Racine Railroad Products 910103 Operating instructions
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 2of 21
Hydraulic Rail Profile Grinder
910103
Record of Changes
Rev No.
Date
Description of Changes
Rev 2
11.2018
Manual Update
2.1
12.2020
Update Service Parts List
2.2
12.2022
Update Service Parts List
2.3
1.2023
Format & layout document changes
2.4
9.2023
Update Technical Support & Service information
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 3of 21
Table of Contents
Section 1: Overview and Safety....................................................................................................................5
Hydraulic Rail Profile Grinder Overview........................................................................................................5
Environmental Protection..............................................................................................................................5
Safety Information.........................................................................................................................................5
Safety Terms .............................................................................................................................................6
Machine Use and Safety Precautions .......................................................................................................6
Section 2: Specifications...............................................................................................................................7
Specifications................................................................................................................................................7
Hose Requirements ......................................................................................................................................8
Hose Types ...............................................................................................................................................8
Hydraulic Hose Recommendation.............................................................................................................9
Hydraulic Fluid Recommendation .............................................................................................................9
Tool Connecting Procedures...................................................................................................................10
Disconnecting Hoses...............................................................................................................................10
Section 3: Tool Operation ...........................................................................................................................11
Personal Protective Equipment ...........................................................................................................11
Cup Stone Installation.................................................................................................................................11
Cup Stone Removal ................................................................................................................................11
Stone Height Adjustment.........................................................................................................................12
Frame Rotation........................................................................................................................................12
Grinder Operation....................................................................................................................................12
Grinder Wheel Placement...........................................................................................................................13
Section4: Maintenance................................................................................................................................15
Troubleshooting ..........................................................................................................................................16
Section 5: Parts and Service Support.........................................................................................................17
Rail Profile Grinder / RRP# 910103............................................................................................................18
Section 6: Warranty Terms and Conditions ................................................................................................21
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 5of 21
Section 1: Overview and Safety
Hydraulic Rail Profile Grinder Overview
RRP designs and manufactures equipment primarily for the repair and new construction of rail and
railroad tie track maintenance.
The Hydraulic Rail Profile Grinder uses a high-efficiency, pressure loaded hydraulic motor that provides
maximum power while reducing heat and minimizing energy waste.
The smooth-operating stone height adjustment is well within easy reach of the operator. Lifting handles
are balanced for ease in transport. Stone access panel and shaft lock make for easy stone removal. The
quick latch is easily adjustable for carriage positioning.
Over speed valves protect the motor and stone from excess RPM. Spark guard offer optimum protection.
Convenient handle with trigger guard automatically stops the tool operation when released.
Do not use this machine for other than its intended purpose.
Please read these instructions when using this tool, which can only be used for the specified purpose.
This instruction manual should be kept throughout the life of the tool.
The operator of this tool should:
•Have access to this operation instruction.
•Read and understand this operation instruction.
Environmental Protection
Comply with relevant national waste disposal laws and regulations. Waste electronic
devices cannot be treated as household waste.
Equipment, accessories, and packaging shall be recyclable.
Do not throw the discarded equipment in trash cans.
Safety Information
For safe installation and operation of this equipment, carefully read and understand the contents of this
manual. Improper operation, handling, or maintenance can result in equipment damage and personal
injury.
Only trained and authorized personnel should be allowed to operate this machine. In addition, all
personnel at the worksite should be aware of the safety concerns and their individual responsibilities prior
to working this machine.
Please read and comply with all the safety precautions in this manual before operating this machine.
Your safety is at risk.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
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Safety Terms
DANGER indicates a hazardous operating procedure, practice, or
condition. If the hazardous situation is not avoided death or
serious injury will occur.
WARNING indicates a hazardous operating procedure, practice, or
condition. If the hazardous situation is not avoided death or
serious injury could occur.
CAUTION indicates a potentially hazardous operating procedure,
practice, or condition. If the hazardous situation is not avoided
moderate or minor injury could occur.
Machine Use and Safety Precautions
Failure to follow safety precautions when operating this equipment can
result in serious injury or death to the operator or other persons in the
area. Observe the following precautions whenever you are operating, working
on or near this equipment.
Do not make any modifications without authorization or written approval from Racine Railroad Products.
Replace all Racine Railroad Products and OEM parts with genuine Racine Railroad Products and OEM
parts. Using non-OEM parts may compromise the safety of the machine.
Do not wear loose clothing, jewelry, radio belts, etc., when operating, working on or near this equipment.
They can be caught in moving parts and may result in severe injury.
Always wear appropriate personal protective clothing when operating this equipment: e.g., orange safety
vest, hard hat, safety glasses with side shields, hearing protection, steel-toed safety boots, leather gloves,
dust respirator, etc.
Always lift heavy objects with the knees and legs, not the arms and back.
