ROBEL ROGRIND P4 190 SWITCH 2.0, Operating Manual

Page 1: ...Content 1 OPERATING MANUAL ROGRIND P4 190 SWITCH 2 0 Rail and switch grinding machine ...

Page 2: ... of original operating manual Status 27 02 2019 Version V2 2019 Robel Bahnbaumaschinen GmbH These operating instructions were produced in accordance with the current state of technology at the time of printing The right to change on the basis of further developments is reserved Dimensions and weights are approximated Photographs show special layouts in some cases ...

Page 3: ... devices 11 2 6 Safety regulations 11 2 7 Qualifications of staff 12 2 8 Personal protective equipment 12 2 9 Information on particular types of dangers 13 2 10 Accident prevention 17 2 11 Fire safety 18 3 Technical data 19 3 1 Drive 19 3 2 Grinding spindle 19 3 3 Dimensions 19 3 4 Filling quantities 19 3 5 Weight 19 3 6 Abrasives 20 3 6 1 For rail head widths up to 75 mm 20 3 6 2 For rail head wi...

Page 4: ...mmissioning 33 6 1 Digital inductive tach hour meter 33 6 1 1 Operation 33 6 1 2 Settings 34 6 2 Re railing 35 6 2 1 Machine without dead man s brake 35 6 2 2 Machine with dead man s brake Option 35 6 2 3 Putting the machine on the rails 35 6 3 Checking the machine 37 6 3 1 Abrasive and grinding spindle 37 6 3 2 Engine 37 6 4 Starting the engine 41 6 4 1 Cold start 43 6 4 2 Warm start 45 6 5 Test ...

Page 5: ...Engine 52 7 1 2 Machine 53 7 2 Engine 53 7 2 1 Checking the oil level 54 7 2 2 Changing the oil 55 7 2 3 Maintaining the air filter 59 7 2 4 Maintaining the spark plug 61 7 3 Lubricate 63 7 4 Changing the abrasive 63 7 5 Check signs and labels 65 7 6 Cleaning and care 65 8 Troubleshooting 66 ...

Page 6: ...y for any legal consequences In the event of differences between prevailing regulations that apply to use of the product and the manufacturer s or sub contractor s specifications whichever limitations are the most stringent must apply The buyer must provide all necessary machinery equipment and material resources for putting the delivered product into operation and training staff He must also make...

Page 7: ...gulations or other instructions supplied by the manufacturer or supplier The manufacturer declares himself to be exempt from any responsibility for damage arising when the product is not used in a designated way This also includes use of the machine without safety mechanisms Any use of the product other than that specified above is not designated and endangers the lives and health of operating and...

Page 8: ... The buyer must equip the goods delivered with all fittings nec essary to meet relevant operational and safety regulations norms statutory regulations or other regulations e g fire ex tinguisher first aid box signal and telecommunications equipment additional warning devices protective clothing safety notices etc Unless otherwise agreed no fittings of this nature are provided with the goods delive...

Page 9: ...se of coolant lubricant and must not be used for anything else It is suitable for Profiling work of crossings with rigid and movable frogs Grinding and abrading of closed and open switch blades Profiling the rail behind the check rail Grinding work on wing rails Machining of expansion joints Machining of rail surface damage e g head checks burr Performing grinding and deburring work on the rail he...

Page 10: ...liance with instructions may result in damage to the product or other assets of the operating company Contains important information about the product its operation or about a section of the instructions on hand Structure of the warnings The warnings are structured as follows SIGNAL WORD Type and source of danger Possible consequences when ignoring the danger Measure to avoid the danger 2 4 Design...

Page 11: ... all personnel affected have been made aware of the following relevant regulations and provisions Statutory national safety regulations Provisions of the respective building code and works rules Provisions of the respective professional and trade associa tions Occupational and environmental health and safetyregula tions Approvals regulations Company internal regulations All other applicable regula...

