Goldschmidt GH-10-28-O User manual

OPERATION MANUAL
GRINDER STRAIGHT HANDLE GH-10-28-O

GRINDER STRAIGHT HANDLE GH-10-28-O OPERATION MANUAL
2

GRINDER STRAIGHT HANDLE GH-10-28-O OPERATION MANUAL
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Change overview
Auditing
Date
Comment, including chapter
changed by
01
02
03
05-23-2018
07-02-2018
08-08-2018
Creation
Updated Title, Tables
Added section 3.6 pg. 14
Sven Kummer
Garrett Lee
Garrett Lee

GRINDER STRAIGHT HANDLE GH-10-28-O OPERATION MANUAL
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1About this manual.............................................................................................................................................. 6
2General............................................................................................................................................................... 7
2.1 General information .............................................................................................................................................................7
2.2 Designated use .....................................................................................................................................................................8
2.3 Environment requirements...................................................................................................................................................8
2.3.1 Operating requirements .......................................................................................................... 8
2.3.2 Emissions ................................................................................................................................. 8
3Safety ................................................................................................................................................................. 9
3.1 Basics ....................................................................................................................................................................................9
Table 1: Signal words and symbols .................................................................................................. 10
3.2 Important safety information .............................................................................................................................................10
3.3 Danger zone........................................................................................................................................................................13
3.4 Qualification of the operating and maintenance personnel ...............................................................................................13
3.5 Emergency information / safety devices ............................................................................................................................14
3.6 Safety signs .........................................................................................................................................................................14
Table 2: Safety signs......................................................................................................................... 14
4Design and function...........................................................................................................................................15
4.1 Design .................................................................................................................................................................................15
4.2 Specifications ......................................................................................................................................................................15
Table 3: Specifications...................................................................................................................... 15
4.2.1 Hydraulic fluid........................................................................................................................ 16
Table 4: Hydraulic fluids................................................................................................................... 16
Table 5: Suitable hydraulic fluids ..................................................................................................... 16
4.2.2 Supply, interfaces and connections....................................................................................... 16
4.3 Function ..............................................................................................................................................................................16
4.4 Boundaries and interfaces ..................................................................................................................................................16
5Transport, assembly and dismantling ................................................................................................................17
5.1 Mounting the grinding stone ..............................................................................................................................................17
6Commissioning and operation ...........................................................................................................................19
6.1 General information for start-up ........................................................................................................................................19
6.2 Specification of the hydraulic system .................................................................................................................................19
6.2.1 Function test .......................................................................................................................... 19

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6.3 Operation............................................................................................................................................................................20
6.3.1 Grinding operation................................................................................................................. 20
7Maintenance .....................................................................................................................................................22
7.1 Recommended maintenance plan ......................................................................................................................................22
Table 6: Maintenance plan............................................................................................................... 22
7.2 Change of hydraulic fluid ....................................................................................................................................................22
8Troubleshooting and repairs..............................................................................................................................23
8.1 General information for troubleshooting and repairs ........................................................................................................23
8.2 Troubleshooting and repairs...............................................................................................................................................23
Table 7: Troubleshooting ................................................................................................................. 23
9Shutdown and re-commissioning ......................................................................................................................24
10 Storage ..............................................................................................................................................................24
11 Dismantling and disposal...................................................................................................................................24
Publisher: PortaCo Inc.
1805 2nd Ave N, Moorhead, MN 56560
Phone [phone], Fax [phone]
[email protected], www.portaco.com/
Date of publication: 05-31-2018
Documentation version: 1.0
Document / order number: 6357-OOP

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1About this manual
This document is the original operation manual for the Grinder Straight Handle GH-10-28-O of PortaCo Inc., 1805 2nd Ave N,
Moorhead, MN 56560
The Grinder Straight Handle is used to remove excess weld on welding seams or rust on rails.
The Grinder Straight Handle is considered to be a complete machine according to the machinery directive 2006/42/EG.
The operation manual is intended to enable the operator to safely operate the system as intended and warn them of foreseeable
misuse. The manual is intended for the operating company´s specialized staff. In addition to the operation manual, the spare part
catalogue and the maintenance manual of the manufacturers of the individual components are to be observed.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
The explanation of the hazard pictograms is contained in chapter safety.
This document is to be treated as confidential. No portion of the document may be disseminated to another party or reproduced
without written permission from PortaCo Inc. All rights reserved.

