Racine Railroad Products Trak Kut II 910084 Operating instructions

Racine Railroad Products ▪ 1955 Norwood Court ▪ Mount Pleasant, WI 53403
Phone: [phone] ▪ Fax: [phone]
Email: [e-mail] ▪ www.racinerailroad.com
Trak Kut II Saw
910084
Operating and Maintenance Manual

910084-M
Trak Kut II Saw
Phone: [phone]
Email: [email protected]
www.racinerailroad.com
10.2018 Rev 1
Page 2
Trak Kut II Saw
910084
Record of Changes
Rev. / Chg./ Bulletin
Description of Changes
No.
Date
Rev 1
10.2018
Engineering and branding updates
Contents
Section 1: Overview and Safety....................................................................................................................3
Trak Kut II Saw Overview..............................................................................................................................3
Warranty Terms and Conditions ...................................................................................................................3
Safety............................................................................................................................................................4
Work Area Safety Precautions ..................................................................................................................5
Technical Specifications................................................................................................................................6
Recommended Spare Parts..........................................................................................................................7
Initial Assembly.............................................................................................................................................8
Blade Installation .......................................................................................................................................9
Setting up The Trak Kut II on a Rail ........................................................................................................10
Daily Inspection...........................................................................................................................................11
Operating Instructions.................................................................................................................................11
Engine Start.............................................................................................................................................11
Shut-Down Procedure .............................................................................................................................13
Emergency Shut Down............................................................................................................................13
Section 2: Maintenance...............................................................................................................................14
Maintenance................................................................................................................................................14
Fueling and Lubrication...........................................................................................................................14
Carburetor Adjustment ............................................................................................................................15
Trak Kut II Maintenance Parts.................................................................................................................15
Trouble Shooting Guide..............................................................................................................................16

910084-M
Trak Kut II Saw
Phone: [phone]
Email: [email protected]
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10.2018 Rev 1
Page 3
Section 1: Overview and Safety
Trak Kut II Saw Overview
RRP 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 Racine Railroad Products Trak Kut II saw is a portable, gasoline engine powered, single blade saw
designed for vertical on track rail cutting. The Racine Trak Kut II has a screw-type rail clamp that
accommodates 80 lb. to 175 lb. rail.
Cutting position is set with clamp and clutch loaded articulating pivoting arms with an adapting rail clamp
and a manual screw with T-handle. The Racine Trak Kut II saw uses ANSI approved abrasive cutting disc
blades
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.

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10.2018 Rev 1
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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
Safety
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.
General Safety Precautions
Racine Railroad 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 power unit 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.

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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 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.
Training Requirements
Operator training for the Impact Wrench should consist of information found in this manual. 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
Work Area Safety Precautions
•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.
•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.
•Always connect hydraulic hoses to the tool before activating the hydraulic circuit on your power unit.
Check that hydraulic couplers are secure before activating the circuit.
•Keep handles clean and dry.
•Disconnect tool from hydraulic source before inspection or cleaning.
•Only a properly trained person should perform any maintenance, service, and or repairs to a tool.
•At the work site, never carry the tool with the wheel rotating.
•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.

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10.2018 Rev 1
Page 6
Technical Specifications
Physical Data
Length:.................................38 in. (~0.965 m)
Width:...................................24 in. (~0.61 m)
Height, Work Mode:.............20 in. (~0.51m)
Weight:.................................50 lbs. (~20.7 kg) 24.0 lbs
Mechanical Data:
Engine..................................2-Stroke, Single Cylinder, Air Cooled, 8.20 cu. in. Disp. /
2.531 Dia. Bore x 1.62 in. Stroke
7.8 hp @ 8000 rpm (4200 +/-250 rpm @ max.) / Model No. 82042
Starter..................................Manual Recoil
Fuel Type.............................Regular Unleaded Gasoline, Minimum 90 Octane
Fuel Capacity.......................2.19 US pints(1.04 Liters)
Fuel Filter.............................Tank Strainer and Carburetor
Oil Type: ..............................Must meet 20cycle air cooled engine oil ISO grade requirements
Oil To Fuel Mix Ratio...........6:1 [6 oz SAE 50 grade 2-cycle oil : 1 U.S. gallon 90 octane gasoline]
Fuel Pick-up Filter................Porous 100 Micron Polyethylene
Fuel filter, In line ..................Nylon -150 Micron Screen Type
Air Filter ...............................Dry-Type Replaceable Element
Ignition.................................Solid state electronic w/ rpm limiter
Spark Plug...........................Resistor Type, Champion RL86C, NGK BR9HS
Spark Plug Gap ....................030 in. (.50-.60mm) Air Gap
Coil Gap...............................010” (2.5 mm)
Performance Data
Production Rate:...................75 minutes/cut @ 4200 R.P.M. 16-inch diameter wheel using generic
brand blade on 132 lbs rail.
Governed Speed..................8000 rpm ±250 rpm
Cutting Blade Speed............16-onch diameter blades are rated for maximum 4800 rpm
Maximum Blade Speed .......4200 rpm ±400 rpm

