Trak-Star RailBoss Manuale utente

OPERATOR’S MANUAL

PORTABLE 4-STROKE RAIL DRILL --- MANUAL FEED

70 LB. A.S.C.E. TO 155 LB. P.S.

Serial #: _______________________ Date: ______________

TRAK-STAR

Portable Gas Rail Drill

Model RB28

Welcome to Trak-Star

Congratulations on your purchase of the Trak-Star Portable Gas Rail Drill. Your model is designed to produce

superior holes quickly and efﬁ ciently. Through constant innovation and development, Trak-Star is committed

to provide you with hole-producing tools and products that lead the industrial world.

Before attempting to operate your new Rail Drill, please read all instructions ﬁ rst. These include the Operators

Manual and warning Label on unit itself. With proper use, care, and maintenance, your model will provide you

with years of effective hole drilling performance. Once again, thank you for selecting our product and welcome

to Trak-Star.

1. Open shipping carton and remove the literature and

hardware packages.

2. Read and Follow All Instructions before attempting

to operate your new Rail Drill.

3. Complete and mail the Product Registration Card

NOW

. It is important that Hougen Manufacturing, Inc.,

have a record of product ownership.

4. Open all hardware packages and check contents.

10565 Hex wrench 1/8”

13013 Hex wrench 5/32”

10570 (2) Knobs

03522 Shaft

03635 Pilot

27019 Feed Handle Assy

01592 Coolant Bottle

27091 Oil

5. Lift Rail Drill out of shipping carton using center

carrying handle and rear support handle.

6. Attach the large feed handle onto the drill using the

enclosed 5/32” hex wrench.

7. Attach Clamp Handle using the enclosed 1/8”

hex wrench.

8. ADD 8 OZ OF OIL TO THE MOTOR.

9. Your new Rail Drill was factory adjusted prior to

shipping. Check to make sure that all screws, motor

hold-down screws, drill housing and shoe mounting

screws are snug and have not vibrated loose in

transit.

10. Hookup Coolant Bottle / Hose Assembly (01592).

Connect the quick-disconnect hose ﬁ tting to the Rail

Drill.

11. Reread Safety Warnings listed in this Operator’s

Manual and on the drill unit to avoid injury. Follow

operating procedures.

Your new Rail Drill is equipped with a twist arbor bore to

accept TRAK-STAR Twister Bits. Order cutters separately.

Install pilot thru cutter before attaching cutter to arbor.

Unpacking Your New Rail Drill

Index

Welcome to TRAK-STAR 2

Unpacking Your New Rail Drill 2

Important Safety Instructions 3

Model features 4

Installing / Replacing Cutter 5

Drill and Pressurized Coolant System 6

Clamping Procedures 7

Positioning of Hole Location Template 8

Important Notice 9

Operating Instructions 9

Section Page

Maintenance - - Engine/Drill 10

Clamp Exploded view & Parts 11

RB28 Exploded View 12

Parts List 13

Engine Parts Diagram and parts 14

Rail and Shoe Data 15

Commercial / Industrial Warranty 16

- Factory Authorized Service Centers

Section Page

OIL MUST BE ADDED TO THE

ENGINE BEFORE STARTING.

FAILURE TO DO SO WILL RESULT IN

ENGINE DAMAGE WHICH IS NOT

COVERED UNDER WARRANTY.

WARNING!

• Quill and cutter should never be used as a

handhold.

• Keep hands and clothing away from all

moving parts.

• Do not use Twister Bits where ejected slug

might cause injury (slug ejected at end of cut).

• Be sure that all safety devices are properly

adjusted and in use. Also, adhere to all

operating instructions.

• Do not attach Rail Drill to live 3rd rail track.

18.

Non-Conforming Cutting Tools

The TRAK-STAR Model RB28 is designed

to use TRAK-STAR Twister Bits only. The use

of drilling tools having different shank styles is

not recommended as they may not tighten

securely in the TRAK-STAR arbor with risk of

accident or injury.

19.

Save These Instructions

20.

Read all instructions concerning the motor

in your HONDA Engine Operator’s manual.

Read All Instructions

Keep Work area clean

Cluttered area and benches invite injuries. Keep dirt

and chips from under Twister Bit area and drill shoe.

