ROBEL 13.45SKS Vers. 01 Operating Manual
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ROBEL 13.45SKS Vers. 01 Operating Manual

Rail head grinding machine
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OPERATING MANUAL
13.45SKS Vers. 01
Rail Head Grinding Machine

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  • Page 1 OPERATING MANUAL 13.45SKS Vers. 01 Rail Head Grinding Machine...
  • Page 2 Translation of original operating manual Status: 22.11.2017 Version 2 © 2017 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.

  • Page 3: Table Of Contents

    Content Content About these instructions ..........General Regulations............Intended Audience for this Operating Manual....Liability Exclusions ............Copyright ................ Acceptance, Equipment and Operating Licence.... Validity of these instructions.......... Safety............................Designated use............... Foreseeable misuse ............Conventions of layout............. Design changes, original parts........10 Protective devices ............
  • Page 4 Content .............Designvariants 4.3.1 Guide rollers ............... 24 4.3.2 Diameter of abrasives ............25 4.3.3 Guiding handle..............26 Control elements ............Accessory (to order)............Signs and Labels ............4.6.1 Signs and Labels used............30 4.6.2 Position on the product ............ 33 Digital tach/hour meter ..........
  • Page 5 Content 6.14 ..........Unrailingthemachine Maintenance......................... Maintenance schedule ..........Engine................7.2.1 Checking the oil level............66 7.2.2 Changing the oil..............68 7.2.3 Maintaining the air filter........... 69 7.2.4 Maintaining the spark plug ..........71 Lubrication..............Changing the abrasive..........Tensioning the V-belt............ 7.5.1 Checking V-belt tension ............ 77 7.5.2 Adjusting V-belt tension............

  • Page 6: About These Instructions

    ROBEL Bahnbaumaschinen GmbH together with its customer service organizations are however happy to provide further advice, training or other consultative services.

  • Page 7: Liability Exclusions

    Specific characteristics and particular attributes of the product are the intellectual property of ROBEL Bahnbaumaschinen GmbH. The copyright on its use remains with ROBEL Bahnbaumaschinen GmbH. It may not be reproduced either in full or in part, published or otherwise exploited for competitive purposes,...

  • Page 8: Acceptance, Equipment And Operating Licence

    2. Safety passed by company employees to anyone outside the busi-ness. Acceptance, Equipment and Operating Licence It is the buyer’s responsibility to check that the condition, fit- tings, performance and especially the safety features of the goods delivered match the relevant specifications agreed and to take account of the regulations specified in the contract.

  • Page 9: Safety

    2. Safety Safety Designated use The 13.45SKS rail head grinding machine is designed and built for true-to-form grinding of weld joints, running surfaces, rail shoulders and rail head side surfaces of Vignole steel rails in manual operation without the use of cooling lubricant. It may only be used for this purpose.

  • Page 10: Design Changes, Original Parts

    2. Safety 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. Design changes, original parts The manufacturer will not be liable if any unauthorised chang-es to product components and attachments are made.

  • Page 11: Qualifications Of Staff

    2. Safety If necessary, the office in charge of operation must lay down additional regulations and measures geared to the special tasks of the product to ensure that all safety requirements are met. In addition to the information mentioned above the specific safety regulations must be observed and adhered to.

  • Page 12: Information On Particular Types Of Dangers

    2. Safety Information on particular types of dangers Danger from rotating parts Risk of clothing getting caught in and wound onto rotating parts (grinding disk, socket etc.). Danger of contusions to fin-gers and hands from rotating parts and abrasives. ► Wear suitable close-fitting clothing that cannot get caught in rotating parts of the machinery or saw blades.
  • Page 13 2. Safety ► Switch off the engine and allow it to cool down before refill-ing, do not pour fuel over a hot engine or the exhaust. ► Refuel in a well-ventilated area with the engine stopped. ► Do not smoke when handling fuel. ►...

  • Page 14: Accident Prevention

    2. Safety Permanent damage, especially to hearing, if the operator does not constantly wear personal hearing protection. ► Wear ear protection. Danger from heat Risk of injury from touching hot parts. ► Do not touch heated parts. ► Prior to work on heated parts, switch off engines and allow hot parts to cool down for at least 30 minutes.