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10.2018 Rev 1
Page 7
Recommended Spare Parts
The following parts are commonly used consumable, wear and / or routine maintenance items. Racine
Railroad Products recommends that these parts be stocked in the quantities indicated below to maintain
your machine at peak performance.
Description
Part No.
Qty
BELT, DRIVE –TK II –16” DIA. SAW BLADE
464344
1
FILTER, ENGINE AIR - PRIMARY
458290
1
FILTER, ENGINE AIR –PRE-CLEANER
385170
1
FILTER, ENGINE AIR –SCREEN
385994
1
CLEANER, FILTER SPRAY (15 OZ.)
462614
1
PLUG, SPARK
458576
1
WHEEL, CUT OFF 16” PREMIUM
460832
1
WHEEL, CUT OFF 16”
460831
1
OIL, 2-CYCLE PREMIX (PT)
462984
1
METAL STORAGE BOX
776810
1
METAL BOX LIFTING STRAP
462380
1

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Initial Assembly
The Trak Kut II was tested after assembly at our factory. After assembly, the machine should receive a
thorough In-Service inspection before initial operation.
If you do not feel qualified to perform this In-Service work yourself, contact a competent mechanic or the
Racine Railroad Products Service Department for technical support.
After unpacking and inspecting the Trak Kut II, prepare it for service by:
•Fill the engine fuel tank.
•Check all aspects of the engine, arm and rail clamp.
•Check all controls for proper operation.
•Install the cutting blade.
Left Side
Right Side
Controls
Hand Position

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Blade Installation
Inner/Outer Flanges
Keyed Blade Spindle
Inner Flange Installed
Saw Blade on Spindle
Outer Flange Installed

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Setting up The Trak Kut II on a Rail
Saw Clamp on Rail
Mounted to Clamp
Saw Crank Installing
Adjust Safety Gear
Set for Lanyard Start

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Daily Inspection
Before starting any cutting operation, perform a daily inspection.
Before operating the Trak Kut II saw, inspect the following and correct any problems as necessary:
•Check the general condition of the machine.
•Check that all guards and safety devices are installed and operational.
•Check that all controls are operational.
•Check that the rail clamp device is operational.
•Check that the ending fuel level is full.
•Check that the engine air filter element is clean and serviceable
Operating Instructions
The Trak Kut II can cut rail from both sides by turning the saw around and reinsert it in alignment with the
same cut without moving the rail clamp thereby using most of the cutting blade.
The typical rail cutting time for 16-inch saws for a 132 lbs. rail is approximately 1.50 minutes.
Rail Top Cutting Method
Rail Side Cutting Method
Engine Start
1. Toggle the Off switch back, opposite the OFF decal.
2. Pull the Choke out to the choke position.
3. Grasp the rope handle and slowly pull until resistance is felt.
4. Then pull rapidly to start engine and avoid kickback.
Note: If the Choke is used, rev the Throttle trigger to RUN in a responsive manner as engine warms
up.
5. Reset the choke after the engine is warm and accelerates smoothly.
6. Operate the engine at full throttle when cutting a rail.

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Rail Cutting
1. Once the Trak Kut II is placed and clamped on the rail and all adjustments are made, start the engine
and advance to full speed.
2. Start the cutting at the top of rail head by working the blade in an arc swinging motion using the arms
and pivot shaft as a vantage factor.
3. Continue cutting through the rail web and rail base then release the engine throttle once the blade
cuts the rail completely.
4. Turn the engine’s off toggle switch toward the OFF decal before unclamping and moving the rail saw
to the next location.
Be aware of the engine and exhaust system and avoid personal contact with hot metal components.
5. Set the rail saw onto the track rail designated work area and clamp securely.
6. Restart engine and repeat the operation.
Turned Around Cutting
Finishing Rail Cut
Finished Rail Cut

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Shut-Down Procedure
To safely transport and store the Trak Kut II perform a normal shut down.:
1. Stop engine with the OFF toggle switch and allow sufficient time to cool off the engine.
2. Disengage the rail clamp.
3. Prepare the unit for transport.
Emergency Shut Down
In the event of any malfunction, immediately shut off the engine and correct the problem.