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2General
This chapter contains basic information about the machine and is intended to provide an initial overview.
2.1 General information
Excess weld on welding seams or rust on rails can be removed with the Grinder Straight Handle made by PortaCo Inc.
The Grinder Straight Handle is hydraulically powered. The hydraulic power is provided by a hydraulic unit. The hydraulic unit is
not
[JB1]
part of the scope of delivery. We recommend the hydraulic power units D-23, E-15,
G-18, G-21, G-23 or G-31.
Use grinding wheels with an 8 inch diameter (20.32 cm) and a 1 inch thickness (2.54 cm). The grinding wheels must also be suited
for use at 3300 RPM.
Further design information is shown and described in chapter 4.
Regarding ergonomics, the stresses and strains resulting from the device are typical for a device in the construction industry.
Because the Grinder Straight Handle is considered to be a complete machine according to the machinery directive 2006/42/EG, an
identification plate (type plate) is attached.
Figure 1: Identification plate

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2.2 Designated use
The Grinder Straight Handle is used to remove excess weld on welding seams and rust from rails.
The Grinder Straight Handle is hydraulically powered. The hydraulic power is provided by a hydraulic unit. The hydraulic unit is not
[JB2]
part of the scope of delivery. We recommend the hydraulic power units D-23, E-15,
G-18, G-21, G-23 or G-31.
Use grinding discs with approximately 20.32 cm (8 inch) diameter and 2.54 cm thickness (1 inch). The grinding discs must be suited
for use at 3,300 rpm.
In order to use the Grinder Straight Handle as intended, all persons who work with the machine must adhere to the guidelines in
the operating manual.
2.3 Environment requirements
2.3.1 Operating requirements
The machine is designed for use on construction sites outdoors. It can be used at temperatures between -20 °C to 45 °C
respectively -4° F to 113° F.
The temperature of the hydraulic fluid should be at least 10 °C respectively 50° F.
The statutory minimum distance must be observed around power lines and conductor rails. When working in tunnels, the country-
specific safety regulations must be observed.
2.3.2 Emissions
In technically perfect condition, the A-weighted emission sound level at the work place is lower than 70 dB(A). Hearing protectors is
not required.
Other emissions do not occur during regular device operation.
In the event of damage, hydraulic fluid may leak. Should this be the case, eliminate the leak and remove any fluid which has leaked
with the intended binders.

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3Safety
3.1 Basics
The machine
[JB3]
corresponds to the generally recognized standards of technology and practice. Nevertheless, knowledge of the
residual risks as well as general knowledge of the device are required to ensure safe and accident-free work.
The safety information is understood to be in addition to the existing accident prevention regulations and laws. The information is
intended to warn operating personnel about foreseeable misuse. Existing safety prevention measures and laws must be followed at
all costs!
The instruction for use must be read and understood by all persons who work on the device. Introduction to the device is to be
documented in writing.
CAUTION
Hazards from the operational environment of the device can lead to injuries of persons.
No alterations to the device may be made which lead to a change in function.
All hazards from the environment or from unforeseeable operating conditions of the device cannot
be captured and depicted within this manual.
Modifications to the machine must be made by the distributing company. In this case this instruction for use
and the system documentation of the machine also be adapted.
The chapter on safety regulations serves to:
-explain the depiction of the safety regulations and symbols
-inform users about dangers, residual risks and measures for reducing risks
-specify the minimum requirements of the operating personnel

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Symbol
Meaning
DANGER
DANGER indicates a hazard with a high degree of risk, which when it is not avoided results in death or
serious injury.
WARNING
WARNING indicates a hazard with a medium degree of risk, which when it is not avoided may result in
death or serious injury.
CAUTION
CAUTION indicates a hazard with a low degree of risk, which when it is not avoided may result in minor
or moderate injury.
NOTICE
NOTE, non-compliance may result in environmental or material damage
Attention risk of injury!
General note[JB4] for helpful tips and additions.
Read the safety information before using the machine. Non-compliance may result in injuries and
damage to property.
Table 1: Signal words and symbols
3.2 Important safety information
Read this chapter and observe the safety information before using.
The safety regulations are to be observed by all persons who work on the device. The regulations and instructions for accident
prevention valid at the place of operation are to be observed. Instruction of the operating and maintenance personnel in system
safety is to be documented.
Please pay particular attention to this chapter to avoid accidents!
PortaCo Inc. is not liable for injury to persons or property which result from misuse of the machine.
DANGER
Touching the rotating grinding disc may lead to irreversible injury.
-Never use the machine without the protective housing and the spark barrier.
-Before beginning maintenance work, ensure that the grinding disc is not moving and cannot be
accidentally switched on.
-Persons who are not working with the machine must stay outside the danger zone.

