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GEISMAR MP.12 Manual

Rail profile grinding machine
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ANGLAIS
French Original handbook
Ref. : 450100 Gb
RAIL PROFILE GRINDING MACHINE
MEULEUSE DE PROFILS
MP.12

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Table of Contents
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Summary of Contents for GEISMAR MP.12

  • Page 1 ANGLAIS French Original handbook Ref. : 450100 Gb RAIL PROFILE GRINDING MACHINE MEULEUSE DE PROFILS MP.12...
  • Page 2 En cohérence avec notre politique de respect de l’environnement, cette notice a été réalisée sur un papier éco-responsable...
  • Page 3 GEISMAR / STUMEC, the fruit of over eighty years’ experience. Every day since 1924, the GEISMAR Group has been investing in research and state-of-the-art construction to offer you the quality and reliability so essential to the requirements of the world of railways.

  • Page 4: Table Of Contents

    1.4 – Specific safety instructions ....................11 4.2.1 – Use on Vignole rail ....................31 1.4.1 – Risks that can be generated by use of the MP.12 type grinding machine ..11 4.2.2 – Use on a grooved rail .................... 32 1.4.2 –...
  • Page 5 The information, drawings and descriptions available in this manual are What is the instruction handbook used for? confidential and remain the property of GEISMAR. On no account must they be This instruction handbook was drafted as per the information provided by the disclosed, lent, copied or used for manufacturing or sales purposes or for any Machines Directive 2006/42/EC.
  • Page 6 Information concerning the instruction handbook Pictograms Combustion engine explanations This instruction handbook refers to the rail profile grinding machine with Read this instruction handbook thoroughly and combustion engine known as MP12. fully before first use. Keep it in a safe place so you can read it again for future use.
  • Page 7 Pictograms Combustion engine explanations Minimum number of carriers Location of unobvious carrying handles Wheel rotation direction To stop the Honda engine On the lifting zones Ref. : 450100 FR P a g e...

  • Page 8: Chapter 1 - Safety

    You will find below a set of rules, You must possess the necessary training, skills GEISMAR Alpes remains at its disposal to provide observance of which will guarantee the and tools to use, service and repair the equipment...

  • Page 9: General Safety Requirements

    1.3 – General safety requirements 1.3.1 – The operator and his environment To guard against the risk of accident or Do not work with the machine until you are Do not work near a conductive rail. ■ ■ ■ injury, operators must wear: certain you can control it.

  • Page 10: The Operator And The Machine

    1.3.2 – The operator and the machine Before each use, check that machine operation Operations on the electrical installations of the ■ ■ Never touch a moving part with a and condition conform to the instructions. In machine can only be carried out by accredited utensil, with your hand or with any other particular, ensure that the control devices operate persons.
  • Page 11 Using and handling fuel and oils ■ Always keep appropriate extinguishers ready Always unscrew tank fuel filler caps slowly so If, for any reason, fuel has been spilled to use in all oil handling areas (storage, filling, as to allow pressure, if any, to dissipate around the filling area, clean it up immediately.
  • Page 12 The tools to be used on the machine The machine engine Using trucks (if applicable) ■ ■ ■ Only use the types of tools provided for A machine designed to work on a truck must Never touch the hot parts of the engine, normal use of the machine.

  • Page 13: Specific Safety Instructions

    1.4.1 – Risks that can be generated by - Only use authorised wheel types, both in terms - Do not use wheels that are damaged, split or use of the MP.12 type grinding of dimensions and composition characteristics. cracked machine...

  • Page 14: Environmental Conditions

    Due to the engine tilt possibilities imposed during work, the following rules must be complied with: Always bring the wheel to vertical position, stop grinding, and stop the engine before opening the fuel filler cap. Never fill the fuel tank with more than ¾ of its capacity (to avoid seepage when working with slanting engine). Never work on a fuel tank, or handle fuel for filling or any other reasons in zones where there may be: •...

  • Page 15: During Use

    1.4.4 – During use “Conform use” assumes compliance with the requirements inherent in the use and maintenance of the machine described in this handbook. Moreover, it is necessary to comply with all the industrial injury prevention instructions described and recommended, while also taking into account of the general safety rules and the legislation applicable in the country concerned.

  • Page 16: Safety Instructions And Pictograms

    1.4.5 – Safety instructions and pictograms The safety instructions and pictograms must be present on the machine in the positions provided. Should one of them be missing or damaged, a new one must be ordered immediately and fitted in the position provided. If a part bearing a pictogram has been replaced, check that a new pictogram has been fitted on the new part.

  • Page 17: Training Programme Instructions

    - Preservation of natural resources as the recycled material is used in the stead of the material that should have been extracted. - The GEISMAR product must be recycled | 15 Ref. : 450100 FR P a g e...

