MODEL RA-00-93-O RAIL ALIGNER OPERATION, MAINTENANCE, AND REPAIR MANUAL 1805 2 nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310 1805 2 nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310 PHONE (218) 236-0223 * FAX (218) 233-5281 E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com 1
TABLE OF CONTENTS 1.0 Introduction 1.1 General Information 1.2 Features 1.3 Safety Summary 1.4 General Safety Precautions 1.5 Warning and Caution Statements 1.6 Training Requirements 2.0 Installation Instructions 2.1 Unpacking Instructions 2.2 Tool Preparations 2.3 Testing 2.4 Work Area Safety Precautions 3.0 Operating Instructions 3.1 Graphics 3.2 Operation of aligners 3.3 Storage preparation 4.0 Maintenance Instructions 4.1 Assembly View and Parts List 4.2 Graphic Set Complete 4.3 Care Requirements 4.4 Jack Replacement and Lubrication 4.5 Jack Screw Replacement 4.6 Lubrication Cross Feed Screw 4.7 Lubrication Horizontal Positioning Plate 4.8 Cross Feed Screw Replacement 4.9 Trouble Shooting 4.10 Technical Specifications 2
1.0 INTRODUCTION 1.1 General Information This manual presents removal, operation, and maintenance information for PortaCo s model RA-OO-93-O Rail Aligner. The rail aligner is designed to quickly position the ends of a rail for welding. This tool will help eliminate the use of other methods that increase the likely hood of injury. PortaCo, Inc. reserves the right to make changes at anytime without notice and without incurring any obligation. 1.2 Features The main features of the PortaCo rail aligner are as follows. Standard unit: Length 18.00 in/45.7 cm Width 6.25 in/15.9 cm Height 5.00 in/12.7 cm Weight 17.75-lbs/8.0 kg Lifting capacity 5 ton/ 4536 kg The rail aligners feature two 1-1/4" nuts at each end of the frame to position the rail ends vertically and one 1-1/4" nut at one end to position the rail horizontally. The jacking assemblies and cross feed are easily removed to perform maintenance and, or replacement. The jack feet accommodate anchor plates in concrete ties and prevent movement from side to side. Each aligner has it's own handle for ease of transportation. Every set of aligners includes one ratchet and 1-1/4 socket for operation. 1.3 Safety Summary Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool. These safety precautions are given for your safety. Review them carefully before operating the tool and before performing maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations. 1.4 General Safety Precautions The PortaCo Inc. tools are designed to provide safe and dependable service if operated according to the instructions provided in this manual. Read and understand this manual and any stickers attached to the power unit before operating. Failure to do so could result in personal injury or equipment damage. Check the rules and regulations at your location. The rules may include an employer s work safety program. Regulations may identify hazards such as working around utility supply lines or hazardous slopes. Read and understand any manuals for additional or optional equipment, which maybe shipped with the tool. 3
1.5 Warning and Caution Statements Warning and Caution statements have been strategically placed throughout the text prior to operating or maintenance procedures, practices, or conditions considered essential for the protection of personnel, equipment, and property. WARNING: HIGHLIGHTS A, ESSENTIAL OPERATING, OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO, OR DEATH OF, PERSONNEL OR LONG TERM HEALTH HAZARDS. CAUTION: HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS. 1.6 Training Requirements Operator training for the rail aligner should consist of information found in this manual. In addition the operator must receive instructions, both verbally and through demonstrations for applications in which the tool is going to be used. The new operator must start in an area without bystanders and use the tool until able to fully operate the tool under the conditions for the work area. 2.0 INSTALLATION INSTRUCTIONS 2.1 Unpacking Instructions Upon receiving your rail aligners 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. 2.2 Tool Preparations No special preparations are required, the rail aligners are ready for use after they have been unpacked. 2.3 Testing WARNING: NEVER STICK FOREIGN OBJECTS, FINGERS, OR OTHER EXTRMITIES INTO MOVING MECHANISMS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY OR TOOL DAMAGE. Use the ratchet and socket provided to raise and lower each jack. If the jacks do not move easily check for obstructions or lubricate as required. Use the ratchet and socket provided to move the cross feed assembly back and forth. If the assembly doesn't move easy check for obstructions or lubricate as required. 2.4 Work Area Safety Precautions - Never operate the tool when you are tired, angry, emotionally disturbed, or under the influence 4