Page 12: ...alifications minimum age No influence of alcohol medicines drugs or fatigue etc 2 8 Personal protective equipment The approved personal protective equipment has to be used when operating and maintaining the product Wear protective gloves Wear steel capped working shoes Wear ear protection when exposed to frequency noise Wear light respiratory equipment Wear appropriate close fitting clothing that ...

Page 13: ...task have been considered Frequency of transport Age Gender Operator s state of health Uneven flooring Poorly lit worksites Bad weather Working under time pressure etc Observe the relevant guidelines on lifting and transporting heavy machinery or equipment Mechanical aids to lifting are always the preferred method of handling where possible e g hoists tail lift rail trolleys etc Always use the han...

Page 14: ...ousings etc straight away Before working on the electrical system Shut off the power supply to the system switch off the drive and disconnect the power supply During work on the electrical system Do not touch any live lines Check earthing cables are securely seated and complete Check that the connecting surfaces of the earthing cables are clean and free from corrosion When the engine is running th...

Page 15: ...ling fuel Keep fuel well away from naked flames and sparks Avoid repeated or prolonged contact with skin or breathing of vapour Be careful not to spill fuel when refuelling Refill fuel only with suitable filling devices e g funnel Wipe up spills immediately Make sure that any fuel spillages have completely evapo rated before starting the engine After refuelling make sure the tank cap is closed pro...

Page 16: ...erly cooled down The transmission of vibrations to the human body causes ad verse health effects Although the operating guide handle is vibration cushioned via rubber buffers a complete decoupling of vibrations is unachievable Wear padded gloves During the work process incorporate vibration free activi ties with mainly dynamic demands on muscles The majority of the components and parts used are su...

Page 17: ... fuel lubricants etc All prerequisites for carrying out work safely have been met with regard to you and other persons material property and the environment Beware of the particular dangers of the product and your work area especially persons and obstacles adherence to safety clearances traffic on adjacent tracks secure fitting of all protective equipment compliance with all operationally necessar...

Page 18: ...be taken in individual cases With smouldering fires in electrical equipment toxic vapours are released from charring cables also with fires of fuels oil or paints Everybody is obliged as far as possible and reasonable to refrain from any actions that may cause a fire or favour the spreading of a fire In addition all measures required to prevent the development or spreading of a fire must be taken ...

Page 19: ...Consumption approx 1 7 l h Exhaust emissions Corresponds to Euro II 3 2 Grinding spindle Maximum speed of output shaft 4 200 rpm Mounting diameter for abrasive 30 mm Fastening thread M20 3 3 Dimensions Length 2 070 mm Width 1 170 mm Height 1 030 mm Distance between rollers 1 045 mm 3 4 Filling quantities Fuel petrol 4 l Engine Engine oil SAE 10W 30 approx 0 6 l 3 5 Weight Standard version with fil...

Page 20: ...unging depth is controlled steplessly Plunging depth of the grinding spindle 0 185 mm Spindle pitch 4 mm rotation Screening Approx 0 19 mm per click Value Range Revolutions per minute RPM 0 60 000 RPM Max value of revolutions per minute ever reached RPM 0 60 000 RPM Operating hours 00 99 999 hours Value Resolution Revolutions per minute RPM 1 RPM Max value of revolutions per minute ever reached RP...

Page 21: ...ion Hand Arm Vibra tions 3 10 Environmental conditions Temperature range 3 11 Structure gauge Fig 1 Structure gauge Emission sound pressure level LpA 82 dB A Sound power level LWA 102 dB A Vibration total value 4 51 m s2 Operation 30 C to 80 C Transport 30 C to 80 C Storage 30 C to 80 C ...

Page 22: ...ng carrying handles Modular design grinding spindle can be modified forother diameters See following figure Fig 2 Overview 1 Handwheel depth infeed 9 Clamping lever gauge adjustment 2 Air filter 10 Frame 3 Tank 11 Guide roller 4 Handles foldable 12 Handwheel horizontal adjustment 5 Angular scale 13 Handwheel tilt adjustment 6 Lateral guide rollers 14 Engine 7 Clamping lever extended angle adjustme...

