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Summary of Contents for ROBEL ROGRIND P4 190 SWITCH 2.0
- Page 1 Content OPERATING MANUAL ROGRIND P4 190 SWITCH 2.0 Rail and switch grinding machine...
- Page 2 Translation 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.
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Page 3: Table Of Contents
Content Content General Information........................6 About these instructions........... 6 General Regulations............6 Intended audience for this Operating Manual....7 Liability Exclusions.............7 Copyright................8 Acceptance, Equipment and Operating Licence.....8 Validity of these instructions..........8 Safety.............................9 Designated use..............9 Foreseeable misuse............9 Conventions of layout............10 Design changes, original parts........10 Protective devices............11 Safety regulations............11 Qualifications of staff............12... - Page 4 Content Description of machine......................22 Structure................22 Design variants..............23 Control elements............. 24 4.3.1 Machine................24 4.3.2 Engine................24 Accessory (to order)............25 4.4.1 Abrasives, steel brushes..........25 4.4.2 Tool box................26 Field of application............26 4.5.1 Necessary/optional equipment........27 Signs and Labels..............27 4.6.1 Signs and Labels used............ 27 4.6.2 Position on the product...........29 Digital tach/hour meter..........
- Page 5 Content 6.8.2 Emergency procedure Maintenance..........................51 Maintenance schedule............ 52 7.1.1 Engine................52 7.1.2 Machine................53 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 Lubricate................63 Changing the abrasive............ 63 Check signs and labels...........
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Page 6: General Information
ROBEL Bahnbaumaschinen GmbH together with its customer service organizations are however happy to provide further advice, training or other consultative services. Further details... -
Page 7: Intended Audience For This Operating Manual
1. General Information Intended audience for this Operating Manual This manual contains the information needed to use the prod- uct they describe correctly. The manual has been written exclusively for technically quali- fied personnel. Qualified personnel in this context are: Personnel who can prove that they are qualified to use this ... -
Page 8: Copyright
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, whether for payment or not. -
Page 9: Safety
2. Safety Safety Designated use The rail and switch grinding machine ROGRIND P4 190 SWITCH 2.0 has been designed and manufactured for true-to- form grinding of welding joints, running surfaces, rail shoulders and rail head side faces of steel rails with a flat bottom profile in manual operation, without the use of coolant lubricant, and must not be used for anything else. -
Page 10: Conventions Of Layout
2. Safety Conventions of layout These instructions make use of the following warning texts and symbols to keep the operator safe and injury-free and prevent damage to the material assets of the operating company: DANGER Indicates that non-compliance with the in- structions will result in death or severe (irre- versible) injuries of the operating personnel. -
Page 11: Protective Devices
2. Safety Protective devices Danger to life for the operator and others from manipulation of the safety devices! ► The operator is obliged to actually fit the designated pro- tective devices during operation or to leave them in the predetermined factory position. ►... -
Page 12: Qualifications Of Staff
2. Safety Qualifications of staff Operator The operator was trained by the operating company in the tasks assigned to him and informed of the potential dangers arising from inappropriate behaviour. Comprehensive training on the product Requirements for the operator ... -
Page 13: Information On Particular Types Of Dangers
2. Safety Information on particular types of dangers Danger due to manual If the permissible per-person lifting weight is exceeded when handling lifting or carrying, there is a risk of injuring muscles, tendons, joints or bones. ► Prior to transportation, ensure that the pathway is free of obstructions or trip hazards. - Page 14 2. Safety Danger from rotating parts Risk of clothing getting caught in and wound onto rotating parts (grinding disk, socket etc.). Crushing injuries to fingers and hands from rotating parts and abrasives. ► Wear appropriate, close-fitting clothing that cannot be caught by rotating machine parts of saw blades.
- Page 15 2. Safety ► Wearers of pacemakers must not carry out any work on the ignition system. Danger of poisoning from exhaust gases. The exhaust gases contain carbon monoxide, a colourless, odourless and toxic gas. If breathed in, carbon monoxide can lead to severe brain injuries or even death.
- Page 16 2. Safety Danger from noise 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. ►...