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DANGER
The operator or persons standing around can be injured by sparks. Highly flammable objects may ignite.
-Wear highly flame-resistant clothing while working.
-Remove highly flammable objects from the surrounding area.
DANGER
The bursting of hydraulic components and uncontrolled whipping of the hydraulic hoses is possible.
-Only use the machine within the prescribed limits.
-Before disconnecting the hydraulic couplings, make sure that the pressure is relieved.
-The machine must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
DANGER
Contact with live parts results in the worker sustaining a lethal electric shock.
-In the case of railway tracks with live rails, the busbar must be shorted or switched off by the control
room of the transport company.
-Check that no voltage is present in the rail system continuously!
DANGER
The operator inhales aerosol of hydraulic oil.
-Only use the device within the prescribed limits.
-The device must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
-In the event of leaks switch the device to a safe state.
DANGER
If an employee is hit by a train or car, severe or fatal injuries may result.
-Pay attention to your own safety!
-Wear work clothing with reflectors and a safety vest!
-The foreman must ensure that the line being worked on has been closed.
-Place a track marshall with a horn on the opposite track.
DANGER
Employees may be severely or fatally injured by lightening during a thunderstorm.
-Stop work during thunderstorms!

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WARNING
In case of leakage, there is a risk of slipping on the oil film.
-Remove spilled hydraulic oil with the prescribed absorbent material.
-Put on S3 safety shoes.
WARNING
The rail being worked on and the grinding disc are very hot. There is a danger of serious burns if they
[JB5]are touched.
-Allow the rail to cool down (400° C / 752° F) after welding.
-Wear work gloves.
WARNING
Improper maintenance or maintenance not carried out on time may result in damage to the machine or
injury to persons.
-Maintenance intervals are to be determined by the operator within the scope of their risk assessment.
-Observe the maintenance intervals and maintenance instructions of the manufacturer and existing
directives.
-Components may only be replaced with identical spare parts. It is imperative that the specifications of
the component manufacturer be followed when mounting the component.
WARNING
Spilled hydraulic oil can lead to an increased risk of fire and environmental pollution.
-Remove spilled hydraulic oil with the prescribed absorbent material.
WARNING
In case of poor weather conditions (rain, snow) there is a risk of injury due to poor visibility or slippery
standing surfaces.
-Stop work if standing surfaces are slippery.
-Stop work if visibility is poor.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.

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CAUTION
Noise emissions occur during operation of the hydraulic unit.
-Wear ear protection
-Switch the device off if unusual noises occur
CAUTION
High noise pollution results from the grinding process during operation.
-Wear ear protection.
-Switch the system off should unusual noises occur.
CAUTION
The machine is heavy. There is a potential for serious injury during transport.
-When carrying the device, use the transport ring which is intended for this purpose.
-Wear safety shoes.
NOTE
Inadequate lighting may result in incorrect switching operations or mix-ups.
-Adhere to the break and recovery times prescribed by law.
3.3 Danger zone
There is a risk of cutting and grazing injury during operation of the Grinder Straight Handle. The area around the grinding area and
the grinding disc can become very hot. Always operate the Grinder Straight Handle with the protective cladding. Wear protective
work clothing during use. After use, allow the rail and grinding disc to cool.
3.4 Qualification of the operating and maintenance personnel
The intended circle of users for the machine includes the operators and maintenance personnel.
Anyone who carries out work on the device must be familiar with the functions and dangers of the machine. Introduction to the
machine is to be documented in writing.
All operators as well as employees that regularly enter the area of the machine should at least be instructed on the following
topics:
-Basic device functions (operators)
-instruction for use (operators)
-Conduct in work area (all)
-Location of safety devices (operators)
-Personal protective equipment (all)