Page 23: ...23 4 Description of machine 4 2 Design variants Diameter of abrasives Standard Ø125 mm optional Ø150 mm Fig 3 Abrasive Ø 125 mm Fig 4 Abrasive Ø 150 mm ...

Page 24: ...s foldable 2 Clamping lever for extended tilt range 6 Handwheel cross adjustment 3 Handwheel swivel mechanism with safety catch 7 Locking lever angle adjustment 4 Clamping lever gauge adjustment 8 Guide handle 4 3 2 Engine Fig 6 Control elements engine 1 Throttle lever Choke lever 2 Handle of recoil starter 3 Engine stop button ...

Page 25: ...to order 4 4 1 Abrasives steel brushes Fig 8 Ø 150 mm Fig 9 Ø 125 mm Fig 10 Ø 90 mm conical or cylindrical Fig 11 Steel brush Order number Ø 90 mm conical EDP no 987 808 1000 Ø 125 mm EDP no 900 200 0688 Ø 150 mm EDP no 900 200 0690 Steel brush EDP no 900 020 0182 ...

Page 26: ...ption of machine 4 4 2 Tool box 4 5 Field of application Fig 13 Field of application Fig 12 Tool box Order number for toolbox EDP no 512 893 0001 1 Open track 4 Frog noses 2 Switch tongue 5 Frog area 3 Check rails ...

Page 27: ... Abrasive Ø 125 mm EDP no 900 200 0688 or Ø 150 mm EDP no 900 200 0690 Frog noses Abrasive Ø 90 mm conical EDP no 987 808 1000 Frog area Abrasive Ø 90 mm conical EDP no 987 808 1000 Ø 125 mm EDP no 900 200 0688 Ø 150 mm EDP no 900 200 0690 or or Rust removal Steel brush Steel brush EDP no 900 020 0182 Nut EDP no 893 100 2007 4 6 Signs and Labels 4 6 1 Signs and Labels used Fig 14 Label Instructed ...

Page 28: ...c tive gloves Fig 17 Label Read and obey instructions Fig 18 Label Crushing hazard Fig 19 Label Lift here Fig 20 Label Fuel and tank capacity Fig 22 Label Direction of rota tion Fig 21 Label Wear ear and eye protection Fig 23 Label Logo of manu facturer ...

Page 29: ...ructions 6 Label Fuel and tank capacity 2 Label Wear eye protection 7 Label Instructed personnel only 3 Label Wear protective gloves 8 Label Logo of manufacturer 4 Type label 9 Label Lift here 5 Label Logo of manufacturer Fig 25 Signs and labels Side 1 Label Direction of rotation 2 Label Logo of manufacturer ...

Page 30: ... rail Ideally the operator stands between the rails of the track and grabs the guiding handle with both hands or when appropriate has one hand on the guiding handle and the other on the handwheel for depth feed In this way the rail head and its inner shoulder can be conven iently reached by tilting the grinding machine towards the op erator The possibility of the structural gauge as per DIN EN 152...

Page 31: ...re the abrasives in a dry place making sure they do not come in contact with moisture oil or grease 2 Store the abrasives in appropriate shelves or containers in such a way that on the one hand they cannot be damaged and on the other hand they can easily be unloaded with out relocating Older stock ought to be used first 3 Observe the following rules for storage Keep the abrasives in a dry and fros...

Page 32: ...uel from spilling out The temperature range for transporting the machine is 20 C to 70 C The machine can be transported on all transport routes without incurring any damage if it is properly tied down and in its origi nal packaging Risk of damage When transporting the machine the clamping lever for gauge adjustment can break off if it comes into contact with other objects Make sure that the clampi...

Page 33: ... minute right When the engine is not running the tach hourmeter displays the actual number of operating hours When the engine is running the tach hour meter dis plays the actual RPM of the engine 1 Press button 2x The display shows 2 RPM and the max RPM stored Fig 29 Max RPM stored If no button is pushed for around 8 seconds the display automatically switches back to standard mode ...

