Racine Railroad Products 910106 Operating instructions

Racine Railroad Products ▪ 1955 Norwood Court ▪ Mount Pleasant, WI 53403
Phone: [phone] ▪ Fax: [phone]
Email: [e-mail] ▪ www.racinerailroad.com
Web Grinder
910106
Operating and Maintenance Manual

910106 – Web Grinder
Phone: [phone]
Email: [e-mail]
www.racinerailroad.com
1.2019 Rev 2
Page ii
Web Grinder
910106
Record of Changes
Rev No.
Date
Description of Changes
Rev 1 6.2012 Release
Rev 2 1.2019 Manual format & branding update, added assembly and parts list

910106 – Web Grinder
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1.2019 Rev 2
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Table of Contents
Section 1: Overview and Safety .................................................................................................................... 4
Web Grinder Overview.................................................................................................................................. 4
Warranty Terms and Conditions ................................................................................................................... 4
Safety Information ......................................................................................................................................... 6
Safety Terms ............................................................................................................................................. 6
Machine Use and Safety Precautions ....................................................................................................... 6
Section 2: Specifications and Installation...................................................................................................... 8
Specifications ................................................................................................................................................ 8
Installation Instructions................................................................................................................................ 10
Hose Requirements .................................................................................................................................... 11
Hose Types ............................................................................................................................................. 11
Hydraulic Hose Recommendation........................................................................................................... 12
Hydraulic Fluid Recommendation ........................................................................................................... 12
Hose Connecting Procedures ................................................................................................................. 13
Disconnecting Hoses............................................................................................................................... 14
Section 3: Tool Operation ........................................................................................................................... 15
Handle Adjustment...................................................................................................................................... 15
Tool Trigger and Trigger Lock ................................................................................................................. 16
Wheel Guard and Wheel Installation .......................................................................................................... 16
Positioning on Rail ...................................................................................................................................... 18
Operation..................................................................................................................................................... 18
Section 4: Maintenance............................................................................................................................... 19
Troubleshooting .......................................................................................................................................... 21
Section 5: Parts and Service Support ......................................................................................................... 22
Technical Support & Service ................................................................................................................... 22
Web Grinder Assembly ............................................................................................................................... 23
Web Grinder Parts List ............................................................................................................................ 25

910106 – Web Grinder
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1.2019 Rev 2
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Section 1: Overview and Safety
Web Grinder Overview
Racine Railroad Product designs and manufactures equipment primarily for the repair and new
construction of rail and railroad tie track maintenance.
Our product line focuses on rail fastening application/removal/adjustment equipment, other tie material
(OTM) reclamation, wood and concrete railway tie repair, and tie plate handling/distribution.
The Web Grinder is designed to remove excess material from the welded area on the web of the rail.
When properly used this tool will help reduce back strain and reduce operator fatigue
•The Web Grinder mounts to the rail for stability and better control of the tool. The mounting system
features a bearing roller for smooth operation.
•The adjustable handle allows the operator to set it in the most comfortable position for them to use.
•The two-position guard allows for the use of either 1" x 8" x 5/8" bore or 2" x 8" x 5/8" bore stones or
wheels.
•The motor is operated by a trigger on the handle bar which when released, stops the rotation of the
motor. The trigger features a lock system to prevent accidental activation.
Warranty Terms and Conditions
Warranty Period
Each new machine and new parts of our manufacture are warranted against defects in material and
workmanship for one year from the date of shipment from our factory.
When contacting customer service for factory parts, service or warranty support please provide the:
•Racine Railroad Products Model
•Serial Number
•Any locally assigned identification
Vendor Parts Warranty Period
Other equipment and parts used, but not manufactured by Racine Railroad Products, Inc., are covered
directly by the manufacturer's warranty for their products.
Warranty Parts and Service
We will repair or replace, without charge, F.O.B. factory, Racine, Wisconsin, USA, any part Racine
Railroad Products manufactures which is proven to be defective during the warranty period.
Material claimed defective must be returned, if requested, to the factory within 30 days from the date of
the claim for replacement. Ordinary wear and tear, abuse, misuse and neglect are not covered by this
warranty. Depending upon the circumstances, we may provide technical assistance and/or technical
service support, without charge, to assist in the correction of warranty related problems.

910106 – Web Grinder
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1.2019 Rev 2
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Non-Warranty Parts and Service
Material damaged through normal wear and tear, abuse, misuse and/or neglect are not covered by our
warranty and should be ordered directly from our Customer Service.
Note: Parts for models that are no longer in production may not be available.
Non-Warranty Parts Orders
When placing a parts order please provide the following information:
•Company Name and Billing Address
•Purchase Order Number and Issuing Authority
•Shipping Address
•Special Handling Instructions
•Contact Phone Number
•Machine Model and Serial Number
•Part Numbers and Quantities Being Ordered
Note: Please use Racine Railroad Products part numbers when ordering parts. Racine Railroad
Products part numbers are shown in the parts lists and drawings of this manual and have only
six (6) numbers.
Any part number with other than six numbers (e.g. contains alpha-numeric characters) is a Vendor Part
Number and not a Racine Railroad Products part number

910106 – Web Grinder
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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 (gang) 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.
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 moderate or
minor injury could occur.
Note: Indicates an essential operating procedure, practice, or condition.
No personal injury is possible.
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 use this machine for other than its intended purpose.
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.
Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals
out of the work area.
Do not overreach. Maintain proper footing and balance at all times.
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.