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Page 14
Section 2: Maintenance
Maintenance
Do not perform maintenance on the Trak Kut II while the engine is
running
Make sure that the following safety devices are installed on the Trak Kut II saw:
•The fuel tank cap is properly installed.
•The rail clamp is secure.
•The rail saw blade is installed properly.
Fueling and Lubrication
At a minimum, perform the following routine daily maintenance on the Trak Kut II saw to keep it in good
working condition.
Do not perform maintenance on the Trak Kut II while the engine is
running.
Fill fuel tank outdoors or in a well-ventilated area, away from sparks,
open flames, pilot lights, heat and other ignition sources. If fuel spills,
wait until it evaporates before starting the engine.
Turn the engine OFF and let it cool at least two minutes before
removing the gas cap. Replace the gas cap before starting.
Do not use gasoline that contains methanol. Some fuels, called
oxygenated or reformulated gasoline, are gasoline blended with
alcohols or ethers. Excessive amounts of these blends can damage the
fuel system or cause performance problems.
If any undesirable operating symptoms occur, use gasoline with a lower
percentage of alcohol or ether.
Grease Type and Locations
Permanently sealed bearing and self-lubricating bushings are used extensively on the Trak Kut II saw
to reduce daily maintenance. Make sure that all bearings and moving parts are properly lubricated.
Engine fuel type and location
The engine mounted fuel tank holds 2.18 US pints. Use clean, fresh regular unleaded gasoline with a
minimum of 90 octane.
Fresh fuel prevents gum from forming in the fuel system or the essential carburetor parts. Purchase
fuel in quantity that can be used within 30 days.

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Carburetor Adjustment
1. Turn the T-handle carburetor adjusting needle in all the way
clockwise to reset.
2. Turn the needle out counter-clockwise two full turns for first
start-up.
3. Start the unit and let it warm up.
Note if the unit shuts down after releasing the throttle
trigger.
If unit continues to run, adjust the throttle linkage at the
carb until the saw shuts down when releasing the throttle
trigger
Attach an rpm gauge to the unit and note the rpm. The saw
should be set @ 8400 rpm.
Adjust the carb needle in or out to reach this setting.
Trak Kut II Maintenance Parts
Air Filtration Kit
Carburetor & Fuel Filters
Air Filter Screen
Base Plate & Fasteners

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Air Filter & Pre-Cleaner
Air Filter Cover
Trouble Shooting Guide
Problem
Possible Cause
Remedy
Engine misses
Dirt in fuel system.
Thoroughly clean fuel tank and replace
both primary and secondary filters.
Fill fuel tank with proper pre-mixed fuel
mixture.
6 ounces of 2-cycle oil (BIA-TCW) low ash
or equivalent to 1 gallon of regular
gasoline or 30 ounces to 5 gallons of
gasoline.
Carburetor out of adjustment.
See Carburetor Adjustment.
Spark plug fouled.
Replace spark plug with L86C Champion
spark plug or equivalent.
Engine lacks power
Air cleaner clogged.
Replace air filter and clean pre-cleaner.
Carburetor out of adjustment.
See Carburetor Adjustment.
Incorrect spark plug.
Install proper spark plug using L86C
Champion spark plug or equivalent.
Poor compression.
Overhaul engine or replace with new
engine assembly.
Belt slipping.
Replace with RRP# 464344 belt.
Exact replacement available only from
Racine Railroad Products).

