP VALVE DRAIN 2

25 3578-OOP FITTING TEE 1

26 3646-OOD MANIFOLD HYD. RETURN 1

27 3741-OOP FITTING 90° 1

28 4016-OOD MANIFOLD HYD. 1

29 4027-OOP GAUGE PRESSURE 1

30 4028-OOP VALVE CONTROL 1

31 4029-OOP VALVE HOLDING 1

26

32 4039-OOP VALVE NEEDLE 1

33 4064-OOP FITTING HYDRAULIC 4

34 4181-OOP 6505-6-4 4NPT MALE 6JIC FEMALE 1

35 4182-OOD SPACER HOLDING VALVE 1

36 4183-OOD SPACER NEEDLE VALVE 1

37 4171-OOP FITTING 90° 2

38 5081-OOP BOLT 10-24 X ¾ BHSC 3

39 5372-OOP NUT 10-32 NYLOCK 3

28


1 4049-OOP HOSE HYDRAULIC 28” 4


3 4052-OOP HOSE HYDRAULIC 2



6 4055-OOP HOSE HYDRAULIC 18.5” 1






12 4062-OOP HOSE HYDRAULIC 14.5” 1

13 4180-OOD HOSE GUARD 12” LONG 2


15 4918-OOP HOSE DRAIN 1

30

CYLINDER ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY

1 3890-00D PISTON CYLINDER 1

2 3891-00P BACKUP PISTON 2

3 3892-00P O-RING PISTON 1

4 3893-00P BOLT 3/8” X 1.00” SHCS 1

5 3895-00P O-RING 1

6 3897-00P O-RING 2

7 3898-00D END CAP ROD 1

8 3899-00P SEAL WIPER 1

9 3900-00P SEAL ROD 1

10 3901-00P BACKUP ROD 1

11 3902-00D END CAP 1

12 4121-00D TUBE CYLINDER 1

13 4122-00D ROD CYLINDER 1

14 3640-OOP ROLL PIN 1

31

LEFT BASE CYLINDER ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY1 4222-00D GLAND CYL. END COMPLETE 1


3 4221-00D ROD CYLINDER COMPLETE 1

4 4223-00D RING RETAINING 1

5 3085-00P O-RING -014 6

6 4226-00P O-RING QR-4448 1

7 4230-00P BACKUP RING 2

8 4227-00P O-RING -273 1

9 4229-00P WHIPPER SEAL ROD 1

10 4228-00P O-RING -362 1


12 4232-00P RING BACKUP 1

13 4219-00W HYDRAULIC CYLINDER (L) 1

14 1914-00P O-RING -010 6

15 4241-00P BOLT 3/8 NC X 1 ¼ SHCS 6

16 4218-00P RETAINING RING 2

17 4225-00P O-RING -258 1

32

RIGHT BASE CYLINDER ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY1 4222-00D GLAND CYL. END COMPLETE 1


3 4221-00D ROD CYLINDER COMPLETE 1

4 4223-00D RING RETAINING 1

5 3085-00P O-RING -014 6

6 4226-00P O-RING QR-4448 1


8 4227-00P O-RING -273 1

9 4229-00P WHIPPER SEAL ROD 1

10 4228-00P O-RING -361 1


12 4232-00P RING BACKUP 1

13 4217-00W HYDRAULIC CYLINDER (R) 1

14 1914-00P O-RING -010 6

15 4241-00P BOLT 3/8 NC X 1 ¼ SHCS 6

16 4218-00P RETAINING RING 2

17 4225-00P O-RING -258 1

33

4.2 Graphic Set Complete(3999-00D)

3999-4D

3492-01D

3999-01D

1859-07D

1859-08D

2158-00D

3999-08D

3999-09D

3999-16D

34

3999-14D

3999-13D

1849-01D

3999-03D

3999-05D

3238-05D

3999-07D

2158-08D

3999-15D

2826-07D

35

2124-01D

2906-00D

RP-103999-06D

3999-11D

3999-12

RED

BLUE

36

4.3 Tool Maintenance

The service life of a tool can be greatlyimproved with proper care andmaintenance. To extend the life of the RailPuller follow the recommendedmaintenance tasks outlined below.

Daily:

Wipe all tool surfaces, fittings, and couplersfree of grease, dirt, and foreignmaterials.

Inspect the Rail Puller for hydraulic leaks.Locate and repair any damaged orworn hydraulic components asrequired.

Inspect gripper pads for worn or damagedteeth and replace pads as required.

Weekly:

1. Grease the gripper cams and gripper arms.(Fig 4.3A and Fig. 4.3B) Use good qualitylithium grease and apply 3-5 strokes perjoint.