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Furthermore, operators should possess the necessary physical and mental capacities which are required to operate and service the
machine.
The operating personnel must wear personal protective equipment according to the job at hand and dangers of the environment.
The operational procedures as well as the professional association guidelines and safety data sheets are to be observed.
3.5 Emergency information / safety devices
The specification of the Working Conditions Act must be observed when working with the machine. Persons who work with the
machine are required to use their personal protective equipment as intended. In this case that means:
-work gloves
-safety glasses or safety mask
-safety shoes S3
-hearing protection
3.6 Safety signs
Safety sign
Meaning
Mandatory sign “Wear hearing protection”: indicates that while working with the machine hearing
protection must be worn by all persons near to the machine.
Mandatory sign “Wear safety glasses”: indicates that while working the machine safety glasses must
be worn by the operator.
Mandatory sign “Wear protective shoes”: indicates that while working the machine protective shoes
must be worn by the operator.
Mandatory sign “Wear protective gloves”: indicates that while working the machine protective gloves
must be worn by the operator.
Mandatory sign “Wear protective clothing”: indicates that while working the machine protective
clothing must be worn by the operator.
Table 2: Safety signs

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4Design and function
4.1 Design
Figure 2: Grinder Straight Handle
No.
Description
1
Transport handle
2
Spark barrier
3
Grinding disc
4
Locking mechanism operating
5
Operating lever
6
Connection hydraulic pump (flow and return flow))
7
Dust caps
4.2 Specifications
Criteria
Value
Width
254 mm / 10 inch
Length
534 mm / 21 inch
Height
305 mm / 12 inch
Weight
7.26 kg / 16 lb
Hydraulic pressure
max. 150 bar / 2,150 psi[JB6]
Hydraulic flow
max. 40 lpm / 10 gpm
Idle speed
3,300 U/min / rpm
Table 3: Specifications

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4.2.1 Hydraulic fluid
The hydraulic fluid should meet the following requirements.
Criteria
Value
Viscosity (at 10° C / 50° F)
95 cSt
Viscosity (at 38° C / 100° F)
27-42 cSt
Viscosity (at 60° C / 140° F)
16,5 cSt
Pour point
-10° C / 14° F
Viscosity index (ASTM-D2220)
min. 140
Flash point (ASTM-D92)
min. 171° C / 340° F
Pump wear test (ASTM-D2882)
max. 60 mg
Demulsibility (ASTM-D1401)
max. 30 minutes
Table 4: Hydraulic fluids
The following hydraulic fluids or equivalent are suitable for use.
Manufacturer
Type
Chevron
Clarity AW ISO 32
Mobil
Univis J32
Gulf
Harmony AW-HVI-150-32
Shell
Tellus T32
Table 5: Suitable hydraulic fluids
4.2.2 Supply, interfaces and connections
The machine is powered by a hydraulic unit. There are quick couplings (3/8" flat face) for connecting the hydraulic unit.
4.3 Function
Excess weld from welding seams or rust can be removed from the rail with the PortaCo Inc. Grinder Straight Handle. Use grinding
discs with an approximately 20.32 cm diameter (8 inch) and 2.54 cm thickness (1 inch). The grinding discs must also be suited for
use at 3,300 RPM.
The grinding disc is started as soon as the handle is pressed and stopped as soon as the handle is released. There is an additional
locking mechanism on the handle to prevent accidental activation of the grinding disc.
The Grinder Straight Handle is hydraulically powered. The hydraulic power is provided by a hydraulic unit. The hydraulic unit is part
of the scope of delivery. We recommend the hydraulic power units D-23, E-15, G-18, G-21, G-23 or G-31.
4.4 Boundaries and interfaces
The Grinder Straight Handle consists of the parts shown in the chapter Design. The battery limit is the connection to the hydraulic
unit. Power and auxiliary devices as well as the grinding disc are not part of the scope of service of PortaCo Inc. Other parts which
are not part of the machine are also excluded.