Consider Work Area Environment

Keep work area well lit.

Keep Children Away

Do not let visitors contact tool.

Store Idle Tools

When not in use, tools should be stored in a dry, and

a high or locked-up place -- out of reach of children.

Do Not Force Tool

It will do the job better and faster at the rate for which

it was intended.

Use Right Tool

Do not force small tool or attachment to do the job

of a heavy duty tool.

Do not use tool for purpose not intended -- for example

do not use a circular saw for cutting tree limbs or logs.

Dress Properly

Do not wear loose clothing or jewelry. They might

entangle with spinning chips or get caught in moving

parts. Rubber gloves and nonskid footwear are

recommended when working outdoors. Wear sturdy

leather gloves when working indoors.

14.

Remove Adjusting Keys and Wrenches

Form a habit of checking to see that keys and

wrenches are removed from tool before Starting drill

unit.

Stay Alert

Watch what you are doing. Use common sense.

Do Not operate tool when you are tired.

Always Wear Safety Glasses or Goggles.

10.

Do Not Overreach

Keep proper footing and balance at all time.

11.

Secure Work

Clamp work securely using appropriate shoe size and

shape.

Tighten Clamp by using two hands with handle

placed in central position and tighten securely.

12.

Maintain Tools With Care

Keep tools sharp and clean for better and safer

performance.

Do not use dull or broken Twister cutters. Follow

instructions for lubricating and changing accessories.

Inspect gas line periodically and, if damaged, have

repaired by authorized service facility.

Keep handles dry, clean, and free from oil and

grease.

13.

Disconnect Tools

Disconnect spark plug wire from spark plug when not

in use, before servicing, and when changing

Twister Bits or accessories.

16.

Check Damaged Parts

Before further use of drill, a part that is dam-

aged should be carefully checked to determine

that it will operate properly and perform its

intended function.

Check for alignment of moving parts, binding of

moving parts, breakage of parts, mounting, and

any other conditions that may affect its opera-

tion.

A part that is damaged should be properly

repaired or replaced by an authorized service

center unless otherwise indicated elsewhere in

this instruction manual.

(See last page for authorized Service Centers)

17.

Additional Safety Precautions

Important Safety Instructions

PLEASE READ THE HONDA ENGINE OPERATOR’S

MANUAL. INSTRUCTIONS ON THE OPERATION,

SAFETY, AND MAINTENANCE PROCEDURES ARE

CONTAINED IN A SEPARATE MANUAL.

IMPORTANT:

Before starting the machine, it is impera-

tive that the operator know and understand instructions

for safe operation.

Add engine oil to motor and use regular

unleaded gasoline only.

Ignition switch located on engine---stops motor, spindle, and cutter

rotation. See diagram at left.

“ON” / “OFF” Switch

The World’s Most Reliable

4-Stroke Rail Drill

Honda Engine Instructions

GAS MUST BE SHUT OFF BEFORE

TRANSPORTING DRILL.

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TRAK-STAR Twister Disposable Rail Cutters

Made from Premium H.S.S.

• Gold Coating for All Around Drilling

• Black Coating for Improved Performance

in New Harder Rail.

TRAK-STAR Rail Drills are designed to use Twister

Bits, and to achieve maximum efﬁ ciency from your

unit, we recommend that no substitutes be used.

** Twister Bits are economical and disposable

--- there is no need to resharpen --- however it is

possible. Tools can be sharpened 2 to 3 times.

Send cutters to Trak-Star to the attention of the

Resharpening Department.

** Twister Rail Bits have been shown to drill holes

in rails up to 4X faster than twist drills or spade

drills, and they produce clean, round, burr-free

holes without the need to chamfer.

** Multiple cutting edge design, along with proper

coolant ﬂ ow, produces a cool cut raising the rail

temperature in the hole no more than 35°F above

ambient temperature. This prevents work harden-

ing, stress cracking, service failures, and repeated

repairs.

