Racine Railroad Products 910215 User manual

1955 Norwood Court
Mount Pleasant, WI 53403
Phone: [phone]
Email: [email protected]
racinerailroad.com
Unit 3 Hartington Industrial Estate
Chesterfield Derbyshire, S43 3YF
Phone: [phone]
Email: [email protected]
racinerailroad.co.uk
Hydraulic Rail Profile Grinder
910215
Operating Manual

1955 Norwood Court
Mount Pleasant, WI 53403
Phone: [phone]
Email: [email protected]
racinerailroad.com
Unit 3 Hartington Industrial Estate
Chesterfield Derbyshire, S43 3YF
Phone: [phone]
Email: [email protected]
racinerailroad.co.uk
Hydraulic Rail Profile Grinder
910215
Record of Changes
Rev No.
Date
Description of Changes
Rev 1
4.2023
Initial release.
Rev 1.1
10.2023
Update Technical Support & Service information

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 3of 30
Table of Contents
Section 1: Overview and Safety....................................................................................................................5
Hydraulic Rail Profile Grinder Overview........................................................................................................5
Environmental Protection..............................................................................................................................5
Safety Information.........................................................................................................................................6
Safety Terms .............................................................................................................................................6
Machine Use and Safety Precautions .......................................................................................................6
Section 2: Specifications and Installation......................................................................................................8
Specifications................................................................................................................................................8
Hydraulic fluid ........................................................................................................................................8
Hydraulic System Specification .............................................................................................................8
Components..................................................................................................................................................9
Installation...................................................................................................................................................10
Hose Requirements ....................................................................................................................................10
Hose Types .............................................................................................................................................11
Hydraulic Hose Recommendation...........................................................................................................12
Hydraulic Fluid Recommendation ...........................................................................................................12
Tool Connecting Procedures...................................................................................................................13
Disconnecting Hoses...............................................................................................................................13
Section 3: Tool Operation ...........................................................................................................................14
Personal Protective Equipment ...........................................................................................................14
Grindstone Installation.............................................................................................................................14
Grinder Functional Test...........................................................................................................................16
Stone Height Adjustment.....................................................................................................................17
Operation.................................................................................................................................................17
Frame Rotation ....................................................................................................................................18
Positioning on the Rail.........................................................................................................................18
Section 4: Maintenance...............................................................................................................................19
Troubleshooting ..........................................................................................................................................20
Maintenance Schedule ........................................................................................................................20
Troubleshooting ...................................................................................................................................21
Section 5: Parts and Service Support.........................................................................................................22
On-Off Rotary Valve Exploded View & Parts List................................................................................22
Motor Exploded View...........................................................................................................................24
Motor Exploded View Parts List...........................................................................................................25

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 4of 30
Handle Exploded View & Parts List.....................................................................................................26
Frame Exploded View & Parts List .......................................................................................................27
Profile Grinder Exploded View.............................................................................................................28
Profile Grinder Exploded View Parts List.............................................................................................28
Section 6: Warranty Terms and Conditions ................................................................................................30

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 5of 30
Section 1: Overview and Safety
Hydraulic Rail Profile Grinder Overview
Racine Railroad Products 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.
Use grinding discs with approximately 15.24 cm (6 inch) diameter and 7.62 cm thickness (3 inch). The
grinding discs must be suited for use at 3,300 rpm.
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.
•Read and understand this operation instruction.
Note: Information in this document is subject to change without notice.
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.
Don't throw the discarded equipment in trash cans.

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 6of 30
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 with 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.
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.
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.

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 7of 30
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 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 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

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 8of 30
Section 2: Specifications and Installation
Specifications
Width ...................................................16 inch / 406 mm
Length .................................................45.5 inch / 1155 mm
Height .................................................35 inch / 889 mm
Weight .................................................95 lbs / 43.1 kg
Hydraulic pressure ..............................max. 2,150 psi / 150 bar
Hydraulic flow .....................................max. 10 gpm / 40 lpm
Idle speed ...........................................3,300 U/min / rpm
The machine is designed for outdoors use. It can be used at temperatures between -20 °C to 45 °C
(-4° F to 113° F).
The temperature of the hydraulic fluid should be at least 10 °C (50° F).
The statutory minimum distance must be observed around power lines.
Hydraulic fluid
The hydraulic fluid should meet the following requirements.
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
Hydraulic System Specification
The hydraulic unit should ensure a flow rate of at least 10 gpm / 40 lpm and pressure of
2,000 psi / 138 bar.
The pressure must be limited to 2,176 psi / 150 bar.
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.

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 9of 30
Components
1 Handle
2 Connection Hydraulic Pump (Supply Flow and Return Flow)
3 Frame Rotation Locking Lever
4 Lifting Handle
5 Spark Guard
6 Stone Height Adjustment Hand Wheel
7 Hand Wheel Brake Knob
8 Guide Wheels
9 Roller
Excess weld from the ball of the rail can be removed with the Hydraulic Rail Profile Grinder. Use grinding
discs called cup stones with an approximately 6 inch / 15.24 cm diameter and 3 inch / 7.62 cm thickness.
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.

910215 –Hydraulic Rail Profile Grinder
racinerailroad.com
racinerailroad.co.uk
4.2023 Rev 1
Original Instructions
Page 10 of 30
Installation
Unpacking Instructions
Upon receiving your Hydraulic Rail Profile Grinder promptly remove it from the shipping container.
Always keep the top side of container up. Inspect unit for damage which may have incurred during
shipping and report it to carrier for claim.
Tool Preparations
The Hydraulic Rail Profile Grinder requires some assembly before use. If the tool is used in cold
weather, preheat the hydraulic fluid by running the power source at low engine speed.
The fluid temperature should be at or above 50° F/10° C before use, when using recommended
fluids. Using too thick of fluid may result in tool damage.
Never stick foreign objects, fingers, or other extremities into the
moving mechanism. Failure to follow these instructions may lead
to severe personal injury or tool damage.
Hose Requirements
Check hydraulic hosed for cracks, leakage, and damage. If the hoses or couplers show any of these wear
characteristics, replace them before operating the tool. Never attempt to locate leaks with your hands,
personal injury may occur from pressure system.
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 for them
to connect. When possible after use, connect the free ends of the operating hoses together.