Page 34: ...e engine is used Fig 30 Setting for two stroke engines Fig 31 Setting for four stroke engines 1 Press the button 1 time The display shows 1P1r or 2P1r 2 Press the button again and hold for around 4 seconds The display flashes 3 Press the button 1 time The display is showing the other setting By pushing the button again the display toggles between the two settings 4 Set 1P1r for two stroke engines ...

Page 35: ...s There is a danger of the transporting device rolling away on inclines This could result in impacts with people or rail vehicles After putting the machine on the rails check the function of the deadman s brake straight away 1 Check the function of the deadman s brake 6 2 3 Putting the machine on the rails Risk of injury The machine is too heavy for one person alone An injury of the vertebral colu...

Page 36: ...el of the adjusting spindle until the bottom edge of the cup wheel is within the swivel axis of the grind ing unit Fig 32 Abrasive completely retracted 2 First put the machine down on the rail on the right hand side with the flanged wheels of the running rollers 1 Fig 33 Re railing the machine 1 Running rollers with flanged wheels on r h s 2 Gauge adjustment clamping lever both sides 3 L h s runni...

Page 37: ... the abrasive pads for cracks or other damage frac tures and adequate height Check safety devices for correct seating and integrity Check welds for proper condition Check the integrity and free movement of the tilt adjust ment Check the integrity and free movement of the height ad justment Check the integrity and free movement of the cross ad justment See also chapter on maintenance Inspecting the...

Page 38: ...the air filter housing and mount air filter cover NOTICE Risk of damaging the air filter If compressed air is used to clean the air filter the sensitive filter elements may be destroyed Brushing forces the dirt into the fibres Do not use compressed air to clean or dry the air filter Do not brush the dirt away 1 Tap the filter 2 several times on a hard surface to remove dirt 2 Wipe dirt from the ai...

Page 39: ...the en gine stopped 2 Remove the oil filler cap 1 Fig 35 Checking the oil level 3 To check the oil level insert the oil filler plug dipstick into the oil filler neck as shown without screwing it in and then remove it Risk of engine damage The use of non soluble oils or two stroke oils has an adverse effect on the service life of the engine Do not use non soluble oils or two stroke oils 4 Remove th...

Page 40: ...y closed Be careful not to spill any petrol when refill ing Before starting the engine without fail ensure any area of spilled fuel is totally dry and the fuel vapours have evaporated Avoid repeated or prolonged fuel contact with the skin and avoid breathing in its fumes Store petrol safely out of the reach of chil dren Risk of engine damage Contaminated petrol can lead to engine damage Do not use...

Page 41: ...ing the engine WARNING Risk of accident If the friction setting on the depth feed is too low on starting the engine the grinding disc may be lowered unintentionally due to the vibrations The grinding disc then acts like a friction wheel and sets the machine in motion along the rail Make sure the abrasive is retracted right to the top Use the knurled nut to adjust the hand wheel friction to the max...

Page 42: ...d that all safety devices are fitted Risk of injury Danger of getting caught or abrasions if the abrasive is touched when the engine is start ed Do not reach into the danger zone Be aware that the abrasive rotates as soon as the engine starts even during start up Preparing to start 1 The throttle lever should always be set to idle 2 Set the engine switch 1 to ON Fig 37 Preparing to start 1 Engine ...

Page 43: ...n the engine is warm or the air temperature is high Best starting conditions when engine is al ready warm Set the throttle lever to half position half throttle 1 Open fuel tap 2 Position as shown infigure Fig 38 Open fuel tap 1 Engine switch in Position ON 2 Fuel tap in position ON open 2 Push the throttle lever 1 beyond the full throttle position to Choke Fig 39 Throttle lever in Choke position ...

Page 44: ...l starter If you just let go of the starter handle after the start up pro cess it can get damaged Do not allow the starter handle to snap back against the engine but move it back gently 3 Pull the starter handle gently several times until the engine briefly fires Fig 40 Pull starter handle 4 Set the throttle lever to Full throttle and vigorously pull the starter handle all the way The engine start...