Cutter

Size,

inches

Decimal

Equivalent

Gold -

TiN Coated

Part Number

Black -

TiAlN Coated

Part Number

7/8 .08750 15228 15328

15/16 .09375 15230 15330

1 1.0000 15232 15332

1-1/16 1.0625 15234 15334

1-1/8 1.1250 15236 15336

1-3/16 1.1875 15238 15338

1-1/4 1.2500 15240 15340

1-5/16 1.3125 15242 15342

1-3/8 1.3750 15244 15344

1-7/16 1.4375 15246 15346

1-1/2 1.5000 15248 15348

1-11/16 1.6875 15254 15354

Pilot for Twister Bits 03635

Installing / Replacing Twister

Bit

1. Be sure engine is stopped and turned off. Turn off

coolant at shut-off. The spring seat system located

within arbor was not designed to be 100% leak proof.

2. Position arbor so the cutter area is easily accessible.

Do not depress pilot pin during procedure to release

seal. Doing so will result in releasing pressurized

contents of arbor cavity and coolant loss. Some loss,

however, is normal due to cavity between cutter shank

and spring seat.

3. Insert pilot in shank end of Twister Bit.

4. Insert the Twister Bit until long ﬂ at on cutter shank is

aligned with roll pin inside arbor. Twist cutter clockwise

(do not depress pilot in case of cutter replacement for

reason noted in #2). The cutter is automatically held

into place.

Insert Cutter

into Arbor

Twist

OFF ON

Twist

Drill & Pressurized Coolant System

1. Install correct shoes for rail type being drilled.

2. Install correct size Twister Bit with pilot and secure

to drill arbor. See Cutter Installation procedure.

3. Fill coolant bottle with TRAK-STAR cutting ﬂ uid ( a water

3. Fill coolant bottle with TRAK-STAR cutting ﬂ uid ( a water 3. Fill coolant bottle with TRAK-STAR cutting ﬂ uid ( a water

soluble and biodegradable product) Conventional ﬁ ll

access is achieved by removing pump handle.

Caution: Contents under pressure. Partially open

to slowly release pressure before removing.

4. Attach coolant bottle quick connect hose ﬁ tting to drill

on the backside of drill under motor.

5. Pressurize coolant bottle (approximately 20 pumps)

6. Open coolant shut off valve.

7. Depress pilot pin approximately 1/4” and watch for

coolant ﬂ ow from the end of the cutter. NOTE - Coolant

is under pressure -- stay out of path of spray. If coolant

does not ﬂ ow, rotate valve further to open or unclog

coolant system.

RotaMagic™ Concentrate Cutting Fluid

A good ﬂ ow of cutting ﬂ uid to the tool is important. It cools

and lubricates the cutting edge, helps evacuate the chips,

keeps the slug from expanding, and helps eject the slug.

Various mineral and sulphur base oils are quite popular,

however, water base solutions have better cooling qualities.

Listed is our own recommended Concentrated Cutting Fluid

for Twister Bits and similar cutting tools. It is a water soluble,

biodegradable product. This cutting ﬂ uid contains no ingredi-

ents that are on the U.S. Government Hazardous Materials

List. It is a super concentrated form that will require a 10:1

mixture of water.

RotaMagic™ Concentrate Cutting Fluid

Coolant Quick Connect Hose and Nipple

rebmuNredrO noitpircseDeziS

4-24711 **snollaG4

34711 +snollaG5

NISEMOC.ETARTNECNOCFOTNUOMADERUSAEM**

FOSNOLLAG44SEKAMDNASRENIATNOCNOLLAG1-4

DIULFGNITTUCELBASU

EKAMLLIW,LLUF,RENIATNOCNOLLAG-5NISEMOC+

DIULFGNITTUCELBASUFOSNOLLAG55

01569 On/Off Valve

05621 Quick Connect Fitting

01592 Coolant Bottle and Hose Assy

Coolant System Replacement Parts

Do Not Use Straight Water or Window

Washer Fluid. Damage to Drill Will Occur!

Only Use Trak-Star RotaMagic Coolant.

FIGURE A.

FIGURE B.

FIGURE C.

FIGURE D.

CLAMPING PROCEDURES

STEP #1:

WITH CLAMP IN OPEN POSITION,

REST UNIT ON RAIL BASE. BOTTOM

OF SHOES SHOULD CONTACT

TAPER ON RAIL BASE.

