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ROBEL ROTAMP 62.05 Operation Manual

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OPERATION MANUAL
ROTAMP
62.05 / 05
Vertical Tamper
1
62.05/5

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Summary of Contents for ROBEL ROTAMP 62.05

  • Page 1 Content OPERATION MANUAL ROTAMP 62.05 / 05 Vertical Tamper 62.05/5...
  • Page 2 Translation of original operation manual Status: 25.03.2024 Version 1c © 2024 ROBEL Bahnbaumaschinen GmbH This operation manual was 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 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 ............................
  • Page 4 Content Description of machine ......................21 Structure ............... 21 4.1.1 Vertical tamper ..............21 4.1.2 Tamping pick ..............21 4.1.3 Guide frame................ 21 Overview ............... 22 Petrol engine ..............23 Work place ..............23 Signs and Labels ............24 4.5.1 Signs and Labels used ............24 4.5.2 Position on the product ............
  • Page 5 Content Troubleshooting ........................47 Engine ................47 Tamper ................. 47 Maintenance ......................... 48 Maintenance schedule ..........49 9.1.1 Engine .................. 49 9.1.2 Gear unit ................50 9.1.3 Machine ................50 Wear parts ..............50 Engine ................51 9.3.1 Check vent passage in the fuel tank cap....... 51 9.3.2 Cleaning the air filter ............

  • 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 and conditions can be obtained separately.

  • 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: •...

  • 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 vertical tamper is used in track construction to consolidate the ballast bed under the sleepers. Foreseeable misuse The vertical tamper must not be used for demolition work or the like. 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...

  • 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 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 13 2. Safety Danger due to unergonomic With some activities there is a risk of injuring muscles, ten- dons, joints or bones if the necessary caution is not exercised operation with the controls. An example is starting the engine by means of the reversing starter.
  • Page 14 2. Safety Danger from fuel Fuel is highly flammable and under certain conditions fuel-air mixtures can be explosive. There is a risk of injury or damage to material property if fuel is not handled properly. ► Switch off the engine and allow it to cool down before refill- ing, do not pour fuel over a hot engine or silencer.
  • Page 15 2. Safety Danger from Some parts may be live and may cause severe to fatal injuries when getting in contact with them. electrical voltage ► Work on the electrical system only by authorised electrical engineers. ► Rectify faults (contact faults, external damage to cables or housings, etc.) straight away.
  • Page 16 2. Safety Danger from vibration 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. ►...

  • 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: First Aid

    2. Safety 2.11 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: Kawasaki TJ45E, air-cooled, single cylinder 2-stroke en- gine Speed 8,000 RPM Output at 8,000 RPM 1.42 kW Speed at the tamping pick (eccentric 2,850 RPM shaft) Fuel (mix) Oil-petrol fuel mix (min. 91 ROZ) Unleaded pet- rol (E10 or less) Mixing ratio 1:50 (2%) Fuel consumption...

  • Page 20: Noise Emission

    3. Technical data 3.6.1 Noise emission Emission sound pressure level L 97 dB(A) Sound power level L 108 dB(A) 3.6.2 Vibration Vibration total value a 5.78 m/s Standard deviation 0.62 Digital tach/hour meter Range Value Range Revolutions per minute (RPM) 0…60,000 RPM Max.

  • Page 21: Description Of Machine

    4. Description of machine Description of machine Structure 4.1.1 Vertical tamper The vertical tamper consists of a petrol engine which, via a gear unit, drives a shaft using an unbalance to produce the vibrations. Mounted on the engine is the "Engine stop" button for cutting it off.

  • Page 22: Overview

    4. Description of machine Overview Fig. 1: Overview Guide frame Housing Petrol engine with digital tach/hour meter "Engine stop" button Throttle lever Rubber buffers (8x) Tamping pick Shim Tamping tool Tamping shovel 62.05/5...