  • Page 15: First Aid

    2. Safety ► Check that the product is in proper working order before putting it into service: Equipment, devices, tools, accessories, safety equipment, • etc. are complete and intact. Inspection and maintenance work has been carried • out professionally and on schedule. Operating fluids have been topped up (fuel, lubricants, etc.) •...
  • Page 16 2. Safety In addition, all measures required to prevent the development or spreading of a fire must be taken in individual cases. With smoldering fires in electrical equipment toxic vapours are released from charring cables, also with fires of fuels, oil or paints.

  • Page 17: Technical Data

    3. Technical data Technical data Drive Type: Robel 190, air-cooled, single cylinder four-stroke engine Speed 4,200 1/min Output at 4,300 1/min 5.0 kW Fuel Regular petrol, min. 91 RON (corresponds to 86 octane) Consumption approx. 1.7 l/h Exhaust emissions Corresponds to...

  • Page 18: Abrasives

    3. Technical data Abrasives Grinding discs of bonded abrasive. 3.6.1 For rail head widths up to 75 mm Outer diameter 125 mm Inner diameter 56 mm Height 65 mm Maximum permissible speed 7,640 U/min 3.6.2 For rail head widths up to 120 mm These abrasive discs must be ordered separately.

  • Page 19: Noise Emissions

    3. Technical data Noise emissions The workplace emission values during operation depend on the tool used (abrasive) and the method of operation (e.g. pressure and feed rate). The stated values may therefore also vary. Since the noise level criterion for personnel is exceeded when working, suitable ear protection must be worn (see also na-tional statutory regulations as well as basic health and safety requirements).

  • Page 20: Structure Gauge

    3. Technical data 3.12 Structure gauge 3.12.1 Version with guiding handle on the left side Fig. 1: Structural gauge, Version with guiding handle on the left side, Grinding of rail head and rail head side surface on land side Fig. 2: Structural gauge, Version with guiding handle on the left side, Grinding of rail head and rail head side surface on track side...

  • Page 21: Version With Guiding Handle On The Right Side

    3. Technical data 3.12.2 Version with guiding handle on the right side Fig. 3: Structural gauge, Version with guiding handle on the right side, Grinding of rail head and rail head side surface on land side Fig. 4: Structural gauge, Version with guiding handle on the right side, Grinding of rail head and rail head side surface on track side...

  • Page 22: Description Of Machine

    4. Description of machine Description of machine Structure The practical design offers the following features: Powerful drive motor • • Fatigue-free ergonomic working is possible due to infinitely height adjustable guiding handle • Single-rail travelling gear, roller-bearing mounted with wheels of insulating material Easily changeable guide rollers •...

  • Page 23: Overview Of Machine

    4. Description of machine Overview of machine Fig. 6: Rail Head Grinding Machine Guiding handle, infinitely adjustable Handwheel height adjustment Drive motor Carrying handles, pluggable Place to attach carrying handles and additional equipment Guide roller, isolated Grinding spindle Clamping lever for guiding handle...

  • Page 24: Designvariants

    4. Description of machine Design variants 4.3.1 Guide rollers Standard guiding system For all work on rails outside of the switch area. Fig. 7: Standard guiding system Universal guiding system Particularly suitable for grinding switches Fig. 8: Universal guiding system...

  • Page 25: Diameter Of Abrasives

    4. Description of machine 4.3.2 Diameter of abrasives The variant with a 125 mm grinding disc diameter differs from the 150 mm variant only in the size of the cover of the abra-sive. If necessary, a switchover to the alternative variant is possible by exchanging both V-belt cover and the hood of the abrasive.

  • Page 26: Guiding Handle

    4. Description of machine 4.3.3 Guiding handle There are two design variants: Guiding handle on the right side • Guiding handle on the left side. • Guiding handle on the right side Fig. 11: Guiding handle on the right side The guiding handle on the right side is infinitely adjustable.