(SEE FIG. A)

** PERFORMANCE TIP: CLOSE

CLAMP UNTIL CLAMP PAD CON-

TACTS WEB OF RAIL PRIOR TO

STEP #2.

STEP #2:

RAISE REAR OF RAIL DRILL TO

LOCATE SHOES IN PROPER

POSITION.

(SEE FIGURE B)

STEP #3:

WHILE MAINTAINING CONTACT

BETWEEN SHOES AND RAIL,

TIGHTEN CLAMP.

(SEE FIG. C)

STEP #4:

WHEN UNIT IS FIRMLY CLAMPED,

CHECK FOR PROPER SHOE AND

PAD CONTACT ON BOTH SIDES

(SEE FIG. D)

WARNING: IMPROPER CLAMPING WILL CAUSE PREMATURE

CUTTER FAILURE

* When properly clamped to the rail there will be

a small gap between the top of the shoe and the rail.

Positioning of Optional Hole Location Template

Template is positioned on head of rail with tapered tip ﬂ ush

with end of rail and side locking screws fastened to rail

head. Notches in template give precise location of hole

centerlines to be drilled.

The rail clamp assembly has a locating arm which rests

in the template notches. The locating arm is adjustable to

accommodate the full range of rail sizes.

To use the locating arm, raise the drill unit over the rail with

the template attached and gently rest drill down until shoes

make contact with the rail. Flip the arm to make contact

with the template. Slowly slide drill across the template

until the arm falls into notch.

The arm must contact the sides of the matching notch.

Following the Clamping Instructions, clamp unit onto rail.

When the hole is completed, raise the arm by ﬂ ipping the

arm back toward the body of the drill. Before drilling next

hole remove chips around cutter. Then move the drill side-

ways, ensuring the arm is clear of the notch, and ﬂ ip arm

down. Slide the drill sideways until arm falls in the next

notch, and repeat the procedure as necessary.

Note: The locating arm must be ﬂ ipped back, resting

on the body of the drill before putting the drill unit on

the rail. Failure to do so can result in damage to the

hole locating arm system.

Hole location templates are offered as optional equipment.

Four of these templates are provided with established hole

spacings. The 40570 template is produced to customer

speciﬁ ed hole spacing. See chart for the template to match

your application.

Template

Part No.Hole Spacing

40570 Customer Specified

40701 3-1/2" X 6" X 6"

40702 2-11/16" X 5-1/2" X 5-1/2"

40703 2-1/2" X 5" x 5"

40704 2-1/2" X 6-1/2" X 6-1/2"

40706 2- 23/32" x 5-1/2" x 5-1/2"

Locating Arm

Location Template

28-1/2"

"A"

"B"

"C"

Specify “A”, “B”, “C” when ordering custom template

Custom Template Spacing

Operating Instructions

NEVER RUN ENGINE INDOORS OR IN ENCLOSED,

POORLY VENTILATED AREAS. ENGINE EXHAUST

CONTAINS CARBON MONOXIDE, AN ODORLESS

AND DEADLY GAS.

KEEP HANDS, FEET, HAIR, AND LOOSE CLOTHING

AWAY FROM ANY MOVING PARTS ON ENGINE AND

EQUIPMENT.

WARNING - TEMPERATURE OF MUFFLER AND NEAR

BY AREAS MAY EXCEED 150°F (65°C). AVOID THESE

AREAS.

1. Make sure workpiece, cutter and shoe surfaces are

free of chips, etc.

2. Place locator template on rail head.

3. Align drill on locator with the Hole Location Template.

4. Clamp drill to rail and insure proper 10 point contact.

5. Turn on coolant (pump to pressurize system).

6. Move choke lever to “FULL CHOKE”. If restarting a

warm engine after a short shutdown, move choke lever

to “NO CHOKE”.

7. Turn motor on/off switch to “ON” position.

8. Move throttle to idle position.

9. Grasp starter handle and pull rope out, slowly, until it

meets resistance. Let rope rewind slowly. Then pull

rope with a rapid full arm stroke. Let rope return to

starter slowly.