Fig. 4.3A

Fig. 4.3B

2. Inspect protective panels and flaps fordamage replace as required.

Annually:

Remove the cover from the opposite end asthe control panel and the cover formthe backside of the control panel. (Fig.4.3C and Fig. 4.3D) Perform a detailedinspection of the systems hoses andfittings for damage and leaks. Replaceitems as required.

Perform hose inspection as stated inSAE standard J1223, may 1989 orlatest revision. A copy of which can befound at the end of this manual.

WARNINGDisconnect Rail Puller from powersource before performing anymaintenance tasks. Cleaning andmaintenance recommendations: aftereach use wipe external surfaces withclean, lint free cloth to remove surfacecontaminants from the Rail Puller.

WARNINGDo not attempt to locate hydraulic leaksby feeling around hoses and fittings withhands. “Pin Hole” leaks can penetratethe skin and cause severe personalinjury and death if not treatedimmediately.

37

Fig. 4.3C

Fig. 4.3D

2. Inspect mechanical components andfasteners for damage and replace itemsas required.

The operators should not attempt to repairthis product. Only properly trainedpersonnel should perform annualinspections and repairs to this tool.

CAUTION:COMPLETE DISASSEMBLY OF THERAIL PULLER IS NOT RECOMMENDED.RETURN THE TOOL TO PORTACO, INC.FOR MAJOR REPAIRS, and CALL (218)236-0223 FOR ADDITIONALINFORMATION.

Servicing and repairs by unqualifiedpersonnel and major repairs preformedwithout authorization by PortaCo, Inc. willvoid the warranty and may lead to seriouspersonal injury.

38

4.4 Trouble Shooting

The following chart can be used as a guide to correct a problem you may experience with thetool.

To determine the problem in operation of the Rail Puller always check that the hydraulic powersource is supplying the correct hydraulic flow and pressure to the tool as listed in the manual.Be sure you are using an accurate flow meter. Check the flow with the hydraulic fluidtemperature at least 80° F/27° C.

NOTE: Stop and depressurize the hydraulic system before connecting or disconnecting a tool.Failure to follow these instructions can lead to severe personal injury. Read and follow theinstructions in this manual for the proper way to connect and disconnect tools from the hydraulicsystems.

PROBLEM CAUSE REMEDYUnable to connecthydraulic hoses to RailPuller.

Pressure trapped in RailPuller hydraulic systems.

Open trapped pressurevalve and lift control leverup while connectinghoses.

Damaged couplers Inspect couplers replace ifrequired.

Rail Puller will not setdown on rail

Wrong size rail Rail Puller designed to fit115-141 lb rail

Cams or gripper arm areclosed

Inspect cams and orgripper arms, fully retractRail Puller so clampingsystem opens.

Rail Puller clampingsystem doesn’t move

Rail holding valve isclosed.

Open rail holding valve.

Trapped pressure valveopen.

Close trapped pressurevalve.

Hydraulic Flow not turned“on” at power source.

Turn flow “on” at powersource.

Damaged hose inhydraulic system.

Check for leaks andreplace damaged hose.

Contaminated relief valveon Rail Puller.

Have relief valve checkedby qualified technicians.

Rail Puller clamps Railbut doesn’t have enoughpower to pull rail.

Trapped pressure valveopen.

Close trapped pressurevalve.

Damaged hose inhydraulic system.

Check for leaks andreplace damaged hose

Low setting orcontaminated relief valveon power source.

Test power source andmake repairs as required.

39

Contaminated relief valveon Rail Puller.

Have relief valve checkedby a qualified technician.

PROBLEM CAUSE REMEDYRail Puller will notunclamp from rail

Rail holding valve isclosed.

Open rail holding valve.

Excess pressure on RailPuller from Rail.

Quickly switch controllever between pull andrelease.

Gap in rail doesn’t closeenough.

Rail Puller is at max pull Release rail and retractRail Puller to “FullyRetracted” position. Trypulling rail again.

Maximum pullingpressure has beenachieved.

Check the hydraulicsystem pressure gaugeand determine the ton ratefrom legend. If readingindicates 120 tons rail hasachieved maximum pullingpressure.

Relief valve set too low atpower source.

Check pressure gaugereading on Rail Puller.

Relief valve defective inRail Puller.

Test Rail Puller relief valveand repair as required.

Rail Puller slips on rail. Irregular surface on railwhere grippers grab

Inspect rail and repositionRail Puller if required.

Worn or damaged gripperpads.

Inspect gripper pads andreplace as required.