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5Transport, assembly and dismantling
The machine must be disconnected from the hydraulic unit for transport. For this purpose, the hydraulic unit must be switched off
and the system depressurized. After that the hydraulic hose couplings can be detached. Then the machine can be transported fully
assembled without being taken apart.
5.1 Mounting the grinding stone
Grinding discs with a diameter of 20.32 cm (8 inches) and a thickness of 2.54 cm (1 inch) must be used with the Grinder Straight
Handle. The grinding discs must be suited for use at 3,300 RPM. Check the grinding discs for damage before using. Damaged
grinding discs may not be mounted.
-Remove the three screws on the cover plate of the spark barrier.
Figure 3: Changing the grinding disc –remove cover plate
-Remove the nut and the dished spring from the grinding disc. Hold down the locking pin to prevent the grinding disc from
turning.
Figure 4: Changing the grinding disc - locking pin

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-Remove the old grinding disc and place the new grinding disc on the axle.
-Fasten the grinding disc using the nuts and the dished spring.
Figure 5 & 6: Changing the grinding disc
-Ensure that the dished spring is in full contact with the grinding disc.
-Mount the cover plate of the spark barrier.
After mounting, allow the grinding plate to turn for a minute. In case of uneven rotation or insufficient rotation, the mounting must
be checked. If the error cannot be remedied, then a different grinding disc must be used.

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6Commissioning and operation
6.1 General information for start-up
DANGER
Incorrect operation of the machine or disregard of safety instructions may lead to endangerment of
persons or damage to the machine.
-Familiarize yourself with the complete instruction for use before beginning work on the machine. Pay
particular attention to chapter 3!
NOTE
A thorough, visual inspection of the machine is to be carried out by the operator before start-up.
Start-up of the machine may only be carried out by qualified specialist personnel. The start-up engineer must be acquainted with
the machine. Requirements for start-up are:
-the Grinder Straight Handle have been tested and is ready for operation
-safety devices have been tested and are ready for operation
-all detachable connections have been checked and tightened if necessary
6.2 Specification of the hydraulic system
The hydraulic unit should ensure a flow rate of at least 40 lpm (10 gpm) and pressure of 138 bar (2,002 psi). The pressure must be
limited to 150 bar / 2,176 psi. The measurement must be carried out at the minimum operating temperature of the hydraulic fluid
by 10° C (50° F). Warm the hydraulic fluid if necessary.
The temperature of the hydraulic fluid must be limited to 60° C (140° F).
We recommend the use of the PortaCo Inc. hydraulic units D-23, E-15, G-18, G-21, G-23 or G-31.
6.2.1 Function test
Carry out the following steps to test the function of the Grinder Straight Handle:
1. Make sure that the operating lever can be easily moved.
If the operating lever is difficult to move, check for damage. If the Grinder Straight Handle is damaged, then the functional test
must be interrupted and the Grinder Straight Handle repaired.
2. Make sure that the grinding disc is securely mounted and that all safety devices are tightly fastened.
3. Connect the Grinder Straight Handle to the hydraulic unit.
4. Switch the hydraulic unit on.
5. Hold the Grinder Straight Handle tight with both hands.
6. Release the locking mechanism while pulling the operating lever.
The grinding disc must turn.
7. Let go of the operating lever.

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The grinding disc must stop.
If the grinding disc does not turn or does not stop, then the function test must be interrupted until the Grinder Straight Handle has
been repaired.
6.3 Operation
A visual inspection is to be carried out before beginning work. In the event of damage, no work may be carried out. Install hydraulic
hoses away from walking and transport routes. Ensure that hydraulic hoses are not installed over sharp edges. Make sure that the
environment is well lit; set up additional work lights if necessary.
6.3.1 Grinding operation
1. Clean the quick couplings.
2. Connect the Grinder Straight Handle with the return flow of the hydraulic unit.
3. Connect the Grinder Straight Handle with the supply flow of the hydraulic unit.
Ensure that the flow and return flow of the hydraulic unit are connected to the correct quick coupling. The hydraulic unit must be
switched off
[JB7]
and without pressure for connection.
Figure 7: Connecting the hydraulic hoses
4. Start the hydraulic unit.
5. Hold the Grinder Straight Handle tight with both hands.
6. Release the locking mechanism and push the operating lever on the handle.
7. After mounting the new grinding disc let the mounting disc run at full speed for a minute before beginning with grinding.