MODEL CF-00-F3-O GAS FLANGE WAY CLEANER OPERATION, MAINTENANCE, AND REPAIR MANUAL 1805 2 nd AVENUE NORTH * MOORHEAD, MN, USA 56560-2310 1
PHONE (218) 236-0223 * FAX (218) 233-5281 E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com 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 Work Area Safety Precautions 3.0 Operating Instructions 3.1 Description of Tool 3.2 Controls and Graphics 3.3 Before Operation 3.4 Wheel Installation and Inspection 3.5 Positioning on Rail 3.6 Operating Instructions 3.7 Cold Weather Operation 3.8 Storage Preparation 4.0 Maintenance Instructions 4.1 Assembly View and Parts List 4.2 Graphic Set Complete 4.3 Tool Maintenance Service schedule, Refueling, Engine oil, Belt replacement 4.4 Trouble Shooting 2
1.0 INTRODUCTION 1.1 General Information This manual presents installation, operation, and maintenance information for PortaCo s model CF-00-F3-O Gas Flange Way Cleaner. The flange way cleaner is designed to remove compacted snow, ice, and dirt from the flange area of the rail at crossings. When properly used this tool will help reduce back strain and also reduce operator fatigue. The Flange Way Cleaner is powered by a 5hp Honda gas engine. Utilizing the engines fuel tank and engine controls. The standard engine uses a rope and recoil starting system. (Fig. 1.1A) Other engine manufactures may be used per customers request. The flange way cleaner is operated from a handle bar style handle. The guide roller has bearings for smooth, effortless motion when operating. (Fig. 1.2A) Figure 1.1A 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 Gas Flange Way Cleaner are as follows. Standard unit: Length 52.5 in/133.4 cm Width 22.0 in/55.9 cm Height 37.0 in/94.0 cm Weight (Dry) 70-lbs/31.8 kg Figure 1.2A A spring assisted rear roller system allows the operator to ease into the work area and work to full depth by simply pressing down on the tool. The spring assist returns the tool to the full upright position when downward pressure is released. Figure 1.2B 3
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. Figure 1.2B Wrench flats are provided on the shaft to aid in wheel and flail removal. Figure 1.2C Figure 1.2C 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 and hoses. 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 tool Read and understand any manuals for additional or optional equipment, which maybe shipped with the tool. 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, ECT. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS. 4
1.6 Training Requirements Operator training for the Gas Flange Way Cleaner 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 Flange Way Cleaner 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 Before starting the engine, check that the engine oil level is at the proper level, see the engines operator s manual which is shipped with the tool. Make sure that the fuel tank has enough fuel to start the engine. Check that the flail and wire wheel retaining nut is tight. 2.3 Work Area Safety Precautions WARNING: NEVER STICK FOREIGN OBJECTS, FINGERS, OR OTHER EXTRMIIES INTO MOVING MECHANISMS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY OR TOOL DAMAGE. - Never operate the tool when you are tired, angry, emotionally disturbed, or under the influence 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. - Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals out of the work area. - 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. 5
