STANLEY RD12 HYDRAULIC RAIL DRILL

User Manual: Safety, Operation and Maintenance

DECLARATION OF CONFORMITY

This section contains declarations of conformity in multiple languages (English, German, French, Spanish, Italian) stating that the equipment manufactured by Stanley meets specified directives and standards.

Representative in the Union: Patrick Vervier, Stanley Dubuis, Blois Cedex, France.

Done at: Stanley Hydraulic Tools, Milwaukee, Oregon USA

Date: 1-4-11

Signed by: Andy Weisbeck, Director of Product Development

SAFETY SYMBOLS

The manual emphasizes the importance of safety symbols and signal words to prevent injury or equipment damage. It defines symbols for Danger, Warning, Caution, and Notice.

Safety Alert Symbol: Indicates potential personal injury hazards.
DANGER: Imminent hazard, 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.
NOTICE: Indicates a situation that will result in damage to the equipment if not avoided.

Local safety regulations should be observed and kept accessible.

SAFETY PRECAUTIONS

Operators and maintenance personnel must comply with all safety precautions outlined in the manual and on tool stickers. Key precautions include:

Work in areas without bystanders due to flying debris.
Only operate if thoroughly trained or supervised.
Always wear appropriate Personal Protective Equipment (PPE): goggles, safety shoes, head, eye, breathing, and ear protection. Use gloves and aprons as needed.
Be aware of prohibited work areas like excessive slopes.
Never inspect, clean, or replace parts while the hydraulic power source is connected.
Connect hoses before energizing the power source and ensure connections are tight.
Do not operate at oil temperatures above 140°F (60°C).
Avoid loose clothing or unrestrained long hair.
All repairs and maintenance must be performed by authorized and trained personnel.
Ensure the hydraulic circuit control valve is OFF when coupling/uncoupling hoses. Clean couplers before connecting.
Never transport or carry the tool with the unit energized.
Use proper lifting techniques and maintain balance.
Keep hands and fingers away from rotating parts.
Do not operate a damaged or improperly adjusted tool.
Do not exceed rated limits or use for unintended applications.
Keep critical tool markings legible.
Check fastener tightness regularly.
Be aware of underground utilities before operating.
Always replace parts with Stanley recommended parts.
Warning: Hydraulic fluid under pressure can cause skin injection injury. Seek immediate medical attention if injured.

Important Note: Information on stickers must remain legible. Replace worn or damaged decals.

HOSE TYPES AND SAFETY TAGS

Hydraulic hose must have a working pressure rating equal to or higher than the hydraulic system's relief valve setting. Authorized hose types include:

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: DANGER tags are attached to all hoses from Stanley Hydraulic Tools and must not be removed. Replace illegible tags immediately.

TOOL TO HYDRAULIC CIRCUIT HOSE RECOMMENDATIONS

This section provides a chart detailing recommended minimum hose diameters for various hose lengths based on flow rate (GPM/LPM) to minimize return line pressure. It also specifies minimum working pressure and requirements for certified non-conductive and conductive hoses.

Figure 1: Illustrates typical hose connections for pressure and return lines.

HTMA / EHTMA REQUIREMENTS

This section details the hydraulic system requirements according to HTMA (Hydraulic Tool Manufacturers Association) and EHTMA (European Hydraulic Tool Manufacturers Association) standards. It includes specifications for flow range, nominal operating pressure, system relief valve settings, maximum back pressure, fluid viscosity, temperature limits, cooling capacity, and filtration for different tool types.

PREOPERATION PROCEDURES

PREPARATION FOR INITIAL USE

The tool requires no special unpacking or assembly. Inspect for shipping damage and packing debris before connecting to a hydraulic source.

CHECK HYDRAULIC POWER SOURCE

Verify the hydraulic power source provides 8-10 GPM / 30-38 LPM at 2000 PSI / 140 BAR using a calibrated flowmeter and pressure gauge.
Ensure the power source has a relief valve set between 2200-2300 PSI / 152-159 BAR.
Confirm return pressure does not exceed 250 PSI / 17 BAR.

CONNECT HOSES

Wipe all hose couplers clean with a lint-free cloth before connecting.
Connect hoses from the power source to the tool. Connect the return hose first and disconnect it last to minimize trapped pressure.
Observe flow indicators on couplers to ensure correct oil flow direction (female coupler is inlet).
Check IN and OUT port lettering on the valve block assembly for correct hydraulic flow direction.

Note: Connect free ends of hoses together when possible to prevent pressure buildup from heat.

USING COOLANT

Fill the coolant can with tap water if operating above 32°F (0°C).
For operation below 32°F (0°C), use a 50% tap water and 50% biodegradable antifreeze mixture.
Pressurize the coolant can using the carrying handle/pump.
Connect the coolant can assembly to the rail drill using the quick-disconnect coupler.

OPERATING PROCEDURES

Observe all safety precautions.
Ensure the drill bit has sharp carbide inserts. Rotate or replace inserts if worn or chipped.
Install the drill bit into the piston machining assembly and turn clockwise until it stops.

RAIL TEMPLATES & HOLE GUIDES

The RD12 must be used with rail templates and hole guides. Install a hole guide assembly onto the rail and position it. Install templates onto the rail drill, ensuring the rail size faces the rail. Ensure the drill bit/piston assembly is fully retracted before placing the RD12 on the rail. Position the rail drill over the hole guide, nestle the templates, and adjust the threaded shaft until the drill is firmly clamped to the rail.