  • Page 27: Control Elements

    4. Description of machine Control elements Fig. 13: Control elements Handwheel height adjustment Handle recoil starter Engine switch Carrying handles Guiding handle Clamping lever for guiding handle Gas lever Fuel tap Friction adjustment for depth feed...

  • Page 28: Accessory (To Order)

    4. Description of machine Accessory (to order) Abrasive discs, cup wheel and steel brush Fig. 14: Ø 150 mm Fig. 15: Ø 125 mm Fig. 16: Ø 90 mm (conical or cylindrical)
  • Page 29 4. Description of machine Fig. 17: Steel brush...

  • Page 30: Signs And Labels

    4. Description of machine Signs and Labels 4.6.1 Signs and Labels used Fig. 18: Label „Instructed personnel only” Fig. 19: Type label (Example) Fig. 20: Label „Do not turn machine on this side“ Fig. 21: Label „Read and obey instructions“ Fig.
  • Page 31 4. Description of machine Fig. 23: Label “Fuel and tank capacity” Fig. 24: Label „Engine Robel 190“ Fig. 25: Label „EN 13977“ Fig. 26: Homologation number (France only) Fig. 27: Label „Direction of rotation“ Fig. 28: Label „Logo of manufacturer“...
  • Page 32 4. Description of machine Fig. 29: Label „Wear eye protection“ Regularly check that all signs and labels • are present and intact! Replace signs and labels if necessary! •...

  • Page 33: Position On The Product

    4.6.2 Position on the product Right side Fig. 30: Right side Label “Fuel and tank capacity” Label „Wear eye protection“ Label „Engine Robel 190“ Type label Label „Read and obey instructions“ Label „Crushing hazard“ Label “Logo of manufacturer” „Do not turn machine on this side“.

  • Page 34: Digital Tach/Hour Meter

    4. Description of machine Digital tach/hour meter The digital inductive Tach/hour meter is capable of displaying three values: Operating hours (engine off) • Actual RPM (engine running) • Max. RPM ever reached • Fig. 32: Example: display of actual RPM Workplace The guiding handle is used to move the machine along the rail.

  • Page 35: Operating Conditions

    5. Operating conditions Operating conditions Operation From –20°C to max. +70°C (Engine temperature) with slightly reduced performance at increasing altitudes up to 1000 MSL. Storage Machine The temperature range for storing the machine is ― 20°C to +70°C. Ensure that the place of storage is dry and dust-free.. Abrasives NOTICE Risk of damage!

  • Page 36: Transport

    5. Operating conditions Transport WARNING Danger of fire and explosion from spilt fuel or fuel vapour! If the machine is tipped over during transport, fuel can leak out. ► When transporting the machine, turn the fuel tap to "OFF" (CLOSED). ►...

  • Page 37: Commissioning

    6. Commissioning Commissioning Digital inductive tach/hour meter 6.1.1 Operation Display standard mode: Fig. 33: Operating hours (left) and revolutions per minute (right) When the engine is not running, the tach/hour meter – displays the actual amount of operating hours. When the engine is running, the tach/hour meter dis- –...

  • Page 38: Settings

    6. Commissioning 6.1.2 Settings The digital Tach/hour meter has been factory-set according to the engine used. Do not change settings without reason. • The digital Tach/hour meter can be used both for two- stroke and four-stroke engines. Check settings: Press the button 1 time. The value “1P1r”...

  • Page 39: Re-Railing

    6. Commissioning Re-railing CAUTION Risk of injury! The machine is too heavy for one person alone. Risk of spinal injury. ► Only transport the machine with suitable lifting gear, crane or at least a three-man team. NOTICE Risk of damaging the abrasives! the abrasive is outside the protective hood it can be easily damaged when being put on to the rail.