Always keep hands, arms, feet, head, clothing, etc., out of the operating area and away from all rotating
or moving components when operating, working on or near this machine.
Always make sure that all guards, covers, belts, hoses and operating components are in good working
order and that all controls are in the appropriate position before starting the engine.
Always make sure that all safety equipment installed properly and are in good working order. Do not
operate the machine until unsafe conditions have been corrected.
Always operate in a well-ventilated area and make sure that the air filters, air filter covers, and muffler
are in good condition.
Always keep the work area and machine free of debris. Operate the machine in a safe and responsible
manner. Exercise caution when fueling, working on or near rotating or moving components, hot
components and fuel systems. Be aware of potential fire hazards and prevent sparks, exhaust, etc., from
starting fires on the machine and/or work area.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
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Always comply with all instructions provided on any decals or placards installed on the machine and with
any relevant amplifying information provided in this manual or other general operating procedures.
Always read all tags and decals attached to the tool by the factory. Read and understand all tags before
removal or before operating the tool. Do not exceed the tools rated flow and pressure at any time.
Always replace worn or damaged tags and decals. The information on them should be legible at all
times. Replacement tags and decals are available from your Racine Railroad Products distributor.
Always disconnect the power source and make sure that all controls are in a safe position and install all
appropriate locking and safety devices before doing any of the following:
•Lubricating
•Adjusting
•Installing Tooling
•Making Repairs
•Performing Service
Section 2: Specifications
Specifications
Maximum Flow..............10 gpm / 40 lpm
Maximum Pressure .......2000 psi / 140 bar
Maximum Wheel ...........3 in X 6 in
Arbor Hole Size.............5/8-11 Threaded
Hydraulic System ..........Open Center
Length: ..........................45.5 in / 115.5 cm
Width:............................16 in /40.6 cm
Height:...........................35 in / 88.9 cm
Weight: (less stone) ......110 lbs / 49.9 kg
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 8of 21
Hose Requirements
It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface
and an abrasion resistant outer surface. Each hose must have male pipe ends for most application.
Longer hoses can be used when necessary but can affect the operation of the tool due to resistance in
the hose.
If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return
ports, the pressure required to push the fluid through the system and back to the tank will be higher. This
will reduce tool power.
Important: Oil should always flow from the male coupler through the female coupler.
Note: The pressure increases in uncoupled hoses left in the sun. This may make them difficult to
connect. When possible after use, connect the free ends of the operating hoses together.
Hose Types
Hydraulic hose types authorized for use with the tool are:
1. Labeled and certified non-conductive.
•This is the only hose authorized for use near electrical conductors.
•Constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement,
and weather resistant thermoplastic or synthetic rubber cover.
2. Wire braided (conductive)
•This hose is conductive and must never be used near electrical conductors.
•Constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and
weather resistant synthetic rubber cover
3. Fiber braided (not certified or labeled non-conductive)
•This hose is conductive and must never be used near electrical conductors.
•Constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement,
and weather resistant thermoplastic or synthetic rubber cover.
The rated working pressure of the hydraulic hose must be at least 175 bar (2500 psi).
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 9of 21
Hydraulic Hose Recommendation
Hydraulic Hose Recommendation
Flow Per Circuit
Length Each Hose
Use
Inside Diameter
SAE Spec Hose
(Wire Braid)
SAE Spec Hose
(Fiber Braid)
GPM
LPM
Feet
Meter
Inch
MM
5 to 8
19 to 30
To 50
To 15
Both
1/2
13
SAE 100R1-8
100R7-8
5 to 8
19 to 30
51 to 100
15 to 30
Both
5/8
16
SAE 100R2-10
SAE 100R8-10
5 to 8
19 to 30
100 to 300
30 to 90
Pressure
Return
5/8
3/4
16
19
SAE 100R2-10
SAE 100R1-12
SAE 100R8-10
SAE 100R7-12
9 to 12
34 to 45
To 50
To 15
Both
5/8
16
SAE 100R2-10
SAE 100R8-10
9 v 12
34 to 45
51 to 100
15 to 30
Pressure
Return
5/8
3/4
16
19
SAE 100R2-10
SAE 100R3-12
SAE 100R8-10
SAE 100R7-12
9 to 12
24 to 45
100 to 200
30 to 60
Pressure
Return
3/4
1
19
25.4
SAE 100R2-12
SAE 100R1-16
SAE 100R8-12
SAE100R7-16
The rated working pressure of the hydraulic hose must be at least 2500 psi / 173 bar.
Hydraulic Fluid Recommendation
Inspect hoses for cuts, crushing, leaks, or abrasion,
which may be a safety hazard or reduce fluid flows.
The following fluids work well over a wide temperature
range at startup, allow moisture to settle out, and resist
biological growth likely in cool operating hydraulic
circuits.
Others that meet or exceeds the specifications of these
fluids may also be used.