TO BEGIN DRILLING

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

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

TO STOP DRILLING

Move the control lever to the "0" mark.

TO RETRACT THE DRILL BIT

Move the control lever to the "retract" symbol.

REMOVING THE DRILL BIT

Uncouple the water hose.
Turn the hydraulic circuit control valve OFF and disconnect from the power supply.
Turn the bit counter-clockwise and pull it out from the bit end.

STORAGE

Clean the tool thoroughly.
Remove the drill bit.
Advance the piston 0.250 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) before use. Use a biodegradable antifreeze solution in the spray can. Drain water from the drill after use.

TEMPLATES & HOLE GUIDES

This extensive table lists various rail sizes and the corresponding RD12 drill template sets, guide assembly part numbers, and country of origin. It covers a wide range of international rail standards.

TOOL PROTECTION & CARE

Notice: In addition to safety precautions, observe the following for equipment protection:

Wipe all couplers clean before connection.
Ensure the hydraulic circuit control valve is OFF when coupling/uncoupling.
Store the tool in a clean, dry, and secure space.
Connect the PRESSURE hose (male quick disconnect) to the IN port and the RETURN hose (female quick disconnect) to the opposite port. Do not reverse circuit flow.
Use only Stanley recommended replacement parts. Supply hoses must have a minimum working pressure rating of 2500 PSI / 172 BAR.
Do not exceed the rated flow to prevent rapid failure of internal seals.
Keep critical tool markings legible.
Tool repair should be performed by experienced personnel only.
Ensure recommended relief valves are installed in the pressure side of the system.
Do not use the tool for unintended applications.

TROUBLESHOOTING

This chart provides solutions for common problems:

PROBLEM	CAUSE	SOLUTION
Drill does not run.	Hydraulic power source not functioning.	Check power source for proper flow (8-10 GPM/30-38 LPM) and pressure (2000 PSI/140 BAR).
	Couplers or hoses blocked.	Locate and remove restriction.
	Hydraulic motor failure.	Inspect and repair.
	Hydraulic lines not connected.	Connect lines.
Drill bit dulls quickly.	Incorrect oil flow.	Verify 8-10 GPM/30-38 LPM at 2000 PSI/140 BAR at the rail drill.
	Using insufficient amount of coolant.	Rotate or replace insert. Increase coolant flow. Ensure pressure tank is pumped up. Check for plugged water port or clogged inlet filter. Flush and clean filter.
Drill moves on rail during drilling operation.	Not clamped properly.	Refer to clamping instructions.
	Wrong templates.	Use correct templates and verify fit.
	Template knob(s) not tight.	Tighten knobs securely.
Drill vibrates during drilling.	Inserts dull or damaged.	Rotate or replace inserts.
	Template knob(s) loose.	Tighten knobs securely.
	Not clamped properly.	Refer to clamping instructions.
Inserts chipped.	Some chipping is normal.	Rotate or replace if poor hole finish is noted.
	Incorrect template.	Use correct template and verify fit.
	Using insufficient amount of coolant.	Rotate or replace insert. Increase coolant flow. Ensure pressure tank is pumped up. Check for plugged water port or clogged inlet filter. Flush and clean filter.
	Not clamped properly.	Refer to clamping instructions.
	Template knob(s) loose.	Tighten knobs securely.
	Handling damage.	Ensure drill bit is retracted when installing. Avoid insert contact with hard objects.
Insert screw difficult to remove.	Not assembled with lubricant.	Install screw with anti-seize lubricant on threads.

SPECIFICATIONS

Bit Capacity: up to 1-9/16 in. diameter / 36 mm diameter
Bit Type: Carbide Inserts (2) on Insert Holder
Pressure: 2000 psi / 140 bar
Flow Range: 8-10 GPM / 30-38 LPM
Porting: 8 SAE O-ring
Connect Size and Type: 3/8 in. Flush Face Couplers
Weight (with couplers, w/o templates & bit): 59 lb / 26.75 kg
Length (handle extended): 33 inches / 84 cm
Width: 8.5 inches / 21.6 cm
Height (w/o templates, maximum): 21 inches / 53.35 cm
EHTMA Category: "D" (30 lpm @ 138 bar)
Sound Power Level: 102 dBA
Vibration Level: N/A

Note: Weights, dimensions, and operating specifications are subject to change. Consult the factory for critical application specifications.

ACCESSORIES

Rail Templates & Hole Guides: See "TEMPLATES & HOLE GUIDES" section.
Ten-Piece Carbide Insert Kit (P/N 31969)
Carbide Insert Package (10 inserts per package)
Flat Head Capscrew (Torx 5.40 x 1/4)
Drill Bits: Various sizes from 1 in. to 1-9/16 in. and 22 mm to 36 mm are listed with part numbers.
Service Tools: Piston Seal Installation Kit (P/N 31879), Piston Wrench (P/N 28868).

RD12 PARTS ILLUSTRATION & LIST

Detailed illustrations and a comprehensive parts list are provided for the RD12 Hydraulic Rail Drill, including part numbers, quantities, and descriptions for each component. This includes items like capscrews, handles, decals, valves, seals, pistons, motors, and various fittings.

Contact Information

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon 97267-5698 USA

(503) 659-5660 / Fax (503) 652-1780

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