STANLEY RD12 HYDRAULIC RAIL DRILL

Declaration of Conformity

This document declares that the STANLEY RD12 Hydraulic Rail Drill (Models RD12101, RD12101L11) has been manufactured in conformity with relevant directives and standards, including EN ISO 3744:2010, EN ISO 13732-1:2008, and the Machinery Directive 2006/42/EC. The representative in the Union is Patrick Vervier, STANLEY Dubuis, Blois, France. The declaration was made on 12/08/2022.

Safety Symbols

Safety symbols and signal words are used to emphasize actions that, if not followed, could result in serious injury or equipment damage.

• ⚠️ Safety Alert Symbol: Alerts to potential personal injury hazards.
• ? DANGER: Imminently hazardous situation; will result in death or serious injury if not avoided.
• ⚠️ WARNING: Potentially hazardous situation; could result in death or serious injury if not avoided.
• ? CAUTION: Potentially hazardous situation; may result in property damage if not avoided.
• ℹ️ NOTICE: Potentially hazardous situation; may result in equipment damage if not avoided.
• ⭐ IMPORTANT: Indicates a situation that will result in damage to equipment if not avoided.

Always observe safety symbols for your protection and the protection of the tool.

Safety Precautions

• Operate in a work area clear of bystanders.
• Ensure operators are thoroughly trained or supervised.
• Always wear appropriate Personal Protection Equipment (PPE) including eye, head, ear, and breathing protection, safety shoes, gloves, and aprons.
• Be familiar with prohibited work areas (e.g., excessive slopes).
• Never inspect, clean, or replace parts while the hydraulic power source is connected.
• Connect hoses before energizing the power source; ensure connections are tight and in good condition.
• Do not operate at oil temperatures above 140°F (60°C).
• Avoid loose clothing or unrestrained long hair.
• All repair, maintenance, and service must be performed by authorized and trained personnel.
• Ensure the hydraulic circuit control valve is OFF when coupling/uncoupling. Wipe couplers clean.
• Never transport or carry the tool with the unit energized.
• Use proper lifting techniques; maintain footing and balance.
• Keep hands and fingers away from rotating parts.
• Do not operate damaged, improperly adjusted, or incompletely assembled tools.
• Do not exceed rated limits or use for unintended applications.
• Keep tool markings (labels, stickers) legible.
• Check fastener tightness regularly.
• Be aware of underground utilities (electrical, gas) to avoid electrocution or explosion hazards.
• Always replace parts with STANLEY recommended parts.
• Warning: Hydraulic fluid under pressure can cause injection injury. Seek medical attention immediately if injured.
• Be aware of potential chemical hazards in dust from certain operations (e.g., lead, silica, arsenic). Work in well-ventilated areas with approved safety equipment.

Tool Stickers & Tags

Various stickers and tags provide critical information and warnings. Key stickers include:

• Circuit Type D Sticker (11207)
• Manual Sticker (28788)
• Railroad Help Desk Sticker (73680)
• Sound Power Sticker (81441)
• RD12 Model Sticker (31096, 31096)
• Eye Protection Sticker (31049)
• Pinch Point Warning Sticker (17572, 88345)
• UKCA Sticker (88724)

Ensure all stickers are legible and replace them if worn or damaged. The safety tag attached at the factory must be read and understood before removal.

DANGER tags on hoses warn about specific hazards related to hydraulic hose use, especially near electrical lines, and emphasize proper handling and maintenance.

IMPORTANT tags remind users to read the operation manual and use only approved parts and procedures.

Hose Types and Recommendations

Hydraulic hose must meet or exceed the system's relief valve setting. Three authorized types are available:

• Certified Non-conductive: For use near electrical conductors.
• Wire-braided (conductive): Must NOT be used near electrical conductors.
• Fabric-braided (not certified non-conductive): Must NOT be used near electrical conductors.

Hose Safety Tags must not be removed. If illegible, replace them.

The Hose Recommendations Chart provides guidance on selecting minimum hose diameters based on oil flow (GPM/LPM) and hose length to maintain optimal tool performance and minimize return line pressure. All hoses must meet or exceed SAE J517 specifications and have a working pressure rating at least equal to the system's relief valve setting.

Figure 1 illustrates typical hydraulic circuit and tool hose connections (Pressure, Return, Flow).

HTMA / EHTMA Requirements

These sections detail hydraulic system requirements for different tool types (HTMA) and classifications (EHTMA).

HTMA Hydraulic System Requirements specify flow range, nominal operating pressure, system relief valve setting, maximum back pressure, fluid viscosity, temperature limits, cooling capacity, filtration, and fluid type for Tool Types I, II, RR, and III.

EHTMA Hydraulic System Requirements provide flow ranges and pressure ratings for classifications B through F.