Type
Hydraulic fluid
Amsoil
AWH ISO 32
Chevron
Rando HD Premium Oil MV ISO VG 32
Rando HDZ ISO 32
Gulf
Harmony AW ISO Multi-Grade 32
Mobil
DTE Oil Excel 32
Schaeffer
Dilex Supreme Hydraulic Fluid w/
Dynavis ISO 46.
Shell
Shell Tellus S2 VX 32
Sunoco
Sunvis 1032 HVI Hydraulic Oil
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 10 of 21
Tool Connecting Procedures
1. Stop the engine before connecting the tool and or hoses to the power unit, and when switching hoses
or tools.
2. Turn the hydraulic on/off valve to the off position before starting the engine.
Make sure all hoses are connected for correct flow direction to and from the tool being used.
When routing hose in the work area, position them where personnel will not be at risk of tripping over
them where vehicles can run over the hoses. Do not lay hose over sharp objects.
Pressurized fluid escaping from a damaged hose can penetrate the
skin and be injected in the body causing injury or death.
Do not pull on hoses to drag the power unit or tool.
Connecting Hoses
1. Wipe quick couplers with a clean lint free cloth before connecting them.
2. Depressurize the system.
3. Allow system and hydraulic fluid to cool if too hot to handle.
4. Securely connect the return (tank “R”) hose from the power source to the tool.
5. Securely connect the supply (pressure “P”) hose from the power source to the tool.
It is recommended that you connect the return hoses first and disconnect last to minimize or avoid
trapping pressure within the tool.
When connecting the quick couplers, the flow should run from male coupler to the female coupler.
The female coupler on the tool is the inlet. Quick couplers are marked with a flow direction arrow.
Pressurized fluid escaping from a damaged hose can penetrate the
skin and be injected in the body causing injury or death.
Do not pull on hoses to drag the power unit or tool.
Note: When possible, connect the free ends of uncoupled hoses to prevent build up in the hoses. The
sun can also increase pressure in the hoses and make connecting them difficult.
Disconnecting Hoses
1. Stop the hydraulic power source.
2. Depressurize the system.
3. Allow system and hydraulic fluid to cool.
4. Disconnect the supply (pressure) hose to the power source (pressure port) from the tool (IN port).
5. Disconnect the return (tank) hose to the hydraulic power source (return port) from the tool (OUT port).
6. To prevent contamination, always install dust caps over the hydraulic ports of the tool when
disconnected.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 11 of 21
Section 3: Tool Operation
Personal Protective Equipment
Before operating this machine, make sure that all general safety precautions are observed,
and that proper personal protective clothing is worn as described below.
At a minimum, operators should wear the following Personal Protective Equipment:
1. Safety Glasses
2. Hearing Protection
3. Hard Hat
4. High Visibility Safety Vest
5. Leather Work Gloves
6. Steel Toed Safety Shoes
Cup Stone Installation
Inspect the stone before installation.
Use blotters between the stone and backups. The blotters should be made from highly compressible
material and should not be more than .025 inches thick.
Check that the backup is pressed all the way on the spindle shaft. NOTE: The square on the spindle
should slide into the square in the back of the backup.
Turn the spindle end until the backup contacts the stone.
Cup Stone Removal
1. Disconnect the hoses from the tool.
2. Align the hole in the frame with the hole in the motor spacer. Insert the stone locking pin though the
holes in the motor spacer.
If the pin does not slide through the holes easily, adjust stone housing until it does.
3. Open the door on the frame to expose the stone. Hold the stone by hand counter-clockwise (left) until
the pin locks the shaft.
Place the stone removal strap around the stone with the ratchet receiver end in the door opening.
4. Loosen the stone. Once the stone is loosened it can be turned by hand and removed.
5. After the stone has been removed return the stone locking pin to its storage hole and check that the
door is securely fastened.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 12 of 21
Stone Height Adjustment
The stone can be adjusted to a desired height by turning the large hand wheel at the center of the Profile
Grinder.
Use the smaller knob located under the hand wheel as a brake to increase or decrease drag on the hand
wheel.
Frame Rotation
The Grinder’s frame can be set at any position within a 90° arc by loosening the locking lever and pulling
the frame towards the handle.
Always turn the locking lever into a locked position before grinding.
Grinder Operation
1. Place the Profile grinder on the rail with the two large diameter guide wheels on one side of the rail
and the two smaller diameter wheels on the opposite side.
The grinder should set on the rail at each roller and roll back and forth freely.
2. When grinding, position the weld between the left set of wheels and the stone housing (left and right
are determined from the operator’s position at the handle).
3. Adjust the stone in installed, run the grinder at full speed for one minute before grinding.
4. Grip the handle firmly with both hands and draw the trigger to the handle to start the grinder. With the
grinder at full speed move it from the right to the left into the weld.