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Problem
Possible Cause
Remedy
Engine fails or is difficult
in starting.
No fuel in tank.
Fill fuel tank with the proper pre-mixed
fuel mixture 6:1.
6 ounces of 2-cycle oil (BIA-TCW) low ash
or equivalent to 1 gallon of regular
gasoline or 30 ounces to 5 gallons of
gasoline.
Fuel line or filter clogged.
Clean fuel line or replace fuel filter.
Flooded.
Open choke and crank until engine starts.
Spark plug fouled.
Replace spark plug with L86C Champion
spark plug or equivalent
Coil to flywheel-air gap out of
adjustment.
Reset air gap to .010”
Water in fuel or stale fuel mixture.
Replace with proper pre-mixed fuel
mixture.
6 ounces of 2-cycle oil (BIA-TCW) low ash
or equivalent to 1 gallon of regular
gasoline or 30 ounces to 5 gallons of
gasoline.
Too much oil in fuel mixture.
Replace with proper pre-mixed fuel.
6 ounces of 2-cycle oil (BIA-TCW) low ash
or equivalent to 1 gallon of regular
gasoline or 30 ounces to 5 gallons of
gasoline.
Carburetor out of adjustment
See Carburetor Adjustment.
Gasket leaks (scavenger plates or
crankcase cover).
Replace gaskets as needed.
Seal leak (crankcase seal).
Replace seal with exact replacement.
Broken or bent reed plate (dirt in reed
plate).
Clean or replace reeds or plate assembly.
Engine noisy or knocking.
Loose flywheel.
Tighten flywheel nut.
Incorrect spark plug causing carbon
build-up.
Install correct spark plug using L86C
Champion spark plug or equivalent and
clean carbon deposits from exhaust
ports, using ONLY a wooden scraper.
Worn bearings or loose connecting rod.
Overhaul engine or replace with new
engine assembly.

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Problem
Possible Cause
Remedy
Engine overheats
Insufficient oil in fuel
Do not mix batch with mixed fuel
presently in container.
Start fresh each time.
Fill fuel tank with proper pre-mixed fuel
mixture.
6 ounces of 2-cycle oil (BIA-TCW) low ash
or equivalent to 1 gallon of regular
gasoline or 30 ounces to 5 gallons of
gasoline.
Carburetor adjustment incorrect.
Adjust carburetor correctly. See
Carburetor Adjustment.
Incorrect spark plug.
Install proper spark plug using L86C
Champion spark plug or equivalent.
Poor acceleration
Carburetor out of adjustment.
See Carburetor Adjustment.”
Broken or bent reeds.
Replace reeds with exact replacement
part.
Leaking engine gaskets.
Low compression in crankcase.
Replace reeds with exact replacement
parts.
Exhaust restriction
Do not use metal scraper when removing
carbon from exhaust ports.
Clean carbon from exhaust ports using
only a wooden scraper.
Poor high-speed
performance
Carburetor out of adjustment.
Adjust to proper setting and speed See
Carburetor Adjustment.
Low compression.
Check for broken or worn rings or leaky
head gasket.
Replace needed gasket or overhaul
engine using exact replacement parts.
Pre-ignition.
Turn ignition switch to OFF.
Dirty or incorrect spark plug.
Replace spark plug using plug using L86C
Champion spark plug or equivalent.
Excessive back pressure from muffler.
Clean muffler or replace with exact
replacement part.
Excessive carbon or foreign matter in
combustion chamber.
Clean and remove carbon using extreme
care not to damage or gouge head or
cylinder wall.
Carburetor adjustment too lean.
Adjust carburetor to proper setting.
See Carburetor Adjustment.
Carburetor icing.
Snow or ice in carburetor bore causes
richness and smoking and poor power.
Do not lean out to compensate as the
adjustment will be too lean when thawed
out.
Clean out foreign material

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Problem
Possible Cause
Remedy
Engine stalls under load
Carburetor adjustment too lean
Adjust carburetor to proper setting and
speed. See Carburetor Adjustment.
Fuel pump not working properly.
Worn diaphragm.
Rebuild carburetor using correct
replacement parts kit.
Fuel line restricted.
Clean or replace fuel line using exact
replacement.
Tank vent inoperative.
Replace with correct tank fuel cap.
Available only from Racine Railroad
Products.
Manifold or carburetor gaskets installed
incorrectly.
Correctly install proper gaskets noting
location of vacuum hole.
Improper belt or belt slipping.
Tighten belt to proper tension with
RRP# 710988 belt tension gauge or
install.
Improper wheel or glazed wheel.
Side surfaces become glazed or smooth.
Glazing normally occurs through
improper use of saw.
Do not continue cutting with bad wheel.
Install proper wheel RRP# 460832 16”
abrasive wheel.