  • Page 23: Petrol Engine

    4. Description of machine Petrol engine Fig. 2: Petrol engine Grip of recoil starter Fuel tank "Engine stop" button Throttle lever Gear unit Work place The operator stands behind the machine and holds onto both the handles or uses the right hand to open the throttle. Fig.

  • Page 24: Signs And Labels

    4. Description of machine Signs and Labels 4.5.1 Signs and Labels used Fig. 4: Combination sticker Fig. 5: Identification plate (Example) Fig. 6: Manufacturer’s logo Fig. 7: Label “Tank capacity” Fig. 8: Label “STOP” (near Fig. 9: Label “Safety notes Engine stop button) concerning engine”...

  • Page 25: Position On The Product

    4. Description of machine 4.5.2 Position on the product Fig. 10: Position on the product Combination sticker Label “Manufacturer’s logo” Label “Manufacturer’s logo” Identification plate 62.05/5...
  • Page 26 4. Description of machine Fig. 11: Position on the product (from above) Label “STOP“ Label “Tank capacity“ Fig. 12: Position on the product (Air filter cap) Label “Safety notes engine” Identification plate 62.05/5...

  • Page 27: Digital Tach/Hour Meter

    Accessory (not included in delivery) 4.7.1 Safety cut-off cable drum WARNING Risk of accident! If other than the original ROBEL connection cable is used, the function of the safety cut-off can be impaired. ► Only use the original ROBEL connection cable.

  • Page 28: Rail Movement Indicator

    4. Description of machine 4.7.2 Rail movement indicator The rail movement indicator can be used to show the rail movement when a train is travelling over the track. Fig. 15: Rail movement indicator Indicator part Scale Scale part Arrow Clamping lever 4.7.3 Shoulder strap Fig.

  • Page 29: Wear Gauge Tamping Tool

    4. Description of machine 4.7.4 Wear gauge tamping tool Fig. 17: Wear gauge tamping tool 62.05/5...

  • Page 30: Preparing The Machine

    5. Preparing the machine Preparing the machine Digital inductive tach/hour meter 5.1.1 Operation Display standard mode: Fig. 18: Operating hours (left) and revolutions per minute (right) • When the engine is not running, the tach/hour meter dis- plays the actual amount of operating hours. •...

  • Page 31: Settings

    5. Preparing the machine 5.1.2 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: 2.

  • Page 32: Checking The Machine

    5. Preparing the machine Checking the machine 5.2.1 Checking tamping tool for wear See label on machine: min. 105 mm Fig. 22: Label „Caution wear part“ 1. Measure the length of the tamping tool with a measuring tape: Replace the tamping tool if the gap between the tip and the flange is less than 370 mm, see ch.

  • Page 33: Check Engine Housing

    Fig. 25: Crack in proximity to mounting eyes for attachment screws 3. If cracks become visible, remove tamper from operation, mark as defective and do not use it any more. 4. Send the tamper to ROBEL aftersales for repair. 62.05/5...

  • Page 34: Checking The Petrol Engine

    ► Do not use compressed air to clean or dry the air filter. ► Do not brush the dirt away. ROBEL recommends replacing air filters and spark plugs at regular intervals in line with the specifications in the maintenance schedule.

  • Page 35: Tank Spout

    5. Preparing the machine 5.3.2 Tank spout WARNING Risk of fire! Risk of fir due to fuel leakage if the tank spout is not tight. ► Check the tank spout daily for leakage. ► Replace the tank spout if there is leakage. Fig.

  • Page 36: Refilling The Tank

    5. Preparing the machine 5.3.3 Refilling the tank Petrol WARNING Risk of fire or explosion! Petrol is extremely flammable and is explosive under certain conditions. ► Obey the safety notes concerning the combustion engine and fuel in Chap. 2. The heat generated by the engine can cause the fuel to expand and leak through the open- ings in the fuel filler cap.
  • Page 37 5. Preparing the machine Mixing 1. Always mix the petrol and oil in a clean container that is approved and intended for petrol. 2. Always pour in half of the petrol first and then the entire quantity of oil. 3. Stir (gently shake) the fuel mix and then add the rest of the petrol.