10. Repeat step #9 until engine ﬁ res.

11. Move throttle to run position.

12. Manually feed cutter very gently to start cutting.

13. Once all teeth are cutting aggressively, feed tool

through workpiece at an even rate. Do not over-

load unit to induce an arbor stalling situation. Certain

rail compositions workharden easily. Do not pause

during cut nor release feed pressure if changing hand

grip on feed handle. This will result in premature

cutter wear and drilling problems while in the cut.

14. Move feed handle to retract arbor and cutter. Slug

should eject from spring loaded pilot pin pressure.

15. Move throttle to idle position.

16. At the end of the cut, move ignition switch on engine

to “STOP” or “OFF” position.

17. Loosen clamp and remove drill to clean chips from

around cutter. Drill cycle is complete and you are

ready to go on to the next hole. Shutting off coolant

after use is suggested, if use is intermittent.

If Slug Has Not Fallen Free

, disconnect spark plug

wire from spark plug and shut off coolant supply. Use a

screwdriver to carefully ﬂ ip slug by inserting it between

slug ﬂ ange and cutter gullet. It generally will remove

easily while discharging a squirt of coolant. Avoid

prying with force, damage to the cutter and cutting

edge may result.

WHEN EQUIPMENT WILL NOT BE USED FOR

EXTENDED PERIODS, DISCONNECT SPARK PLUG

WIRE FROM SPARK PLUG AND KEEP IT AWAY

FROM SPARK PLUG.

NEVER STORE ENGINE WITH FUEL IN TANK

INDOORS OR IN ENCLOSED, POORLY

VENTILATED AREAS, WHERE FUEL FUMES MAY

REACH AN OPEN FLAME, SPARK, OR PILOT

LIGHT AS ON A FURNACE, WATER HEATER,

CLOTHES DRYER OR OTHER GAS APPLIANCE.

Important Notice

1. Make sure cutter is properly installed.

2. The #1 cause of premature cutter failure is improper clamping. (see page 7 for

clamping procedures.)

3. The # 2 cause of premature cutter failure is improper feed, usually feeding too slow.

4. Always use caution when contacting the rail with the cutting tool. Allow the cutter to

completely enter the rail before applying full feed pressure.

GAS MUST BE SHUT OFF BEFORE TRANSPORTING DRILL.

Maintenance -- Engine/Drill

AIR CLEANER

IMPORTANT: NEVER RUN ENGINE WITHOUT

COMPLETE AIR CLEANER INSTALLED ON ENGINE

1. To remove and install ﬁ lter:

Press tabs on the top of the air cleaner, and remove

the cover. Remove and inspect the foam ﬁ lter for

discoloration or dirt accumulation. If either is present,

service per below instructions. Clean inside of cover

and body thoroughly.

2. To service ﬁ lter

Foam Filter

: Clean and re-oil every three months or

every 25 operating hours. Clean and re-oil daily if use

in extremely dusty conditions. Wash in water and

detergent solution and squeeze (don’t twist) until all

dirt is removed. Rinse thoroughly in clear water. Wrap

in a clean cloth and squeeze (don’t twist) until

completely dry. Saturate with motor oil and squeeze to

distribute oil and remove excess oil.

3. Reassemble air cleaner.

SPARK PLUG

1. Check spark plug yearly or every 100 operating hours.

2. Clean around spark plug. Remove and inspect spark

plug.

3. Replace spark plug if electrodes are pitted, burned, or

porcelain is cracked. Use NGK CR5HSB or

equivalent.

4. Check electrode gap with a wire feeler gauge and set

gap at .026” if necessary.

5. Install spark plug and tighten securely.

MUFFLER AND CYLINDER EXHAUST PORTS

The mufﬂ er and cylinder exhaust ports require cleaning

after every 100 hours of operation. For this maintenance

procedure, we recommend that you take your engine to a

Authorized TRAK-STAR Service Center or your

Honda Registered Service Dealer.

COOLING SYSTEM

Important: Frequently remove debris from cooling ﬁ ns, air

intake screen, and levers and linkage. This will help ensure

adequate cooling and correct engine speed.

The RailBoss requires minimal maintenance to keep drill in

top working condition.

• Every four to six months or as needed apply a light

coat of grease to the quill and arbor assembly and the

large screw that tightens the handle.

• Keep drill clean.

• Maintain motor as outlined in your Honda motor

operator’s manual.

Maintenance -- Drill

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