5. Adjust the stone height and rotate the frame as required for optimum results.
6. When finished release trigger and allow stone to stop before removing the grinder from the rail.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 15 of 21
Section4: Maintenance
It is highly recommended to practice regular check-ups and maintenance in accordance with the
usage
frequency to keep your tool in better condition and reduces total
run
ning
costs.
Do not perform maintenance on the machine while the hydraulic
power source motor is running or when hoses are connected.
All maintenance must be done with the tool disconnected from the
power source.
Cleaning and Maintenance Recommendations
•
Wipe
all external surfaces after each use with a clean, lint free cloth to remove surface
contaminants from the tool.
•
Store all
tools in an enclosed area to prevent weather from contaminating their systems.
Safety Devices
When maintenance is complete, make sure the following:
•
The hydraulic
control valves are operable.
•
The hydraulic quick couplers and hoses are safe to use.
Storage Preparation
•Cover male and female hose whips.
•Store in the upright position. Secure tool to prevent it from being knocked over.
•Store the Web Grinder on a smooth level surface.
•The tool should be stored in a cool, dry environment which is not subjected to rapid temperature
changes.
Daily
Do not attempt to locate hydraulic leaks by feeling around hoses
and fitting with hand. Pin-Hole leaks can penetrate the skin.
•Wipe all tool surfaces, fittings, and couplings free of grease, dirt, and foreign materials.
•Inspect the tool, hydraulic system, hoses, and fittings for signs of leaks, cracks, wear, and/or damage.
Replace if necessary.
•To prevent contamination, always install dust caps over the hydraulic ports when disconnected.
•Inspect machine for damage and wear, replace as required.
Monthly
•Perform a detailed inspection of the systems hoses and fittings according to the hydraulic hose
operator’s manual and as stated in SAE standard j1273, May 1989 or latest revision.
Replace the hoses and/or fittings if necessary.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 16 of 21
Troubleshooting
Use the following chart as a guide to correct any problem you may experience with the too.
To determine the problem in operation of the grinder always check that the hydraulic power source is
supplying the correct hydraulic flow and pressure to the tool as listed in the table.
Be sure you are using an accurate flowmeter. Check the flow with the hydraulic fluid temperature at least
80° F / 27° C.
PROBLEM
CAUSE
REMEDY
Tool will not run.
Power source.
Check power source flows and
pressure (8-10 gpm / 30-38
lpm at 1500-2000 psi 100-140
bar).
Coupler or hoses.
Check for/remove
obstruction.
mechanical failure.
Disassemble tool and check
for damage.
Tool runs backwards.
Pressure too high.
Correct hose connection or
flow direction.
Motor shaft rotates clockwise
as viewed from the end of the
shaft.
Trigger (ON/OFF) hard to
draw in.
Back pressure too high.
Should not exceed 250 psi /
17 bar at 10 gpm / 38 lpm.
Grinder grinds too slow.
Insufficient fluid flow or low
relief valve setting.
Adjust flow for proper gpm.
For best performance to
2100-2250 psi / 145-155 bar.
910103
Hydraulic Rail Profile Grinder
9.2023 Rev 2.4
Original Instructions
Page 17 of 21
Section 5: Parts and Service Support
Technical Support & Service
Telephone and web-based technical support is available for current production models through our
Customer Service Department. Service Manuals and limited technical support may be available for
models that are no longer in production.
Telephone and E-mail Technical Support
Telephone and e-mail technical support is available on normal U.S. business days from 8:00 AM to 5:00
PM U.S. Central Time Zone (GMT +6 (+5 Daylight Savings Time)).
Phone: (262) 637-9681
Email: custserv@racinerailroad.com
Racine Railroad Products
1955 Norwood Court
Mount Pleasant, WI 53403
Non-Warranty Technical Support
Depending upon the circumstances and availability of technical service personnel, we may provide
technical assistance and/or field service support, at the customer's expense, to assist in the correction of
non-warranty related problems. Contact our Customer Service Department to coordinate Non-Warranty
Technical or Field Service Support.
Warranty Support Technical Support
Depending upon the circumstances and availability of technical service personnel, we may provide
technical assistance and/or field service support, at no charge to the customer, to assist in the correction
of warranty related problems. Contact our Customer Service Department to coordinate Warranty
Technical or Field Service Support.
Warranty Parts Claims
Material claimed to be defective must be returned to our factory for evaluation. Defective materials will be
replaced, or your account will be credited if replacement materials have already been purchased. Please
contact our Customer Service Department at the address provided below if you have any questions or
problems.
Warranty Service Support
Depending upon the circumstances and availability of technical service personnel, we may provide
technical assistance and/or field service support, at no charge to the customer, to assist in the correction
of warranty related problems. Contact our Customer Service Department at the address provided above
to coordinate Warranty Service Support.
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