  • Page 40: Adjusting The Guiding Handle

    6. Commissioning Adjusting the guiding handle 6.3.1 Variant with guiding handle on the right The position of the guiding handle is infinitely adjustable. In the “locked” position, a clamping lever with a cam presses against brake shoes and thereby retains the guiding handle in the de-sired position.
  • Page 41 6. Commissioning Fig. 39: Moving the guiding handle into the desired position 3. Tighten the clamp. Fig. 40: Tightening the clamp. The height of the guiding handle is adjusted.
  • Page 42 6. Commissioning Fig. 41: Side grinding (handle on the right)

  • Page 43: Variant With Guiding Handle On The Left

    6. Commissioning 6.3.2 Variant with guiding handle on the left 1. Operate the latch (1) by foot. Fig. 42: Operating the latch The locking (2) of the guiding handle is released. 2. Move the guiding handle into the slewed position for the side grinding (see illustration below).

  • Page 44: Fitting Additional Equipment

    6. Commissioning Fitting additional equipment The holders for the carrying handles are also used to hold the additional equipment. If additional equipment is to be used, the carrying handles must first be removed. Tools required: 2x AF 16 open-ended spanners •...

  • Page 45: Mounting The Guide Rollers

    6. Commissioning Mounting the guide rollers The guide rollers are mounted on the machine by plugging in via a splined shaft and securing them via an AF 19 screw. Us-ing a splined shaft ensures the guide rollers always have the same alignment to the guiding handle. Depending on the particular application, it may be necessary to fit different guide rollers in order to grind switches or their frogs, for example.

  • Page 46: Fitting The Guide Rollers

    6. Commissioning 6.5.2 Fitting the guide rollers 1. Insert the new guide rollers (4) into the holder ensuring correct orientation of the splined shaft (3). Fig. 46: Fitting the guide rollers Hexagon screw AF 19 Washer Splined shaft Guide rollers 2.

  • Page 47: Adjusting The Spacing Of The Guide Rollers

    6. Commissioning Adjusting the spacing of the guide rollers The spacing of the guide rollers of the standard guiding system can be adjusted in steps of 2 mm using 4 distance discs. Upon delivery the 4 distance discs are mounted inside and the spac- ing is at maximum as a result.

  • Page 48: Adjusting The Friction Of The Depth Feed

    6. Commissioning Adjusting the friction of the depth feed The friction of the depth feed can be infinitely adjusted to suit the operator’s personal needs. Upon delivery the friction is set to a high level so that the grinding spindle does not move downwards unintentionally when the engine is first started.

  • Page 49: Checking The Machine

    6. Commissioning Checking the machine 6.8.1 Abrasive and grinding spindle WARNING Risk of injury! Abrasives whose use-by date has expired or abrasives with dents or cracks can burst dur-ing operation! Fragments can fly everywhere and cause serious injuries. ► Do not use abrasives whose use-by dates have expired.

  • Page 50: Motor

    6. Commissioning 6.8.2 Motor ROBEL recommends replacing air filters and spark plugs at regular intervals in line with the specifications in the maintenance schedule. Only perform the described cleaning proce- dures on air filters and spark plugs in an emergency, i.e. if no spare parts are available.
  • Page 51 6. Commissioning 7. Set the paper element and screen grid in the air cleaner body then install the air cleaner cover. Cleaning the air filter NOTICE Risk of damaging the air filter! If compressed air is used to clean the air filter, the sensitive filter elements may be destroyed.
  • Page 52 6. Commissioning Engine oil NOTICE Risk of engine damage! There is a risk that engine lubrication will not work if the oil level falls too low. The engine will be seriously damaged. ► Make sure the engine is operated with a sufficient amount of oil.
  • Page 53 6. Commissioning 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).
  • Page 54 6. Commissioning Fuel WARNING Risk of fire or explosions! Petrol is highly flammable and under certain conditions can be explosive. Petrol vapour or spilled fuel could ignite. ► Refill the tank only in a well-ventilated place and with the engine switched off. When refilling and at places where fuel is stored, do not smoke and keep well away from naked flames or sparks.

  • Page 55: Starting The Engine

    6. Commissioning Fig. 52: Refuelling Fuel level mark Max. fuel level 2. Top up with fuel up to the lower edge of the max. mark in the fuel tank neck. Do not overfill. 3. Screw the fuel cap back on again. 4.
  • Page 56 6. Commissioning WARNING Danger from toxic gases! The exhaust gases contain toxic carbon mon- oxide. ► Never allow the engine to run in closed or poorly ventilated spaces. Risk of an accident! As soon as the engine is started, the grinding disc turns! ►...