  • Page 18: Chapter 2 - Description Of The Machine

    Rail profile grinding machine Type: MP.12 The MP.12 rail profile grinding machine was designed to grind rail heads and welds, including the radius of curvature and sides. Its outstanding performances and sturdiness due to its non-deformable alloy rigid chassis ensure operators an optimum comfort of use.

  • Page 19: Overview

    2.2 - Overview Item Description Operating handle Wheel adjustment flywheel Engine stop Engine Handle Guide roller Wheel casing Limit stop Operating arm locking handle Wheel lowering locking handle Photographs and illustrations for information only and non-binding: they may include options | 17 Ref.

  • Page 20: Technical Characteristics

    2.3 – Technical characteristics ENGINE TYPE (Combustion) HONDA GX270 (4-stroke) Machine size Length / width / height 1120 / 760 / 800 Weight Machine (empty) Machine (in operation) 76.1 Noise Acoustic pressure level (Laeq) dB (A) (±2) dB (A) Acoustic power level (Lwa) (±2) Vibrations Vibration level (Aeq)

  • Page 21: General Information

    2.4 – General information 2.4.1 – Load distribution The diagram below defines load distribution as a percentage of machine weight. 26 % 23 % Load distribution when lifting, using the 25 % carrying areas or handles. 26 % ADVICE CONCERNING CARRYING OF HEAVY LOADS - Keep a straight back aligned with your pelvis and head, respecting the natural curvature of the spine - Force with your legs to prevent placing all the strain on your back.

  • Page 22: Handling The Machine

    2.4.2 – Handling the machine In accordance with the requirements of standard EN 13977:2011, Before moving the the authorised weight per person must not exceed 20kg per machine, ensure that the gripping zone, when the load is distributed over several persons, or engine is stopped 25kg for lifting by one person.

  • Page 23: Transporting The Machine

    2.4.3 – Transporting the machine 2.4.4 – Installing the machine on the rail The machine must be transported by a ■ means of locomotion appropriate for its With the help of 4 operators, grip the ■ weight and size. machine by the 4 carrying zones ②...

  • Page 24: Storage

    2.4.5 - Storage ■ General storage instructions ■ Storage protection When the equipment is not in use, it must be stored to preserve its integrity. Choice of storage protection systems depends on 2 main factors: Badly stored equipment could deteriorate during its use. Therefore, it is - storage duration important that the personnel responsible for the storage operations take the - storage conditions: “unsheltered”...

  • Page 25: Control And Ergonomic Parts

    2.4.6 – Control and ergonomic parts ■ Operating arm locking handle: ■ Wheel adjustment flywheel Item ② Used to adjust wheel lowering - Operating arm ① FOLDED the operator can tilt the machine against Item himself to -90° - Turn the flywheel in a clockwise direction to lower the wheel - Operating arm ①...

  • Page 26: Machine Position In The Gauge

    2.5 – Machine position in the gauge The diagram below shows the machine dimensions with respect to gauge UIC 505-1 (nominal track gauge of 1435). P a g e Réf. : 450100 FR...

  • Page 27: Operator Work Zone

    2.6 – Operator work zone 2.7 – Operator work position The operator work zone is located between the two rails of the same During work, the operator must always be in the position shown in track. This work zone guarantees that the operator works in optimum the photo below with his hands firmly holding the operating handle.

  • Page 28: Chapter 3 - Installation And Implementation

    CHAPTER 3 - Installation and implementation 3.1 – Inspecting the machine Each machine part must be examined by a competent person prior to ■ Checking the safety equipment putting into operation, so as to detect any faults. Start the engine (be sure to refer to 4.1 Stopping and starting) and check Inspection shall mainly comprise a visual and a functional part.

  • Page 29: Installing The Wheel

    3.2 – Installing the wheel The wheel must be installed with the engine stopped and Proceed as follows to install the wheel: the machine placed on the ground. ■ Disassembling the wheel: - Lower the wheel as far as it will go (flywheel anti-clockwise direction), Assembling the wheel: ■...

  • Page 30: Adjusting The Guide Rollers

    3.3 - Adjusting the guide rollers Guide roller spacing can be adjusted so as to be able to place the machine on all rail types, irrespective of head width. 3.3.1 - Adjustment for Vignole rails Adjust one of the two guide rollers of the machine as follows: ■...

  • Page 31: Fuel

    3.4 - Fuel 3.4.1 – General instructions 3.4.2 – Refuelling Never open the cap with a tool, as the cap The rail grinding machine four-stroke engine must Take care when opening the fuel canister. could be damaged and fuel could escape. be supplied by petrol with an octane rating of at least 90 RON.

  • Page 32: Chapter 4 - Using The Machine

    CHAPTER 4 – Using the machine 4.1 – Starting and stopping The wheel must be retracted inside its protective guard once grinding is complete. This precaution prevents operators from accidentally coming into contact with a moving wheel and also The machine must only be started once it is on the track avoids destruction of the wheel or flying stones in the event of incorrect operation.