  • Page 38: Working With The Machine

    6. Working with the machine Working with the machine Starting the engine Fig. 27: Position of suction pump Overflow house Fuel inlet house Suction pump The engine is designed such that overflowing fuel is returned to the fuel tank when the suc- tion pump is pressed.
  • Page 39 6. Working with the machine On warm days or if the engine is already hot do not turn the choke lever. Easy use of the throttle handle allows a better start. CAUTION Risk of injury! ► Grasp only the handle on the recoil starter and not the cord.

  • Page 40: Working With The Tamper

    6. Working with the machine Working with the tamper 6.2.1 Tamping (sleeper) Avoid contact with the sleeper! ► Place the blade approx. 1 to 5 cm next to the sleeper. ► Do not touch the sleeper with the tamping tool while tamping. Apply force ergonomically! ►...
  • Page 41 6. Working with the machine 5. Pull the tamper towards the operator so that the ballast is compacted under the sleeper. Fig. 31: Compact ballast under the sleeper 6. Withdraw the tamper. 7. Repeat steps 1-6 two or three times in order to achieve an optimal and sustainable result.

  • Page 42: Tamping (Track Panel)

    6. Working with the machine Do not position the tamping tool too close to the sleeper. ► Maintain min. distance: 1 cm. 6.2.2 Tamping (track panel) For optimum tamping result all sleepers must be tamped from both sides (directions): FORWARD and BACKWARD. Example illustration: •...

  • Page 43: Installing Rail Movement Indicator (Accessories)

    6. Working with the machine Installing rail movement indicator (accessories) The rail movement indicator can be used to show the rail movement when a train is travelling over the track. Fig. 34: Rail movement indicator Indicator part Scale Scale part Arrow Clamping lever 1.

  • Page 44: Transport And Storage

    7. Transport and storage Transport and storage Transport The temperature range for transporting the machine is –20°C to +60°C. If the product is placed in its original packaging and properly lashed down, it can be transported by any means of transport without damage.

  • Page 45: Storage

    7. Transport and storage Centre of mass Fig. 37: Centre of mass The centre of mass is at the location with the centre of gravity symbol. Storage 7.2.1 Storage conditions The temperature range for storing the machine is -20°C to +60°C.

  • Page 46: Laying Down The Machine

    7. Transport and storage 7. Press in the starter pump button several times until all the fuel in the fuel return line has been pumped back into the fuel tank. 8. Tilt the engine towards the fuel filler neck to let the fuel in the fuel tank flow into the container.

  • Page 47: Troubleshooting

    8. Troubleshooting Troubleshooting Engine Type of error Reason Remedy ► Fill the tank Engine will not start No fuel ► Close choke lever, actuate No choke applied although en- suction pump, see chap. 6.1 gine is cold ► Clean spark plug, see Spark plug wet / oily chap.

  • Page 48: Maintenance

    9. Maintenance Maintenance WARNING Risk of Injury! During maintenance work the engine might be cranked, and started unintentionally as a re- sult. ► Before commencing 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 49: Maintenance Schedule

    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 50: Gear Unit

    9. Maintenance 9.1.2 Gear unit Interval Part/Component Activity Remarks Once a Gear unit Check the toothed belt See chap 9.5 month or tension 50 operating hours 9.1.3 Machine Interval Part/Component Activity Remarks 10 operating Vertical tamper Clean See chap. 9.7 hours (daily) Rubber buffer Visual check...

  • Page 51: Engine

    9. Maintenance Engine Periodic inspection and adjustment of the engine are essential if high level performance is to be maintained. Regular maintenance will also ensure a long service life. The required maintenance intervals and the type of the mainte- nance work to be carried out are described in the table in chapter 9.1 (see also original operating instructions of the en- gine manufacturer).