NOTE: After reviewing trouble shooting chart and still unable to determine problem call theservice department at PortaCo, Inc. (218-236-0223) for advice.

40

4.5 Technical Specifications

Features

Rail Puller/Base Unit 1130 lbs/512.5 kgRail Puller/Rail Size accommodations 115 lb/141 lb railMax Pressure 2000 psi/150 barMax Flow 9-10.5 gpm/34-40 lpm

Consumable Items List

Description Part Number SourceCoupler HYD #FF371 8FP NPT F 2701-00P PortaCo, Inc.Coupler HYD #FF372 8FP NPT M 2702-00P PortaCo, Inc.Cover Coupler #NR-37 BRUNNING 2241-00P PortaCo, Inc.Cover Coupler #NR-50 2513-00P PortaCo, Inc.Gripper Pad 3998-00D PortaCo, Inc.

41

Hydraulic Fluid Requirements

Viscosity (Fluid Thickness)

METRIC U.S.A.10°C 95 Centistokes 50°F 4450 SSU Max38°C 27-42 C.S. 100°F 130-200 SSU60°C 16.5 C.S., Min. 140°F 85 SSU Min.

Pour Point – 10°F/-23°C Minimum (for cold startup)Viscosity Index (ASTM D 2220) 140 MinimumDemulsibility (ASTM D-1401) 30 Minutes MaximumFlash Point (ASTM D-92) 340°F/171°C MinimumRust Inhibition (ASTM D-665 A & B) PassOxidation (ASTM D943) 1000 Hours MinimumPump West Test (ASTM D2882) 60 mg Maximum

Recommend Hydraulic Fluids

Type Hydraulic fluidChevron “Clarity” AW ISO 32Exxon “Univis” J 32Mobil D.T.E. 13 MGulf “Harmony” AW-HVI-150-32Shell “Tellus T” 32Texaco “Rando” HDZ 32Union “Unax” AW-WR-32Amsoil AWH ISO 32Sunvis Low Pour H/032-product code 193000

Coupler recommendation: 3/8 inch FLAT FACE HTMA couplers rated at 2500 psi workingpressure. Threads are to match fittings used on hoses or fittings used as adapters.

Bolt Size Torque#10-32¼-205/16-183/8-16

38 in. lbs.76 in. lbs.13 ft. lbs.23 ft. lbs

42

SERVICE AND REPAIR NOTES

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

43

APPENDIX A

SELECTION, INSTALLATION AND MAINTENANCE OF HOSE AND HOSEASSEMBLIES

SAE J1273 MAY 1986*

SAE RECOMMENDED PRACTICEThe following recommendations on selection, installation and maintenance ofhose and hose assemblies were established by SAE in 1979 and reaffirmed May1986. Please read these general instructions carefully.

1. SCOPE

Hose (also includes hose assemblies) has a finite life and there are a number offactors which will reduce its life.

This recommended practice is intended as a guide to assist system designersand/or users in the selection, installation and maintenance of hose. Thedesigners and users must make a systematic review of each application and thenselect, install and maintain the hose to fulfill the requirements of the application.The following are general guidelines and are not necessarily a complete list.

2. SELECTION

The following is a list of factors that must be considered before final hoseselection can be made.

2.1 Pressure – After determining the system pressure, hose selection must bemade so that the recommended maximum operating pressure is equal to orgreater than the maximum operating pressure will shorten hose life andmust be taken into account by the hydraulic designer.

2.2 Suction – Hose used for suction applications must be selected to insure thehose will withstand the negative pressure of the system.

2.3 Temperature – Care must be taken to insure that fluid and ambienttemperatures, both static and transient, do not exceed the limitations of thehose. Special care must be taken when routing near hot manifolds.

2.4 Fluid Compatibility – Hose selection must assure compatibility of the hosetube, cover, and fittings with the fluid used. Additional caution must beobserved in hose selection for gaseous applications.

2.5 Size – Transmission of power by means of pressurized fluid varies withpressure and rate of flow. The size of the components must be adequateto keep pressure losses to minimum and avoid damage to the hose due toheat generation or excessive turbulence.

44

2.6 Routing – Attention must be given to optimum routing to minimize inherentproblems.

2.7 Environment – care must be taken to insure that the hose and fittings areeither compatible with or protected from the environment to which they areexposed. Environmental conditions such as ultraviolet light, ozone, saltwater, chemicals, and air pollutants can cause degradation and prematurefailure and therefore, must be considered.

2.8 Mechanical Loads – External forces can significantly reduce hose life.Mechanical loads that must be considered include excessive flexing, twist,kinking, tensile or side loads, bend radius, and vibration. Use of swiveltype fittings or adapters may be required to insure no twist is put into thehose. Unusual applications may require special testing prior to hoseselection.