  • Page 33: Operating The Machine

    4.2 – Operating the machine 4.2.1 – Use on Vignole rail Roll the machine on the rail using its two flat rollers. The guide flanges, Grind the entire profile until all weld traces have vanished (starting with ■ located on either side of the rail, hold it in place laterally (Refer to 3.3 the top, then the side and finally the curve).

  • Page 34: Use On A Grooved Rail

    4.2.2 – Use on a grooved rail (if the machine if equipped with grooved rollers) Roll the machine on the rail using its two flat rollers. The guide Once grinding is complete, rotate by 3 or 4 turns in an anti-clockwise direction flanges, centred in the groove, hold it in place laterally (Refer to 3.3 the wheel forward flywheel Item ①.

  • Page 35: Placing The Machine Off The Track

    4.3 – Placing the machine off the track According to the situation (varying length of time to place the machine off the track), the machine must be placed off the track according to the NORMAL or the EMERGENCY procedure. ■ NORMAL procedure •...

  • Page 36: Chapter 5 - Servicing And Maintenance

    CHAPTER 5 – Servicing and maintenance 5.1 - Servicing It is necessary to possess the training, skills and tooling required to correctly service and repair the equipment. Usage safety relies largely on proper machine servicing. Equipment servicing and repair can be performed only by personnel with sound general mechanical knowledge.

  • Page 37: Cleaning

    2.3 Technical characteristics. Apart from routine servicing during use, we recommend that you have any carburettor repairs or adjustments carried out by GEISMAR sales or troubleshooting operators. All carburettor adjustments must be performed when the engine is heated. To perform these adjustments, refer strictly to the manufacturer’s instructions.

  • Page 38: Drive Belt Tension

    5.1.5 – Drive belt tension (must be carried out with the engine stopped) Belt tension is given by the variation in pitch diameter of pulleys by If the resulting tension is not sufficient, repeat the operation. means of wedge sets. The drive pulley and the driven pulley are both To guarantee proper belt alignment, the same adjustment must be performed adjustable.

  • Page 39: Engine Oil

    Use a detergent 4-stroke automotive oil equivalent to or higher than the requirements for the API SJ service category, higher or equivalent. The Honda GX.270 engine mounted on the MP.12 type Always check the API service label on the oil canister to ensure it is machine must contain 1 litre of oil marked with the label SJ or higher (or equivalent).
  • Page 40 - Also adjust side horizontality so that the engine base is parallel to the 5.1.6.3 – Renewing engine oil (only 4-stroke engine) ground Drain engine oil after or 100 hours’ work. Worn oil is replaced when the engine is hot and has run for 5 min. Drainage is performed more quickly and fully when oil is tepid.

  • Page 41: Filters

    5.1.7 - Filters A soiled filtering system can cause the following ■ Reassembling Cover nut problems: - Place the O-ring seal in the decantation cup. • abnormal fuel consumption • engine start-up problems - Tighten the decantation cup to its maximum. Air filter cover •...

  • Page 42: Cleaning The Spark Plug

    5.1.8 – Cleaning the spark plug - Put back the spark plug manually, taking care not to damage its threading Recommended spark plugs: BPR6ES (NGK); W20EPR-U (Denso) The recommended spark plug has the correct thermal index for - Once the spark plug has touched its centre, continue to tighten it using normal engine operating temperatures.

  • Page 43: Maintenance

    5.2 - Maintenance 5.2.1 – Preventive maintenance schedule FREQUENCY PARTS TYPE OF OPERATION Inspect the machine Carry out overall cleaning with a Complete machine clean cloth or a blow gun to eliminate any dirt deposited on the machine Grease Greasing Adjust tension Drive belt Replace...
  • Page 44 FREQUENCY PARTS TYPE OF OPERATION Clean Combustion chamber Clean Fuel tank and filter Check Fuel pipe Replace Inspect the machine Pictogram Replace The machine must be overhauled regularly The information provided in this preventive maintenance schedule is for routine use; In case of more difficult conditions or longer work days, the frequencies indicated must be shortened.

  • Page 45: List Of Normal Wear Parts

    5.2.5 – List of normal wear parts We define below the list of machine normal wear parts together with their replacement conditions. However, it is essential to change or replace all worn, damaged or missing parts, particularly when there is a safety risk. Description Replacement conditions Ø...

  • Page 46: Chapter 6 - Accessories And Options

    CHAPTER 6 – Accessories and options Do not bend the hose excessively, as this could damage the drive and, in 6.1 – Optional equipment some cases, lead to accidents in the case of sudden breakage due to 6.1.1 – Take-off unit improper use.