  • Page 52: Cleaning The Air Filter

    9. Maintenance 9.3.2 Cleaning 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 Danger of fire and explosion! If the air filter is cleaned with petrol or a low...
  • Page 53 9. Maintenance Fig. 40: Cleaning the air filter Air filter housing Air filter cap Filter element 1. Undo the air filter cap and remove the air filter cap from the air filter housing. 2. Remove the air filter element from the air filter housing. 3.

  • Page 54: Cleaning The Fuel Filter

    9. Maintenance 9.3.3 Cleaning the fuel filter WARNING Risk of fire and explosion! Petrol is extremely flammable and is explosive under certain conditions. ► Do not smoke or allow flames or sparks in the working area. 1. Undo the fuel tank cap. 2.

  • Page 55: Spark Plug Maintenance

    9. Maintenance 9.3.4 Spark plug maintenance To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. NOTICE Risk of engine damage ! The engine may be damaged if a spark plug with inadequate heat range is used. ►...

  • Page 56: Idle Adjustment

    9. 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 (tighten- ing angle). 7.

  • Page 57: Checking The Fuel Spout

    9. Maintenance 9.3.6 Checking the fuel spout WARNING Risk of fire! Risk of fire due to leaking fuel. ► Check the tank spout daily for leakage. ► Replace the tank spout if there is leakage. Fig. 44: Fuel lines and tank spout Overflow hose Tank spout Fuel inlet house...

  • Page 58: Checking The Clutch

    9. Maintenance 9.3.7 Checking the clutch ROBEL recommends to replace all the rele- vant parts ( both coupling elements and both coupling pins) even if wear on only one part is detected. Use a high-strength retaining compound (e. g. Loctite 603) for the clutch pins (Torque 8.8 Nm).

  • Page 59: Changing The Fuel Pipe

    9. Maintenance Checking the clutch pin 3. Check the clutch pins (Pos. 97) for wear, replace if neces- sary. Replace the clutch elements and the clutch pins if the play is more than 0.2 mm. 9.3.8 Changing the fuel pipe WARNING Danger of fire and explosion! Petrol is highly flammable and explosive un-...

  • Page 60: Rubber Buffers

    9. Maintenance Rubber buffers 9.4.1 Check rubber buffers The rubber buffers for vibration damping fitted between grip, carrier plate and tamping pick are parts subject to wear. 1. Replace the rubber buffers when necessary (e.g. showing obvious fissures). Fig. 46: Rubber buffers 4 pcs.

  • Page 61: Changing The Rubber Buffers

    9. Maintenance Fig. 47: Rubber buffer new/worn Rubber buffer new Rubber buffer worn 9.4.2 Changing the rubber buffers Tools, means, material: • Open ended spanner AW 17 • Pliers with protection • Rubber buffer 4 pcs. between handles and carrier plate: EDP-No.
  • Page 62 9. Maintenance Mounting rubber buffers NOTICE Risk of damage to the rubber buffers! Twisted or deformed rubber buffers lead to pre-tensioning of the rubber, even at standstill. These stresses will add to the compressive and tensile stresses during operation and will lead to excessive strain during operation.

  • Page 63: Gear Unit

    9. Maintenance Gear unit 9.5.1 Checking the toothed belt tension Check the tension of the toothed belt once a month. 1. Use a SW8 open-ended spanner to undo the two screws (1) and take off the cover plate (2). Fig. 50: Remove cover plate M5 screw Cover plate 2.

  • Page 64: Adjusting The Belt Tension

    9. Maintenance 9.5.2 Adjusting the belt tension 1. Undo the three nuts on the cast housing. Fig. 52: Adjusting the belt tension Nut (and 1 more on opposite side of housing) Cast housing 2. Push the cast housing backwards until the belt does not deflect more than 2 mm when light pressure is applied (see page before).