910106 – Web Grinder
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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 machine clean and 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.
Always hold the tool with both hands, using a firm grip when activating and operating.
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 shut 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
Stone / Wheel Safety
Always remove wheel from the tool during transportation and storage.
Always use wheels that meet the minimum requirements of the tool.
Do not cock, wedge, or jam the wheel in a cut.
Do not use the tool if the wheel doesn't stop turning when the trigger is released.
Do not exceed the tool's maximum speed rating.
Do not reverse the tool rotation.
Inspect the wheel before operating the tool. Do not use damaged wheels.
Make sure the grinding wheel has stopped turning before removing the tool from the rail.
Never carry the tool with the wheel turning.

910106 – Web Grinder
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1.2019 Rev 2
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Section 2: Specifications and Installation
Specifications
Hydraulic System Open Center
Frame Type Tube
Length 47 in. [119.38 cm]
Width 29 in. [73.66 cm]
Height (Adjustable) 27-38 in. [68.58 – 96.52 cm]
Weight (Less Stone) 34 lbs [15.42 kg]
Circuit 10 GPM @ 2000 psi
38 LPM @ 138 bar
Hydraulic Fluid Requirements [Viscosity (Fluid Thickness)]
USA Metric
50° F 450 SSU Max 10° C 95 Centistokes
100° F 130-200 SSU 38° C 27-42 C.S.
140° F 85 SSU Min. 60° C 16.5 C.S., Min.
Pour Point ............................................ 10° F / 23° C Minimum (for cold startup)
Viscosity Index (ASTM D 2220)........... 140° F Minimum
Demulsibility (ASTM D-1401) .............. 30 Minutes Maximum
Flash Point (ASTM D-92) .................... 340° F / 171° C Minimum
Rust Inhibition (ASTM D-665 A & B) ... Pass
Oxidation (ASTM D943) ...................... 1000 Hours Minimum
Pump Wear Test (ASTM D2882)......... 60 mg Maximum

910106 – Web Grinder
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Power Unit Requirements
•The power source must provide a flow of 8 – 10 GPM / 30 – 38 LPM at 1500 – 2000 psi /
100 – 400 bar.
•A relief valve setting between 2100 – 2250 psi / 145 – 155 bar is required for the operation of this
tool.
•The hydraulic system's back pressure should be less than 250 psi / 17 bar, measured at the tool
end of the operating hoses. All system checks should be made at a minimum operating
temperature 100 °F / 38 °C (maximum fluid viscosity of 400 ssu / 82 centistoke.
•The hydraulic fluid cooling system should limit the maximum temperature to 140 °F / 60 °C at the
maximum expected ambient temperature.
•The minimum cooling capacity should be 5 hp /3.73 kW at a 40 °F / 22 °C difference between
ambient temperature and fluid temperature.
•A minimum of 25-micron filtration is required for the hydraulic system. For cold weather startup
and maximum dirt holding capacity a filter element sized for 30 GPM /14 LPM is recommended.
•Racine Railroad Products recommends the use of the Diesel Power Unit. The Diesel Power Unit
is a versatile power unit that can meet the needs for most hydraulic tools used by the rail road
industry.
This power unit is capable of powering two tools simultaneously at 5 GPM (20 LPM) or one tool a
10 GPM (40 LPM) all the flows are at 200 psi / 138 bar. The maximum pressure of the hydraulic
system is limited to 2150 psi / 148.3 bar.
The power source provides the required flow and pressure to operated HTMA type I 15 – 23 LPM
(4 – 6 GPM) and type RR 34 – 40 LPM (9 – 10.5) tools. All which are open-center tools required
an operating pressure of 2000 psi / 138 bar.

910106 – Web Grinder
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Email: [e-mail]
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1.2019 Rev 2
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Installation Instructions
Unpacking Instructions
Upon receiving your Web Grinder 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.
Tool Preparations
Some Web Grinder are shipped with the handles removed
from the frame to conserve space.
If your web grinder is shipped in this manner, insert the
handle tube into the frame and tighten the locking lever to
secure the handle in place.
When inserting the handle, avoid kinking the hoses, they
should flow in a hanging arc from the motor to the handle.
Web grinders are shipped without grinding stones, unless
otherwise requested, so a stone will need to be installed
before operation.
Hydraulic fluids are thicker in cold weather; therefore, run the engine at low idle long enough to bring
the fluid temperature up to minimum of 10°C/50 F or until the top of the hydraulic tank feels warm,
before operating tool.
Never stick foreign objects, fingers, or other extremities into
moving mechanism. Failure to follow these instructions may lead
to severe personal injury or tool damage.
Testing
Before operating the Web Grinder it is important to inspect the grinding wheel for damage, replace as
required. Check that all guards and securely in place before operating the tool. Follow all safety
precautions when inspecting tool.
All testing must be done by a trained technician.
1. To test the web grinder, apply a thin strip of masking tape to the outer edge of the grinding stone.
2. Secure the grinder by clamping it in a vice or other suitable device with the stone positioned clear of
any objects.
3. Connect the tool to a suitable power source. See Hose Connecting Procedures section for installation
details.
4. Engage the trigger and run the grinder at maximum speed.
5. Use a strobe light tachometer to measure the RPM's.
•The wheel should be rotating between 3300 rpms and 3700 rpms.
•If the RPM's do not fall in this range, see Troubleshooting in the Maintenance section.
6. When testing is complete, disconnect the tool from the power source and remove it from the vice.
When testing the lock installer, follow all safety guidelines.