Page 45: ...tures when running or fragments of a previously damaged abrasive are flying around Perform a test run complying with the following guidelines Start the machine correctly and perform a test run during ini tial commissioning and after each time the abrasive is re placed 1 Position the machine so that the abrasive can turn freely and without hindrance 2 Make sure that no one is standing in the danger...

Page 46: ...nding the rail head radii 3 Lock the horizontal adjustment into place clampinglever 4 Adjust the height of the abrasive infeed first flying sparks 5 Grind with reciprocating movements 6 6 2 Positioning the grinding spindle Fig 41 Horizontal adjustment Turn the handwheel 1 clockwise red arrows to move the spindle axis towards the rail centre Turn the handwheel 1 counter clockwise green arrows to mo...

Page 47: ...eel for angle adjustment 4 Ratchet lever 1 Release the ratchet lever 4 pressing it inwards blue ar row Turn the handwheel 3 counter clockwise green ar rows to move the spindle axis towards the centre of the rail Turn the handwheel 3 clockwise green arrows to move the spindle axis towards the outside of the rail The tilting angle is displayed on a scale Adjustment 20 80 1 Release the clamping lever...

Page 48: ...g the guide handles over the area to be worked on with reciprocating movements 2 Feed the abrasive using the handwheel 1 as required Fig 44 Grinding with reciprocating movement 6 7 Switching off the engine Risk of engine damage The engine can be damaged if it is stopped suddenly when operating at a high speed Before switching off the engine when it has been running at high speed and under full loa...

Page 49: ...r to STOP Slow 2 Turn the engine switch to OFF Fig 45 Setting the engine switch to the OFF position Engine stops 3 Close the fuel tap 4 Also turn off the fuel tap whenever a work break exceeds 15 minutes If the engine is not going to be used for a prolonged period wait until the carburettor is empty and the engine stops ...

Page 50: ... machine off the rail with suitable lifting device 6 8 2 Emergency procedure Risk of damage If the machine is unrailed in a hurry and as a result put down harshly without the abrasive being fully retracted into the protective hood the abrasive or machine may get damaged After unrailing the machine in a hurry check the machine and repair it if necessary 1 Stop engine 2 Lift the machine off the rail...

Page 51: ... work Risk of engine damage There is a risk of damage if the spare parts used do not meet the specified quality requirements Use only original spare parts or parts of equivalent speci fication 1 Use only the recommended lubricants and when carrying out repairs use only original spare parts This is important firstly for warranty cases and secondly to enhance the operational reliability of the produ...

Page 52: ...ate the operating hours counter Interval Component Maintenance work After each de ployment or every 2 hours Engine oil Check oil level Air filter Check 1 Clean 1 After the first month or after the first 5 hours Engine oil Change Every 25 operat ing hours Air filter Replace 2 After every season or every 50 oper ating hours Engine oil Change 2 Air filter Check Spark plug Check adjust replace Every 1...

Page 53: ...d skills Inspection and adjustment of the engine at regular intervals are prerequisites for long lasting high performance Regular maintenance contributes to a long service life The required maintenance intervals and type of work to be carried out are described in the table in chapter 7 1 see also the en gine manufacturer s original operating instructions ROBEL recommends replacing air filters and ...

Page 54: ...dipstick into the oil filler neck as shown without screwing it in and then remove it NOTICE Risk of engine damage The use of non soluble oils or two stroke oils has an adverse effect on the service life of the engine Do not use non soluble oils or two stroke oils 4 dipstick remove the oil filler plug dipstick and top up with the recommended oil as far as the upper limit 3 Do not overfill Recommend...

Page 55: ...your local waste oil collection point Drain the oil while the engine is still warm to ensure speedy and complete draining Basic sequence engine not mounted to machine 1 Turn the fuel tap to the OFF position so that no fuel can leak out 2 Place a large container pan etc Fig 47 Changing the oil 1 Oil filler plug dipstick 2 Oil filler neck 3 Upper limit 3 Remove the oil filler plug dipstick 1 and til...