- Always hold the tool with both hands, using a firm grip when activating and operating. - Be sure to keep hands and other body parts clear and free from all moving parts. - Stop the engine and make sure the wire wheel has stopped turning before removing the tool from the rail. - Never carry the tool with the wheel turning. - Do not operate this tool without all guards in place. - Inspect the wire wheel and flails before operating the tool. Do not use damaged wheels or flails. - Remove all flammable materials from work area before operating the tool. SAFETY REGULATION - Always use wheels that meet the minimum requirements of the tool. - Keep handles clean and dry. - Shut the engine off 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. - Operate tool in well ventilated areas only. - Allow the engine to cool before handling. 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 (fig. 3.2A) (arrow A fig 3.2B) 3.1 Description of Power Tool PortaCo s model CF-00-F3-O Gas Flange Way Cleaner is designed for removing compacted snow, ice, and dirt from rail road crossings. When properly used it also reduces operator fatigue. A 5hp gas Honda engine powers the flange way cleaner. The tool is operated by using the existing controls and starting system featured on the engine. The power is transmitted to the flail and wire wheel by a standard v-belt which can be tightened by sliding the engine forward. Figure 3.2A A B The Flange Way Cleaner set over the rail with a guide wheel in the flange way. The spring assist rear roller allows the operator to lower the tool to different heights for the most effective cleaning depth. 3.2 Controls and Graphics The following decals are placed on the Flange Way Cleaner to aid in its operation and maintenance. The operator should locate and understand them before using this power tool. On the frame is a serial # decal. This decal has the serial number as well as the model number of the unit. Each unit has its own unique serial number. It is important to keep this decal protected and kept legible. The serial number is needed when ordering replacement parts. Figure 3.2B 3.3 Before Operation Check the engine oil level. Oil levels should be kept at the full mark to assure proper lubrication. The Oil filler cap/dip stick is located at the lower right of the engine. (fig 3.2B arrow B) Caution: Do not operate tool if oil level is below the add mark or if the controls do not operate correctly. Failure to follow these instructions may result in tool damage or personal injury. Check the fuel level. Be sure there is enough fuel to start the job. (fig 3.3A arrow A) 7
A B Figure 3.3A Operate all the engine controls to make sure they move freely. See the engine manual for locations and proper range of motion. The engine controls for the Honda engine are shown in figure 3.3A arrow B. Wheel guard Inspect the wheel guard and fasteners for damage. Repair any damage before using the tool. (fig 3.3B) Warning: Do not operate tool without the wheel guard in place. Failure to follow these instructions may lead to severe personal injury. Warning: Do not put fingers, feet, or any other body parts in the area of the Flail and wire wheel illustrated in figure 3.3B. Failure to follow these instructions may lead to severe personal injury. Figure 3.3B 3.4 Wheel Installation and Inspection Wheel inspection Inspect the wire wheel and flails for damage and wear before using the tool. Damaged or badly worn components should be replaced before use. Wheel installation 1) Remove the wheel guard. 2) To remove the retaining nut and backup, hold the spindle with a wrench. Wrench flats are located behind the guard machined into the spindle. (fig 3.4A arrow A) Using a second wrench turn the retaining nut counterclockwise (left) until it is removed. (fig 3.4A arrow B) 8
B A Figure 3.4A 4) Remove the worn or damaged flail and/ or wire wheel. 5) Place the wheel and flails and outer backup on the spindle and tighten the retaining nut. A flail should be on each side of the wire wheel. (Fig 3.4B) Figure 3.6A 3.6 Operating Instructions 1) Position Flange Way Cleaner on the rail. See section 3.5. 2) Start at the end of the crossing. (Fig 3.6B) Figure 3.4B 6) Install the wheel guard in the proper location. 3.5 Positioning on Rail 1) When positioning on the rail, the Flange Way Cleaner frame should set above the rail with the front rollers in side the grove to stabilize the tool. Allow the rear rollers to span the opening between the rail and the guarding.(fig. 3.6A) Figure 3.6B 3) Start the engine. Make sure the flail and wheel assembly is not touching anything. Start the engine following the procedure in the engine operator s manual provided. Set the throttle in the fastest position. The Honda engine controls are located on the front left area of the engine. (fig 3.6 C) 9