of alcohol, drugs, medications, or anything that could affect your vision, alertness, coordination or judgement. - Establish a training program for all operators to ensure safe operation. - Do no operate the tool unless thoroughly trained or under the supervision of an instructor. - Always wear safety goggles, ear, leg, and head protection devices, safety footwear, and snug fitting clothes. - Do not operate the tool near energized transmission lines. - Do not overreach. Maintain proper footing and balance at all times. - Be sure to keep hands and other parts clear and free from all moving parts. - Keep all body parts out from under the rail and between the rail ends when using the rail aligners. - Keep handles clean and dry. - Remove the tool from under the rail before inspection or cleaning. - Only a properly trained person should perform any maintenance, service, and or repairs to a tool. - Never operate a tool that is damaged, improperly adjusted, or not completely and securely assembled. - Do not operate the tool until you have a clear work area and a secure balance. 5
SAFETY REGULATION Enter below any local or other safety regulations required for the operator to follow. Make sure the operator and maintenance personnel have knowledge of these regulations. 6
3.0 Operating Instructions 3.1 Graphics The following decals are placed on the tool to aid in its operation and maintenance. The operator should locate and understand them before using this power tool. (figure 3.1A arrow B) This decal instructs the operator to "align red notches to center before positioning under rail". By having the horizontal positioning plate centered on the aligner, it allows for maximum movement in both directions. 3.2 Operation of Aligners A D D C B Set horizontal slide to the center marks. The center marks are red lines engraved into the edge of the frame. (figure 3.1A, arrow C) Also adjust the end jacks to the most retracted position to make positioning under the rail easier. (figure 3.1A, arrow D) Figure 3.1A The serial number decal is located on the jacking tower. (Figure 3.1A arrow A) This decal has the serial number as well as the model number of the tool. Both aligners in a set have the same serial number. It is important to keep this decal protected and legible. The serial number and model number are required when ordering replacement parts (Fig. 3.1B). Remove the tie plate at the end of the rail to be aligned. Place the rail aligner under the rail with the jacks facing away from the end of the rail, and on top of the tie, approximately in the same location as a tie plate. (figure 3.2A) Use the area that's cribbed out for welding, to position the aligner under the rail. A Figure 3.2A Fig. 3.1B An instructional decal is located on the horizontal positioning plate. The opposite aligner should be positioned in the same manner, with the horizontal adjustment nut on the 7
same side of the rail as the first aligner. WARNING: NEVER GET FINGERS OR OTHER EXTREMITIES UNDER OR BETWEEN THE RAILS BEING ADJUSTED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY. Adjust the horizontal position of the rail end using the nut on the side of the aligner. See Figure 3.2B Figure 3.2C Leave the rail aligners in position while performing the welding process. To remove the rail aligners, retract both jack assemblies completely. Slide the jacks out from under the rail through the area which is cribbed out. 3.3 Storage Preparation Figure 3.2B Adjust the height and twist as required using the nuts on top of the jack assemblies located at each end of the aligner. (See Figure 3.2C) Twist can be accomplished by adjusting one jack higher than the other. When working on ties, which are in poor condition, it may be required to anchor the rail aligner in position using a spike. A square hole is located in the end of the frame for this purpose. (Figure 3.2A arrow A) If the aligners are to be stored for an extended length of time, over 3 months, a light film of grease should be applied to the exposed threads on both jacks and the cross feed screw. A thin layer of grease should also be applied between the horizontal positioning plate and the frame. Applying the grease will prevent parts from becoming rusty during storage. The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes 8
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4.2 Graphic Set Complete (3713-00D) 2158-00D 3463-00D 2382-00D 4040-00D 3713-01D 10