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Page 17: Accident Prevention
2. Safety 2.10 Accident prevention The accident prevention regulations of the Civil Engineering association also find application in these operating instructions and are to be carefully read and adhered to. ► Always observe the general and internal accident preven- tion regulations. ►... -
Page 18: Fire Safety
2. Safety First Aid Ensure the following to be able to provide First Aid in an emer- gency: ► Make sure that the First Aid kit is in proper condition, com- plete and clean at all times. ► Consult the medical service or doctor at your office regard- ing First Aid measures and appropriate equipment. -
Page 19: 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 4,200 1/min approx. 5 kW Fuel Regular petrol, min. 91 RON (corresponds to 86 octane) Consumption approx. 1.7 l/h Exhaust emissions... -
Page 20: 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 rpm 3.6.2 For rail head widths up to 120 mm These abrasive discs must be ordered separately. -
Page 21: Noise Emissions
3. Technical data 3.9.1Noise emissions Emission measurements Emission sound pressure level L 82 dB(A) Sound power level L 102 dB(A) 3.9.2 Vibration Vibration ‘Hand-Arm Vibra- Vibration total value 4.51 m/s tions’ 3.10 Environmental conditions Temperature range Operation -30°C to 80°C Transport -30°C to 80°C Storage... -
Page 22: Description Of Machine
4. Description of machine Description of machine Structure The practical design offers the following features: Powerful drive motor Travelling gear, with roller bearing, wheels made frominsu- lating material Easily replaceable guide rollers Folding carrying handles Modular design, grinding spindle can be modified forother ... -
Page 23: Design Variants
4. Description of machine 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: Control Elements
4. Description of machine Control elements 4.3.1 Machine Fig. 5: Control elements machine Handwheel depth infeed Handles (foldable) Clamping lever for extended tilt range Handwheel cross adjustment Handwheel swivel mechanism with safety Locking lever angle adjustment catch Clamping lever gauge adjustment Guide handle 4.3.2 Engine Fig. -
Page 25: Accessory (To Order)
4. Description of machine Fig. 7: Fuel tap (arrow) Accessory (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 Fig. 11: Steel brush cylindrical) Order number: Ø... -
Page 26: Tool Box
4. Description of machine 4.4.2 Tool box Fig. 12: Tool box Order number for toolbox: EDP no. 512 893 0001 Field of application Fig. 13: Field of application Open track Frog noses Switch tongue Frog area Check rails... -
Page 27: Necessary/Optional Equipment
4. Description of machine 4.5.1 Necessary/optional equipment Open track Abrasive: Ø 125 mm, EDP no. 900 200 0688 – Ø 150 mm, EDP no. 900 200 0690 – Switch tongue Abrasive: Ø 125 mm, EDP no. 900 200 0688 –... - Page 28 4. Description of machine Fig. 16: Label “Wear protec- Fig. 17: Label “Read and tive gloves” obey instructions” Fig. 18: Label “Crushing hazard” Fig. 19: Label “Lift here” Fig. 20: Label “Fuel and tank Fig. 21: Label “Wear ear and capacity”...
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Page 29: Position On The Product
4. Description of machine 4.6.2 Position on the product Fig. 24: Signs and labels Label “Read and obey instructions” Label “Fuel and tank capacity” Label “Wear eye protection” Label “Instructed personnel only” Label “Wear protective gloves” Label “Logo of manufacturer” Type label Label “Lift here”... -
Page 30: 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. 26: Example: display of actual RPM. Button Workplace The guiding handle is used to move the machine along the rail. -
Page 31: Operating Conditions
5. Operating conditions Operating conditions Operation From -20°C to max. +70°C (engine temperature) with slightly reduced performance when operated in altitudes up to 1000 m MSL. Storage Machine The temperature range for storing the machine is ― 20°C to +70°C. 1. -
Page 32: 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 33: Commissioning
6. Commissioning Commissioning Digital inductive tach/hour meter 6.1.1 Operation Display standard mode: Fig. 28: Operating hours (left) and revolutions per minute (right) When the engine is not running, the tach/hour meter – displays the actual number of operating hours. When the engine is running, the tach/hour meter dis- –... -
Page 34: 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 1. Press the button 1 time. The value “1P1r”... -
Page 35: Re-Railing
6. Commissioning Re-railing 6.2.1 Machine without dead man’s brake WARNING Risk of accidents! There is a danger of the transporting device rolling away on inclines. This could result in impacts with people or rail vehicles. ► Before putting the machine on the rails, make sure that a suitable device is avail- able that safely prevents the machine from rolling away. - Page 36 6. Commissioning NOTICE 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 clamping lever always points up- wards, so it is protected better. 1.
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Page 37: Checking The Machine
6.3.2 Engine See also chapter on maintenance. 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. - Page 38 6. Commissioning Fig. 34: Air filter Air filter cover Filter element Air filter housing Air duct 1. Remove the air filter cover (1). 2. Remove the filter element (2) from the air filter housing (3). 3. Check the filter element (2) to be sure it is clean and in good condition.
- Page 39 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 40 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.
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Page 41: Starting The Engine
6. Commissioning Fig. 36: 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 42 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! ►...
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Page 43: Cold Start
6. Commissioning 6.4.1 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 44 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.