2.9 Abrasion – While a hose designed with a reasonable level of abrasionresistance, care must be taken to protect the hose from excessive abrasionwhich can result in erosion, snagging, and cutting of the hose cover.Exposure of the reinforcement will significantly accelerate hose failure.

2.10 Proper End Fitting – Care must be taken to insure proper compatibilityexists between the hose and coupling selected based on themanufacturer’s recommendations substantiated by testing to industrystandards such as SAE J517d (November, 1976).

2.11 Length – When establishing proper hose length, motion absorption, hoselength changes due to pressure, as well as hose and machine tolerancesmust be considered.

2.12 Specifications and standards – When selecting hose, government, industry,and manufacture’s specifications and recommendations must be reviewedas applicable.

2.13 Hose Cleanliness – Hose components vary in cleanliness levels. Caremust be taken to insure that the assemblies selected have an adequatelevel of cleanliness for the application.

2.14 Electrical Conductivity – Certain applications require that the hose be non-conductive to prevent electrical current flow. Other applications require thehose to be sufficiently conductive to drain off static electricity. Hose andfitting must be chosen with these needs in mind.

INSTALLATION

After selection of proper hose, the installer must consider the following factors:

45

3.1 Pre-Installation Inspection – Prior to installation, a careful examination of thehose must be performed. All components must be checked for correct style,size, and length. In addition, the hose must be examined for cleanliness,I.D. obstructions, blisters, loose cover, or any other visible defects.

3.2 Follow Manufactures’ Assembly Instructions.

3.3 Minimum Bend Radius – Installation at less than minimum bend radius maysignificantly reduce hose life. Particular attention must be given to precludesharp bending at the hose/fitting juncture.

3.4 Twist Angle and Orientation – Hose installations must be such that relativemotion of machine components produces bending of the hose rather thantwisting.

3.5 Securement – In many applications, it may be necessary to restrain, protect,or guide the hose to protect, or guide the hose to protect it from damage byunnecessary flexing, pressure surges, and contact with other mechanicalcomponents. Care must be taken to insure such restraints do not introduceadditional stress or wear points.

3.6 Proper Connection of Ports – Proper physical installation of the hoserequires a correctly installed port connection while insuring that no twist ortorque is put into the hose.

3.7 Avoid External Damage – Proper installation is not complete withoutinsuring that tensile loads, side loads, kinking, flattening, potential abrasion,thread damage, or damage to sealing surfaces are corrected or eliminated.

3.8 System Checkout – After completing the installation, all air entrapment mustbe eliminated and the system pressurized to the maximum system pressureand checked for proper function and freedom from leaks.

Note: Avoid potential hazardous areas while testing.

MAINTENANCE

Even with proper selection and installation, hose life may be significantly reducewithout a continuing maintenance program. Frequency should be determined bythe severity of the application and risk potential. A maintenance program shouldinclude the following as a minimum.

4.1 Hose Storage – Hose products in storage can be affected adversely bytemperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids andfumes, insects, rodents, and radioactive materials. Storage areas should berelatively cool and dark and free of dust, dirt, dampness and mildew.

46

4.2 Visual Inspection – Any of the following conditions requires replacement ofthe hose:

(a) Leaks at or in hose. (Leaking fluid is a fire hazard.)

(b) Damage, cut, or abraded cover. (Any reinforcement exposed.)

(c) Kinked, crushed, flattened, or twisted hose.

(d) Hard, stiff, heat cracked, or charred hose.

(e) Blistered, soft, degraded, or loose cover.

(f) Cracked, damaged, or badly corroded fittings.

(g) Fitting slippage on hose.

4.2 Visual Inspection – The following items must be tightened, repaired, orreplaced as required:

(a) Leaking port conditions.

(b) Clamps, guards, shield.

(c) Remove excessive dirt build-up.

(d) System fluid level, fluid type, and any air entrapment.

4.3 Functional test – Operate the system at maximum operating pressure andcheck for possible malfunctions and freedom from leaks. Note: Avoidpotential hazardous areas while testing.

4.4 Replacement Intervals – Specific replacement intervals must be consideredbased on previous service life, government or industry recommendations, orwhen failures could result unacceptable down time, damage, or injury risk.

4.5 Replacement Intervals – Specific replacement intervals must be consideredbased on pervious service life, government or industry recommendations, orwhen failures could result unacceptable down time, damage, or injury risk.

maintenance, and repair manual - hydraulic … · 1 model rp-10-86-1 rail puller operation,...

Documents