  • Page 65: Tamping Tool

    9. Maintenance Tamping tool 9.6.1 Checking the coupling elements Tools, means, material: • Hex wrench A/F 5 • Large cable tie • Cloth and oil binding agent • Approx. 60 ml engine oil (SAE 15W-40, Shell Helix HX5) • Cleaning agent for degreasing thread (e.g. brake cleaner) •...
  • Page 66 9. Maintenance 2. Slide up the bellows (6) in order to get access to the two attachment screws (1) that fix the upper coupling element (5) to the shaft of the gear unit. 3. Remove this two screws and slide down the tamping pick. 4.

  • Page 67: Checking Tamping Tool For Wear

    9. Maintenance 9.6.2 Checking tamping tool for wear To prevent a hole appearing in the bottom of the tamping pick and oil escaping or to prevent damage to the bearing, regular checks must be made prior to each use to see how much ma- terial has already worn away.

  • Page 68: Replacing Tamping Tool

    9. Maintenance 9.6.3 Replacing tamping tool Tools, means, material • 4 new hexagon nuts (EDP-No. 990 980 0009) • 4 new washers (EDP-No. 990 125 0840) • 2 new shims (EDP-No. 988 037 1140) • 4 new hexagon screws (EDP-No. 990 931 0028) •...
  • Page 69 9. Maintenance Remove worn tamping tool 4. Pull out the tamping tool (1) from the tamping pick (2). Fig. 56: Remove tamping tool 5. Slide new O-ring (1) onto the tamping pick (2). Fig. 57: Slide new O-ring O-Ring Tamping pick 62.05/5...
  • Page 70 9. Maintenance 6. Slide new tamping tool (1) over the tamping pick (2). Fig. 58: Slide new tamping tool Tamping tool Tamping pick 7. Mount the shims. Fig. 59: Mount the shims NOTICE Risk due to loose screws! If old lock washers and nuts are used, there is a risk that the screws can become loose or get torn.
  • Page 71 9. Maintenance 8. In the four boreholes, insert one hexagonal nut (1) with one washer (2) each from the bottom up. At the end of the hex- agonal screw, thread 14 disc springs (3) (see right figure below) and one nut (4) and tighten by hand. Fig.

  • Page 72: Changing Angular Contact Ball Bearings

    9. Maintenance 9.6.4 Changing angular contact ball bearings Tools, means, material: • Dynamometric key AF 30 • Hex wrench A/F 5 • Approx. 60 ml engine oil (SAE 15W-40, Shell Helix HX5) • Large cable tie • Cloth and oil binding agent •...
  • Page 73 9. Maintenance Pulling down tamping pick Fig. 63: Pulling down tamping pick Replacing angular 5. Unscrew nut (3) and remove old bearings from the drive ball bearing shaft (1). 6. Push new angular contact ball bearings (2) (EDP No. 900 600 3128) on to the primary shaft (1).
  • Page 74 9. Maintenance 9. Fill approx. 60 ml engine oil into the tamping pick and push it over the eccentric shaft. Fig. 65: Pushing tamping pick back on 1. Insert the threads of the rubber buffers into the respective holes and tighten the nuts. Torque: 20 Nm.

  • Page 75: Cleaning And Care

    9. Maintenance Cleaning and care Regular care and maintenance of the vertical tamper will pro- long its service life significantly. NOTICE Risk of damage! Cleaning the product with solvents, aggressive or combustible cleaning agents may result in damage. The use of high-pressure washers can result in damage caused by water getting into the motor (silencer, air filter, carburettor) and articulated joints of the product.

  • Page 76: Environmental Protection And Disposal

    10. Environmental protection and disposal Environmental protection and disposal 10.1 Environmental protection • 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 77: Appendix

    11. Appendix Appendix CE-Declaration of Conformity Fig. 66: EG Declaration of Conformity 62.05/5...

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