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Page 45: Warm Start
6. Commissioning 6.4.2 Warm start 1. Open fuel tap. 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- cess it can get damaged. -
Page 46: Working With The Machine
6. Commissioning 6. If any of the above occurs, find out the reason, carry out remedial action. 7. Repeat the test run. Working with the machine 6.6.1 Basic approach grinding 1. Position the abrasive horizontally. 2. Tilt the grinding head (only when grinding the rail head radii). -
Page 47: Tilting The Grinding Spindle
6. Commissioning 6.6.3 Tilting the grinding spindle NOTICE Risk of damaging the rail! If the grinding spindle is tilted without the grinding tool being retracted, a dent will be ground into the rail. ► Retract the abrasive before adjusting the tilt. Range +25°/-20°... -
Page 48: Grinding Spindle Infeed
6. Commissioning 6.6.4 Grinding spindle infeed Fig. 43: Infeed using the handwheel Turn the handwheel clockwise (red arrow) Infeed Retract Turn the handwheel counter clockwise (green arrow) 6.6.5 Grinding with reciprocating movement 1. Move the machine using the guide handles over the area to be worked on with reciprocating movements. - Page 49 6. Commissioning Also let the engine run for a while (at idling speed) so that it can cool down). 1. Set the throttle lever to “STOP/Slow”. 2. Turn the engine switch to “OFF”. Fig. 45: Setting the engine switch to the “OFF” position Engine stops.
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Page 50: Unrailing The Machine
6. Commissioning Unrailing the machine CAUTION Risk of injury! The machine is too heavy for one person. Risk of spinal injury. ► Only transport the machine with a suitable lifting device or a crane. 6.8.1 Standard procedure 1. Stop engine. 2. -
Page 51: 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 52: Maintenance Schedule
(1) Service more frequently when operating the engine in extremely dusty areas. (2) Under heavy duty conditions and high outdoor temperatures change the engine oil every 25 hours. (3) These servicing points should only be carried out by authorised ROBEL after-sales service or directly in the works. -
Page 53: Machine
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 54: Checking The Oil Level
7. Maintenance 7.2.1 Checking the oil level 1. Check the oil level on horizontal ground and with the en- gine stopped. 2. Remove the oil filler cap (1) and wipe the dipstick clean. Fig. 46: 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. -
Page 55: 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 56 7. Maintenance 1. Remove the oil filler plug/dipstick. Real process (engine mount- ed to machine) 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.
- Page 57 7. Maintenance Filling with oil 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. Recommended oil: SAE 10W-30 1.
- Page 58 7. Maintenance Checking the oil level Fig. 51: Checking the oil level 1. 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. 2. Remove the oil filler plug/dipstick and top up with the rec- ommended oil as far as the upper limit (3).
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Page 59: 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 60 7. Maintenance Inspecting the air filter Clean dust and dirt from the air filter at regular intervals. Fig. 52: Air filter Air filter cover Filter element Air filter housing Air duct 1. Remove the air filter cover (1). 2. Remove the filter element (2) from the air filter housing (4). 3.
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Page 61: Maintaining The Spark Plug
7. Maintenance 7.2.4 Maintaining the spark plug To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. Recommended spark plug NGK BPR6ES Spare part spark plug: EDP No. 900 085 0377 The recommended spark plug has the correct heat rating for normal engine operating temperatures. - Page 62 7. Maintenance Fig. 53: Remove spark plug 4. Visually inspect the spark plug. Discard 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.
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Page 63: Lubricate
7. Maintenance 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. 7. Ensure that the sealing washer is satisfactory, then screw the spark plug back in by hand to avoid cross threading. - Page 64 7. Maintenance 2. Loosen 4 wing nuts (1) and lift the protective cover of the abrasive (3). Fig. 55: Lift the protective cover of the abrasive 3. Tighten wing nuts (1). 4. Place an AF 30 open ended spanner into the slot of the protective hood and engage the spanner flats on the grind- ing shaft.
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Page 65: Check Signs And Labels
7. Maintenance 12. Reset the angle adjustment of the grinding spindle (play almost vertical). 13. Perform test run, see ch. 6.5. Check signs and labels 1. Regularly check if all signs and labels are present and in proper condition. 2. Replace signs and labels if necessary. Cleaning and care NOTICE Risk of damage! -
Page 66: Troubleshooting
8. Troubleshooting Troubleshooting Error Cause Remedy ► Refill the tank Engine does not start No fuel ► Set engine switch to “ON” Engine switch is at “OFF” ► Open fuel tap Fuel tap closed ► Move choke lever to "CLOSE" Choke not used when engine is position cold...
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