Note: Always ensure the hydraulic system meets the specific requirements for the RD12 tool.

Operation

Pre-Operation Procedures

Preparation for Initial Use: Inspect the tool for shipping damage and debris. No special assembly is required.

Check Hydraulic Power Source: Verify flow (8-10 gpm/30-38 lpm at 2000 psi/140 bar), relief valve setting (2200-2300 psi/152-159 bar max), and return pressure (not exceeding 250 psi/17 bar).

Connect Hoses: Wipe couplers clean. Connect return hose first, then pressure hose. Observe flow indicators and IN/OUT port lettering for correct direction. Connect free ends of hoses if left in the sun to prevent pressure buildup.

Using Coolant: Fill the coolant can with ordinary tap water (above 32°F/0°C) or a 50/50 water/biodegradable antifreeze mix (below 32°F/0°C). Pressurize the can and connect it to the rail drill.

Operating Procedures

1. Observe all safety precautions.
2. Ensure drill bits have good carbide inserts; rotate or replace as needed. Check bit holder for damage.
3. Install the drill bit into the piston machining assembly and turn clockwise until it stops.

Rail Templates & Hole Guides

The RD12 requires rail templates and hole guides for operation. Install a hole guide assembly onto the rail, then install templates onto the rail drill. Ensure the drill bit/piston assembly is fully retracted before positioning the tool. Set the rail drill over the hole guide, nest templates, and adjust the threaded shaft to clamp the tool firmly to the rail.

To Begin Drilling

Note: Do not operate the drill in the fully advanced position for more than 5-10 seconds at a time.

1. Engage the hydraulic power source control valve to ON.
2. Move the control lever toward the "drill bit" symbol. The drill bit will turn and advance. Ensure water is spraying from the bit.

To Stop Drilling

Move the control lever to the "0" mark.

To Retract the Drill Bit

Move the control lever to the "retract" symbol.

Figure 2: Retract the Drill Bit (Symbol depicted as a downward arrow with zig-zag lines)

Removing the Drill Bit

1. Uncouple the water hose.
2. Turn the hydraulic circuit control valve to OFF and disconnect from the power supply.
3. From the bit end, turn the bit counter clockwise and pull it out.

Storage

• Clean the tool thoroughly.
• Remove the drill bit.
• Advance the piston .250 in./6 mm.
• Drain water from the tool.
• Retract the piston.
• Store in a dry area.

Cold Weather Operation

Preheat hydraulic fluid. Ensure fluid temperature is at or above 50°F (10°C). Use a biodegradable antifreeze solution in the spray can. Drain water from the drill after use.

Templates & Hole Guides

This section contains an extensive list of rail sizes and their corresponding RD12 drill template sets (double-sided/single-sided) and guide assembly part numbers. It is crucial to select the correct template and guide for the specific rail size being worked on to ensure proper fit and operation.

Tool Protection & Care

In addition to safety precautions, follow these guidelines for equipment protection:

• Wipe all couplers clean before connection.
• Ensure the hydraulic circuit control valve is OFF when coupling/uncoupling to prevent damage to quick couplers and overheating.
• Store the tool in a clean, dry space, protected from damage or pilferage.
• Connect the PRESSURE hose to the IN port and the RETURN hose to the OUT port. Do not reverse circuit flow.
• Always replace parts with STANLEY recommended parts. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.
• Do not exceed the rated flow rate specified for the model.
• Keep all critical tool markings (stickers, tags) legible.
• Tool repair should only be performed by experienced personnel.
• Ensure recommended relief valves are installed in the pressure side of the system.
• Do not use the tool for unintended applications.

Troubleshooting

If performance issues arise, consult the following chart. Always verify hydraulic power source flow and pressure.

Specifications

Weights, dimensions, and operating specifications are subject to change without notice. Consult the factory for critical specifications.

Accessories

• Rail Templates & Hole Guides: See "TEMPLATES & HOLE GUIDES" section.
• Ten-Piece Carbide Insert Kit (31969)
• Carbide Insert Package (10 inserts)
• Flat Head Capscrew (Torx 5.40 × 1/4)

Drill Bits

A comprehensive list of available drill bits by size (inches and mm) is provided, along with their part numbers. Examples include 1 in. Drill Bit (29471), 36 mm Drill Bit (31647).

Service Tools

• Piston Seal Installation Kit (31879)
• Piston Wrench (28868)

Parts Illustration

An exploded view diagram (Figure 19) is provided, illustrating the assembly of the RD12 Hydraulic Rail Drill and its components. This diagram helps in identifying parts and understanding their relative positions for maintenance and repair.

Parts List

Detailed parts lists (Pages 20-21) enumerate all components of the RD12 Hydraulic Rail Drill, including item number, part number, quantity, and description. This list is essential for ordering replacement parts and for servicing the tool.