Page 56: ...ount ed to machine 1 Remove the oil filler plug dipstick 2 Tilt the engine approx 80 inwards Fig 48 Tilt the engine 80 inwards and lift the whole machine 3 Lift the whole machine The engine oil drains approx 550 ml Fig 49 Engine oil drains ...

Page 57: ...s has an adverse effect on the service life of the engine Do not use non soluble oils or two stroke oils Recommended oil SAE 10W 30 1 Bring the engine and the machine back to its original posi tion 2 Fill in the oil use a oil can with flexible outlet or a funnel Filling quantity 550 ml Fig 50 Filling with oil ...

Page 58: ...e oil level insert the oil filler plug dipstick into the oil filler neck as shown without screwing it in and then remove it 2 Remove the oil filler plug dipstick and top up with the rec ommended oil as far as the upper limit 3 Do notoverfill 3 Re insert the oil filler plug dipstick 1 ...

Page 59: ... low flash point solvents for cleaning the air filter insert Risk of increased engine wear If the engine is operated without an air filter particles of dust can enter the combustion chamber Scoring of the en gine moving parts occurs pistons and cylinders The engine loses compression and hence performance Never leave the engine running without the air filter Risk of damaging the air filter If compr...

Page 60: ...tion 4 Reinstall the filter element into the air filter housing 3 and mount air filter cover NOTICE Risk of damaging the air filter If compressed air is used to clean the air filter the sensitive filter elements may be destroyed Brushing forces the dirt into the fibres Do not use compressed air to clean or dry the air filter Do not brush the dirt away 1 Tap the filter 2 several times on a hard sur...

Page 61: ...or normal engine operating temperatures Risk of engine damage The engine may be damaged if a spark plug with inadequate heat range is used Use a spark plug with adequate heat range Risk of burns from hot silencer During engine operation the silencer will get hot If the engine was in operation a short time earlier be careful not to touch the silencer 1 Remove the spark plug connector 2 Clean the su...

Page 62: ...d the spark plug if there is apparent wear or if the insulator is cracked or chipped 5 Measure the spark plug gap with a feeler gauge 6 Correct as necessary by bending the side electrode Spark plug gap 2 0 70 0 80 mm 0 028 0 031 Fig 54 Spark plug gap 1 Sealing washer 2 Spark plug gap ...

Page 63: ... the sealing washer 7 3 Lubricate 8 After the spark plug is seated tighten it with a spark plug wrench to compress the sealing washer 9 Reattach the spark plugconnector 7 4 Changing the abrasive Maintenance schedule see ch 7 1 Check adjust clean and lubricate all other moving parts as required After 50 operating hours lubricate the two grease nipples on the spindle housing with friction bearing gr...

Page 64: ...s on the grind ing shaft 5 Loosen and unscrew the central nut counter clockwise with the AF 30 spanner 6 Remove the abrasive 7 Push a new or desired abrasive onto the shaft 8 Screw on the M20 nut and tighten it clockwise to 60 to 100 Nm with the AF 30 spanner 9 Remove the AF 30 open ended spanner from the slot of the protective cover 10 Loosen the 4 wing nuts 1 andslide the protective cover 2 down...

Page 65: ...esult in damage caused by water getting into the motor silencer air filter carburettor and articulated joints of the product Do not use any solvents or aggressive combustible cleaning fluids Do not use petrol for cleaning Do not use a jet of water or a high pressure washer Risk of engine damage Dirt or dust adhering to the cylinder fins can cause piston seizure because heat cannot be dissipated Ke...

Page 66: ...lug clean and dry it Engine dies when idling Idling speed is too low Adjust the idling speed Engine does not run at 3 800 rpm minimum Throttle lever is not at Full throttle Set throttle lever to Full throttle See engine manufacturer s operating instructions for other possible causes of faults Engine gets hot poor perfor mance Chocked fuel filter Clean fuel filter Engine runs unevenly with poor per...