  • Page 57: Cold Start

    6. Commissioning 6.9.1 Cold start The choke is needed in cold weather or when the engine is cold to enrich the mixture by narrowing the cross section of the suction inlet. Do not use the choke when the engine is •...
  • Page 58 6. Commissioning CAUTION Risk of injury” If you just let go of the starter handle after the start-up process, it can cause injury to the fingers, hands and arms. ► Do not allow the starter handle to snap back against the engine but move it back gently.. NOTICE Risk of damage to the recoil starter! If you just let go of the starter handle after the start-up pro-...

  • Page 59: Warm Start

    6. Commissioning 6.9.2 Warm start 1. Open fuel tap. 2. Move gas lever to „Choke“ position. CAUTION Risk of injury! Risk of injury to fingers, hands and arms. ► Do not allow the starter handle to snap back against the engine but move it back gently. NOTICE Risk of damage to the recoil starter! If you just let go of the starter handle after the start-up pro-...

  • Page 60: Test Run

    6. Commissioning 6.10 Test run WARNING Risk of accidents! Risk of serious injuries, when a non-circular abrasive fractures when running or fragments of a previously damaged abrasive are flying around. 1. 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.

  • Page 61: Working With The Machine

    6. Commissioning 6.11 Working with the machine 6.11.1 Grinding Vignole rails The machine is tailored to the required grinding pressure through its self-weight. During the grinding of the sides of the rail head the machine is pulled on to the rail by the guide discs, thus generating the required grinding pressure.

  • Page 62: Retracting The Grinding Disc And Increasing The Friction Of The Depth Feed

    6. Commissioning 4. Also turn off the fuel tap whenever a work break exceeds 15 minutes. 5. If the engine is not going to be used for a prolonged period, wait until the carburettor is empty and the engine stops. 6.13 Retracting the grinding disc and increasing the friction of the depth feed Retract abrasive...

  • Page 63: Unrailingthemachine

    6. Commissioning Fig. 59: Depth feed Depth feed handwheel Bellows Knurled nut for adjusting the friction Fig. 60: Adjusting handwheel friction 6.14 Unrailing the machine CAUTION Risk of injury! The machine is too heavy for one person. Risk of spinal injury.. ►...

  • Page 64: Maintenance

    7. Maintenance Maintenance WARNING Risk of injury! During maintenance work the engine might be cranked and started unintentionally as a re-sult. ► Before commencing all maintenance work, switch off the engine. ► Before performing maintenance work, always disconnect the spark plug connect- ors to prevent accidental starting of the engine.

  • Page 65: Maintenance Schedule

    (2) Under heavy duty conditions and high outdoor tempera- tures change the engine oil every 25 hours. (3) These servicing points should only be carried out by author- ised ROBEL after-sales service or directly in the works. Interval Component Maintenance work...

  • Page 66: Engine

    7.1 (see also the en-gine manufacturer’s original operating instructions). ROBEL recommends replacing air filters and spark plugs at regular intervals in line with the specifications in the maintenance schedule.
  • Page 67 7. Maintenance 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).

  • Page 68: Changing The Oil

    7. Maintenance 7.2.2 Changing the oil WARNING Risk of injury! Repeated and prolonged skin contact with old engine oil may cause skin cancer. ► Wear protective gloves. ► Wash your hands thoroughly with water and soap immediately after each contact with used oil.

  • Page 69: Maintaining The Air Filter

    7. Maintenance 7.2.3 Maintaining the air filter A dirty air filter will restrict air flow to the carburettor. To pre- vent carburettor malfunction, clean the air filter regularly. Clean the filter more frequently when operating the engine in extremely dusty surroundings. WARNING Risk of fire or explosion!! petrol or low flash point solvents are used for...
  • Page 70 7. Maintenance Inspecting the air filter Clean dust and dirt from the air filter at regular intervals. Fig. 63: Air filter Latch tabs Paper element Air filter cover Air filter body Foam element Air duct Screen grid 1. Press the latch tabs (1) on the top of the air cleaner cover (2), and remove the cover.