  • Page 47: Centre-To-Centre Distance Extension

    Centre-to-centre distance extension (ref. 37000 V) Anti-vibration operating arm (ref. 37000 GF) 6.1.6 – Emergency stop button Emergency stop button all models MP.12 and MOD.12 (ref. 12000 EZ) 6.1.3 – Adaptation kit for wave wear grinding (non-EC) Wave wear grinding device to transform an MP12 into an MOD12 with balancing bar (Ref.

  • Page 48: Consumables

    6.2 - Consumables ■ Reinforced resin bonded cup wheel for: M8 4-hole wheel-holder plate: M20 wheel-holder plate or end: − − 150 x 72 mm (code N00734) ; 125 x 65 mm (code N02780) ; − − 125 x 60 mm (code N00733). 80 x 72 mm (code N03313).

  • Page 49: Chapter 7 - Spare Parts Catalogue

    CHAPTER 7 – Spare parts catalogue Tableau d'équivalence - codes machine / plans Table of equivalence - machine codes / plans MP.12_GX.270 MP.12_GX.270 MP.12_GX.270 ST471A07 ST471A55 ST471A57    37000 KJ    37000 PW   37000 PE ...
  • Page 51 37000 KJ 06-01 / R2 Français Anglais Danois 29/846 Ressort de bille Position ball-spring Positions kuglefjeder 8057 Chape de serrage Tightening cap Tætningslåb 11063 Poignée de serrage Hand-lever of feedwheel brake Håndgreb til bremse på sjernehjul 37025 Bras de manœuvre Operating handle-bar (removable) Betjeningshåndtag (aftageligt) 37049...
  • Page 52 37000 PW 04-19 HONDAiGx 2701 Loctite 243 Loctite 243 - 1- - - � � 16078A 37702 EUV+FG Q+KH -------------t--- - 1- 37120 -ffi- 37027 (x2) - ---$- (x2)
  • Page 53 Page 1 de 1 37000 PW 04-19 / R- Français Anglais 16078 A Flasque d'adaptation Flaccid adaptation Pulley adjustment-wedge 37010 Rondelle de réglage Pin M6x28x14 bm=8 37027 Goujon M6x28x14 bm=8 37120 Joue de poulie Flange of adjustable pulley Driving-pulley hub 37702 Moyeu de poulie motrice Huile spéciale MP...
  • Page 58 MP23 x150 M22 x 150 54059 x150 71028 x 150 54015 M22x1.5 4 x Ø9 / Ø 4 x Ø9 / Ø 71186 Ø M22x150 Ø x250 71117 X 150 54015 B 5/8-11 UNC MP12 / MOD 12 / MP5 / MV3 71186 A 5/8 With.
  • Page 59 1019 37000 QD 05-19 Feuille 1/4 37712 37707...
  • Page 60 37706 400119 37699 37701 37000 QD 05-19 Feuille 2/4 FM FG LBG...
  • Page 61 * 37726 entre DAU et NCN 37726 between DAU and NCN 13599 37690 37000 PZ 37000 QD 37726 05-19 Feuille 3/4...
  • Page 62 37718 400115 37699 37705 37719 37000 QD 37704 05-19 Feuille 4/4 Loctite 243 37715 37687...
  • Page 64 noir / black rouge / red jaune / yellow 37000 QE 05-19 Feuille 1/2...
  • Page 66 37000 QE 05-19 Feuille 2/2 37717...
  • Page 67 37000 QE 05-19 / R- Français Anglais 37717 Faisceau arrêt moteur Engine stop beam Bouton poussoir Pushbutton Bouchon d'étanchéité Sealing plug 1 x 0,09 m Gaine annelée fendue Ø16 Ringed split sheath Ø16 Clip Clip...
  • Page 69 Roulement à billes n° 6005 ZZ 37 019 Lèvre de guidage Ø 170 mm 37 020 Axe de lèvre de guidage 1RAIL PROFILE GRINDING MACHINE Model MP.12 37 000 LZ - 2 - Runner Assy, each including : Ref. Description Ref.
  • Page 71 Page 1 de 1 37000 DS 07-86 / R1 Français Anglais Ressort Spring 37013 Douille de raccordement de la gaine Connecting sheath 37125 Entraîneur de flexible Driving part of flexible shaft 37128 Bouchon baïonnette Bayonet-plug Circlips 45 e Circlips 45 e Vis H 6 x 12 Screw H 6 x 12 0,25...
  • Page 73 37000 NN 03-18 / R- Page 1 de 1 Français Anglais N° KIT Machine : ST471Z50 - ST471E03 - ST471A50 - Machine : ST471Z50 - ST471E03 - ST471A50 - ST471A03-A - ST471A03-A - ST471A01 - ST471E51 ST471A01 - ST471E51 37026 Carter pour meule Ø150 Grindstone casing Ø150 Screw H10x25...

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