4.3 Care Requirements Maintenance CLEANING AND MAINTENANCE RECOMMENDATIONS Wipe all external surfaces after each use with a clean, lint free cloth to remove surface contaminants from the tool. To remove the jack, turn the adjustment nut located on top of the jack towers clockwise until the jack is unscrewed from the jacking screw. See figure 4.4A Daily: 1. Wipe all tool surfaces, fittings, and coupling free of grease, dirt, and foreign materials. 2. Inspect the tool for excessive wear and damage. Replace any components as necessary. Monthly: 1. Lubricate the threads on both jacks and the cross feed screw, for the horizontal positioning plate, with a good quality lithium grease. Figure 4.4A Once the jack has been removed lubricate the threads on the jacking screw as indicated by the arrow in figure 4.4B. Assemble the jack, replacing the jack with the correct replacement part if required. 2. Lubricate between the horizontal positioning plate and frame with a good quality lithium grease. 3. Perform a detailed inspection of all components for excessive wear and damage. Replace components as required to maintain good working condition. Figure 4.4B 4.5 Jack screw replacement 4.4 Jack replacement and lubrication Follow the instructions for jack lubrication and replacement to remove the jack from the frame. 11
To remove the jack screw complete, item 6 in the parts view portion of this manual, slide the screw assembly to the edge of the housing. See figure 4.5A Figure 4.5C It may be necessary to tap on the side of the nut with a hammer to install the assembly completely. Figure 4.5A It may be necessary to tap on the side of the nut with a hammer to remove the assembly. Replace the jack screw assembly with a new one. Insert the threaded portion into the frame and position the assembly so that the nut is on the outside of the frame and the bronze wear plate is below. See Figure 4.5B and Figure 4.5C Once the screw assembly is installed, lubricate the threads where indicated by the arrow in figure 4.4B with a good quality lithium grease. Finish by installing the jack on the screw assembly. 4.6 Lubrication of cross feed screw for horizontal adjustment plate. To lubricate the screw assembly for the horizontal adjustment plate, turn the screw so the plate moves to one end completely. Lubricate exposed threads with a good quality lithium grease. Turn the screw to move the plate in the opposite direction completely and lubricate the exposed threads again. 4.7 LUBRICATION BETWEEN HORIZONTAL PLATE AND FRAME Figure 4.5B When lubricating between the horizontal positioning plate and the frame, remove the shoulder bolt as shown in figure 4.7A. 12
Remove the set screw from the inside nut. See figure 4.8A Figure 4.7A Turn the cross feed screw until the horizontal positioning plate comes off. Clean the surface between the plates and apply a thin coat of lithium grease to the horizontal positioning plate. See figure 4.7B Figure 4.8A Unscrew the assembly and remove it from the frame. Place the new assembly in position making sure that a bronze washer is on each side of the frame. See figure 4.8B Figure 4.7B After the parts are cleaned and lubricated, thread the, cross feed screw into the horizontal positioning plate and draw it across the frame. Install the shoulder bolt. 4.8 REPLACEMENT OF CROSS FEED SCREW ASSEMBLY When replacing the cross feed screw follow the procedure in 4.7 to remove the horizontal positioning plate. Figure 4.8B Tighten the inside nut until it is snug but loose enough that the whole assembly turns easily by hand. Use a thread locking liquid on the threads of the set screw and install it in the inside nut. Lubricate the threads of the cross screw and the underside of the 13
horizontal positioning plate with lithium grease. Assemble the plate and install the shoulder bolt. 4.9 Trouble Shooting The following chart can be used as a guide to correct any problem you may experience with the tool. PROBLEM CAUSE REMEDY Cross feed screw turns hard. Threads need lubrication or contamination Clean and lubricate threads. Contamination under horizontal positioning plate Check for /remove obstruction and lubricate between plate and frame. Damaged cross feed Inspect mechanisms Jacks operate hard. screw assembly Thread contamination or in need of lubrication. Damaged lower jack component. replace if required. Clean and lubricate threads. Replace lower jack component. Damaged or worn jack screw assembly Replace the jack screw assembly NOTE: After reviewing trouble shooting chart and still unable to determine problem call the service department at PortaCo Inc. (218-236-0223) for advice. 14
4.10 Technical Specifications Consumable Items List Description Part Number Source Jacking screw replacement kit 93-4292-OOK PortaCo Inc. Cross feed screw replacement kit 93-4293-OOK PortaCo Inc. Jack Right lower component 4258-OOW PortaCo Inc. Jack Left lower component 4259-OOW PortaCo Inc. 15
SERVICE AND REPAIR NOTES 16