  • Page 71: Maintaining The Spark Plug

    7. Maintenance Cleaning the air filter 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. ►...
  • Page 72 7. Maintenance NOTICE 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! CAUTION Risk of burns from hot silencer! During engine operation, the silencer will get hot.
  • Page 73 7. Maintenance Fig. 65: Spark plug gap Sealing washer Spark plug gap NOTICE Risk of engine damage! A loose spark plug may become very hot. Over-tightening of the spark plug may damage the thread in the cylinder head. ► Tighten the spark plug to the prescribed torque. 8.

  • Page 74: Lubrication

    7. Maintenance Lubrication Maintenance schedule: see Ch. 7.1. • Check, clean, readjust and lubricate all other moving • parts as necessary. After every 50 operating hours, lubricate both grease nipples on the spindle housing with slide bearing grease, e.g. SHELL Retinax A. Fig.

  • Page 75: Changing The Abrasive

    7. Maintenance Changing the abrasive The machine is equipped with an M20 holder to retain abra-sives with a central nut. Fig. 68: Changing the abrasive AF 30 spanner AF 30 open-ended spanner 1. Insert the AF 30 open-ended spanner (2) into the slot in the protective hood and engage the spanner flats on the grind- ing shaft.

  • Page 76: Tensioning The V-Belt

    7. Maintenance Tensioning the V-belt The drive of the grinding spindle from the engine comes through a V-belt. The V-belt tensioning is via so-called distance discs which are inserted or removed from between the bevel discs. Fig. 69: Distance discs Fig.

  • Page 77: Checking V-Belt Tension

    7. Maintenance 7.5.1 Checking V-belt tension Tools, aids and materials: AF 13 open-ended spanner • Remove the V-belt cover 1. Loosen and unscrew the three AF 13 hexagon screws coun-ter- clockwise. Fig. 71: Fixing screws (arrows) for V-belt cover (version with 150 mm diameter abrasive) Fig.

  • Page 78: Adjusting V-Belt Tension

    7. Maintenance Depress the middle of the V-belt with the finger. The V-belt must not depress by more than about 7 mm. Re-tension the V-belt if it depresses by more than about • 7 mm. If the V-belt depresses by less than about 2 mm, •...
  • Page 79 7. Maintenance The work will be made far easier if the com- ponents are threaded onto one of the fixing screws in the correct order. This will ensure the screw holes are in alignment and the screws can be inserted without any difficulty. 1.

  • Page 80: Replacing The V-Belt

    7. Maintenance 7.5.3 Replacing the V-belt Replace the V-belt if it is torn or can no longer be re- tensioned because all distance discs between the conical discs have been removed. Spare part V-belt: EDP-No. 900 111 0127 Cleaning and care NOTICE Risk of damage! Cleaning the product with solvents, aggressive or...

  • Page 81: Troubleshooting

    8. Troubleshooting Troubleshooting Error Cause Remedy Engine does not start No fuel ► Refill the tank Engine switch is at “OFF” ► Set engine switch to “ON” Fuel tap closed ► Open fuel tap Choke not used when engine is ►...

  • Page 82: Environmental Protection And Disposal

    9. Environmental protection and disposal Environmental protection and disposal Environmental protection 1. While working on or with the product, comply with the legal regulations for waste prevention and proper recycling/ dis- posal and also follow the environmental laws applicable in the user country.

  • Page 83: Appendix

    Maschinen-Richtlinle Anhang defined 1MMachln y Olrective 421EC Annex "CE- ive aux lnes 6/42/CE.Annexe conlormément 1d.lrective â HerSleller (Name Ansch ROBEL Bahnbaumaschlnen GmbH ft): Manu acturer (n8me address): Industries raße 31 Fabri adresse): 0-83395 Freilassing Hlern erkl wir. dass die Schienenkopf-Schleifmaschine...

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