4) Continue this motion until the operator reaches the other side of the crossing. Figure 3.6C 4) Firmly grip the handle bars of the flange way cleaner and hold the wheel a short distance from the web of the rail. 5) Press down on the handle bars removing about 1 to 2 per pass. Trying to clean to deep in one pass could result in the tool becoming difficult to control. Work the tool in a back and forth motion until the desired depth is reach. (Fig 3.6D) 5) When job has been completed or to reposition the tool, turn the engine OFF, this will stop the flail and wheel from turning. Make sure the wheel has stopped before removing tool from the rail. 3.7 Cold Weather Operation Follow the procedures of the engine manufacturer as given in the engine operator s manual. 3.8 Storage Preparation Store the Gas Flange Way Cleaner on a smooth level surface in the upright position. Secure the tool so that I cannot tip over or roll. The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes. Figure 3.6D 10
4.0 Maintenance Instruction CAUTION: USE ONLY GENUINE PORTACO INC PARTS OR EQUIVALENT. THE USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE TOOL. WHEN SERVICING THE GAS ENGINE USE ONLY REPLACEMENT PARTS SPECIFIED BY THE ENGINE S MANUFACTURER. WARNING: UNAUTHORIZED MODIFICATIONS TO THE TOOL MAY IMPAIR THE FUNCTION AND/OR SAFETY AND IMPAIR MACHINE LIFE. USE ONLY APPROVED SERVICE PARTS OR ACCESSORIES. 4.1 Assembly View and Parts List CF-00-F3-O ITEM NO. PART NO. DESCRIPTION QTY 1 1044-OOP BOLT ¼ x ¾ 5 2 1061-OOP NUT, 3/8 5 3 1062-OOP NUT ¼ 3 4 1062-OSP NUT NYLOCK ¼ 8 5 1063-OOP LOCK WASHER, 3/8 6 6 1064-OOP WASHER LOCK ¼ 6 7 1078-OOP BOLT, 3/8 x 1.50 5 8 1080-OOP COTTER PIN 1/8 x 1 ¼ 4 9 1084-OOP KEY ¼ x 1 1 10 1093-OOP FLAT WASHER 3/8 11 11 1099-OOP FLAT WASHER ¼ 6 12 1221-OOP BOLT ¼ x ½ 3 13 14 2729-OOP KEY 3/16 x 1.19 1 15 2994-OOP BEARING BALL 6 16 3069-OOP HANDLE GRIPS 2 17 3089-OOD COVER WHEEL GUARD 1 18 3093-OOP NUT 5/8 1 19 3094-OOP FLANGE DRIVE 1 20 3095-OOP FLANGE DRIVE 1 21 3105-OOD ROLLER 2 22 3106-OOD SPACER BEARING 6 11
23 3108-OOD ROLLER FLANGE 2 24 3129-OOD SPACER PLASTIC 4 25 3202-OOD AXLE ROLLER 1 26 3799-OOP ENGINE 5hp HONDA 1 27 4502-OOD FLAIL 2 28 4505-OOD PLATE CLAMPING 1 29 4506-OOD DEBRIS FLAP 1 30 4507-OOP 8 WIRE WHEEL 1 31 4819-OOW MAIN FRAME 1 32 4830-OOD GUARD BELT 1 33 4831-OOD SPINDLE DRIVE 1 34 4832-OOD RETAINER SPRING 1 35 4833-OOD RETAINER SPRING LOWER 1 36 4834-OOW ROLLER FRAME 1 37 4866-OOP PILLOW BLOCK 2 38 4867-OOP BEARING 2 39 4868-OOP PULLEY DRIVE 1 40 4869-OOP PULLEY DRIVE ¾ 1 41 4870-OOP BELT ½ x 30 1 42 4871-OOP SPRING.975 X 11.75 2 43 4872-OOD TUBE INNER 5/8 x 6 2 44 4873-OOP READY ROD ¼ x 11 2 45 2229-OOD HAIR PIN CLIP 2 46 SPRING GUARD 2 47 4862-OOD ROD AXLE 1 48 2038-OOP SCREW 2 49 N/S SPARK DEFLECTOR 1 12
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4.2 Graphic Set Complete (4163-00D) 2906-OOD 2158-OOD 2158-O1D CLEAR COAT 2632-15D 2124-OOD 3463-OOD 2158-O8D 14
4.3 Tool Maintenance Routine Servicing and Inspections Schedule Maintenance Schedule for CF-00-F3-O equipped with the GC160 Honda engine only. See the Honda engine operators manual for additional information. If the unit features an engine Other than the GC160 Honda or includes optional equipment see the manual provided for that engine or equipment. (Preformed at every indicated month or operating interval, whichever comes first.) Regular Service Period ITEM Engine Oil Check level Change Air Cleaner Check Clean Replace Air Cleaner (200 Each Use or 5 Hrs. o o First Month or 5 Hrs. Every 3 month or 25 Hrs. Every 3 month or 50 Hrs. o o (3) o o (2) Every 100 Hrs. Every 150 Hrs. Hrs) Spark plug Check- Adjust o Spark plug Replace (200 Hrs) Spark arrester Clean o (optional part) Valve clearance Check -Adjust o (4) Fuel tank and strainer Clean o (4) Idle speed Adjust o(4) Fuel line Check Every 2 years (4) (replace if necessary) Combustion chamber Clean After every 250 Hours (4) Inspect wire wheel and flails o Replace components as required Inspect wheel guard fasteners, keep o fasteners tight and guard in good condition. Check engine mounting bolts, make sure they are tight Check drive belt, replace worn, stretched, or damaged belts. NOTE: (1): for commercial use, log hours of operation to determine proper maintenance intervals. (2): Service more frequently when used in dusty areas. (3): Change engine oil every 25 hours when used under heavy load or in high ambient temperatures. (4): These items should be serviced by an authorized Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. Failure to follow this maintenance schedule could result in non-warrantable failures. o o 15
Service Replacements Parts Description Part Number Source Spark Plug NGK-BPR5ES HONDA Engine Air Filter See authorized Honda Dealer Refueling The engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher. Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume. In addition, Methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and/or performance problems. It may also damage meal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty. Adding Fuel: - Remove the fuel tank cap. - Add fuel to the bottom of the fuel level limit in the neck to the fuel tank. Do not overfill. Wipe up spilled fuel before starting the engine. - Secure the fuel tank cap. - Move at least 3 meters (10 feet) away from the fueling source and site before starting the engine. See engine manual supplied with tool of additional information. See engine manual of optional engines for fueling procedures. Engine oil SAE 10W-30 is recommended for general use. See engine manual for other acceptable viscosities. Use the drain plug located at the front of the tool for draining the engine oil. (fig. 4.3A) Warning: Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. Stop engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately. Figure 4.3A 16
Drain the oil when the engine is warm. Warm oil drains quickly and completely. Place a suitable container in a position to catch the used oil. Dispose of the used oil in a responsible manor; take it to a recycling facility. - Slide the engine forward to tighten the belt and tighten the engine mounting bolts. - Install the belt guard and tighten the mounting bolts. Belt replacement When replacing or inspecting the drive belt, follow these steps. - Remove the bolts which mount the belt guard. (fig. 4.3B arrow A) A B - Inspect and replace belt if required. A - Loosen the engine mounting bolts (fig 4.3B arrow B) and slide the engine back to loosen the belt. A - Remove the belt and install a new belt over the pulleys. Figure 4.3B 17
4.4 Trouble Shooting The following chart can be used as a guide to correct any problem you may experience with the tool. PROBLEM CAUSE REMEDY Issues concerning the Consult the engine engine. manufactures manual for Engine runs but flail and wire wheel don t turn. Engine is difficult to turn over. Tool will not stay in the elevated position. Loose drive belt. Loose retaining nut. Sheared key. Flails and wire wheel are contacting the ground. Problem with performance of engine. Worn or damaged spring. trouble shooting. Check belt tension, make sure it is tight enough to turn the cleaning wheel. Check that the wheel retaining nut on the spindle is tight. Check the square keys, one at engine shaft, one at wheel shaft. Replace as required. Make sure the tools stays in the elevated position when pulling start cord. See engine manufacture s operators manual. Replace the compression springs. NOTE: After reviewing trouble shooting chart and still unable to determine problem call the service department at PortaCo inc. (218-236-0223) for advice. 18
SERVICE AND REPAIR NOTES 19