Goldschmidt GP 3600 P4 User manual

GP 3600 P4
PROFILE GRINDER
TRANSLATION OF THE ORIGINAL OPERATION MANUAL

PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
Rev. 00 01/12/2022
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Revision history
REVISION
DATE
COMMENTS, AFFECTED SECTIONS/CHAPTERS
Approval
00
2022-12-01
First version
Product management

PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
Rev. 00 01/12/2022
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PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
Rev. 00 01/12/2022
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1. Notes about the operation manual .......................................................................................... 6
1.1 Using the operation manual ............................................................................................................... 6
1.2 Copyright ............................................................................................................................................ 6
1.3 Trademark use.................................................................................................................................... 6
1.4 Warranty............................................................................................................................................. 6
1.5 Product identification of type plate.................................................................................................... 7
1.6 Signal words and symbols used in this operation manual .................................................................. 8
2. Information about your safety ................................................................................................. 9
2.1 Intended use....................................................................................................................................... 9
2.2 Non-intended forms of use................................................................................................................. 9
2.3 Further regulations............................................................................................................................. 9
2.4 General sources of hazard .................................................................................................................. 9
2.5 Danger to life .................................................................................................................................... 10
2.5.1 Danger to life when working on railway tracks ................................................................... 10
2.5.2 Risk to life from electric shock............................................................................................. 10
2.5.3 Risk of injury........................................................................................................................ 10
2.5.4 Risk of burns........................................................................................................................ 11
2.5.5 Risk of environmental pollution .......................................................................................... 11
2.6 Safety signage................................................................................................................................... 12
2.7 General code of conduct................................................................................................................... 13
2.8 Personnel skills levels ....................................................................................................................... 13
2.8.1 Operating company............................................................................................................. 13
2.8.2 Operating personnel............................................................................................................ 13
2.8.3 Maintenance personnel ...................................................................................................... 14
2.9 Personal protective equipment ........................................................................................................ 15
2.10 Safety equipment and safety systems .............................................................................................. 16
2.11 Fire extinguisher ............................................................................................................................... 16
2.12 Behaviour in case of an emergency .................................................................................................. 16
3. Description of device.............................................................................................................. 17
3.1 Description of function ..................................................................................................................... 17
3.2 Overall design ................................................................................................................................... 18
3.3 Scope of delivery .............................................................................................................................. 19
4. Technical data ........................................................................................................................ 19
5. Operating conditions.............................................................................................................. 20
6. Transport ............................................................................................................................... 21
6.1 Lifting fixtures on the machine ......................................................................................................... 21
6.2 Transport operation.......................................................................................................................... 21
7. Operation............................................................................................................................... 23
7.1 Control and setting elements ........................................................................................................... 23
7.2 Commissioning.................................................................................................................................. 25

PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
Rev. 00 01/12/2022
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7.3 Setting the rail guide......................................................................................................................... 25
7.4 Starting the machine ........................................................................................................................ 26
7.5 Operating the machine correctly...................................................................................................... 27
7.5.1 Grinding the running surface............................................................................................... 29
7.5.2 Grinding the running edge................................................................................................... 31
7.5.3 Replacing the cup grinder.................................................................................................... 32
7.5.4 Setting the rupture protection ............................................................................................ 33
7.5.5 Adjusting the control arm height ........................................................................................ 33
7.6 Switching off the machine ................................................................................................................ 33
8. Maintenance and inspection.................................................................................................. 34
8.1 Cleaning ............................................................................................................................................ 34
8.1.1 Fundamental ....................................................................................................................... 34
8.1.2 Air filter ............................................................................................................................... 35
8.2 Topping up operating fluids and consumables ................................................................................. 35
8.2.1 Checking and topping up fuel.............................................................................................. 35
8.2.2 Checking engine oil, topping up and changing it ................................................................. 36
8.3 Replacing the V-belt.......................................................................................................................... 37
8.4 Inspection ......................................................................................................................................... 38
9. Remedying problems ............................................................................................................. 39
10.Storage................................................................................................................................... 39
11.Disposal ................................................................................................................................. 40
11.1 Disposal of used oil........................................................................................................................... 40
11.2 Disposal of parts containing oil and equipment contaminated with oil ........................................... 40
11.3 Disposal of scrap metal..................................................................................................................... 40
12.List of figures.......................................................................................................................... 41
13.List of tables........................................................................................................................... 41
Publisher:
ELEKTRO-THERMIT GMBH & CO. KG
A GOLDSCHMIDT COMPANY
Chemiestr. 24, 06132 Halle (Saale), Germany
Phone [phone], Fax [phone]
[email protected], www.goldschmidt.com
Date of publication: 2022-12-01
Documentation version: 2022-12-01
Images: André Straub, Elektro-Thermit GmbH & Co. KG

PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
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1. Notes about the operation manual
This operation manual contains all the information relating to the intended use and correct servicing and maintenance of the GP
3600 P4 profile grinder.
Please note the following points:
•The operation manual is part of the GP 3600 P4 profile grinder.
•It must remain available throughout the service life of the machine.
•The operation manual must be available to the user and to the maintenance personnel at all times.
1.1 Using the operation manual
The information in this operation manual and the maintenance manual are binding in nature. Anyone carrying out work with the
machine or handling the machine in any other way must first read and understand the operation manual in full. Follow the
instructions, prohibitions and commands in the operation manual at all times, as well as all safety instructions.
1.2 Copyright
This operation manual is protected by Elektro-Thermit GmbH & Co. KG copyright. Reproduction of this document, whether wholly
or in part and/or its dissemination to third parties requires the prior written consent of Elektro-Thermit GmbH & Co. KG.
1.3 Trademark use
The names of companies and products used in this document may be registered trademarks of their respective owners.
1.4 Warranty
The legally stipulated obligation governing the warranty period applies. The warranty does not cover damage caused by wear
resulting from use of the machine. Elektro-Thermit GmbH & Co. KG accepts no responsibility or warranty and will refute any
possible claims from third parties if personal injury or damage to property is due to one or more of the following causes by the
operator or a third party:
•non-intended use of the machine,
•failure to follow the instructions in this operation manual,
•failure to comply with specified limits and conditions for use,
•incorrect commissioning, operation, inspection or maintenance of the machine,
•failure to comply with specified servicing and maintenance intervals,
•modifications to the machine or to individual components that were not expressly authorised by the manufacturer or
•use of non-approved accessories or spare parts.

PROFILE GRINDER GP 3600 P4 TRANSLATION OF THE ORIGINAL OPERATION MANUAL
Rev. 00 01/12/2022
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1.5 Product identification of type plate
A type plate is attached to the machine that provides precise identification of the machine. The operating company must ensure
that this type plate is replaced in the event of damage or loss. The details on the type plate must always be quoted in any
correspondence with the manufacturer or with customer service.
Figure 1: Type plate
The type plate can be found at this location:
Figure 2: Type plate location

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1.6 Signal words and symbols used in this operation manual
When using this operation manual, pay attention to the symbols and abbreviations used. The safety symbols are based on the ISO
3864 standard and are identical to the safety signs attached to the machine (→ chapter 2.6 Safety signage).
SYMBOL
DESCRIPTION
DANGER
The signal word DANGER indicates a hazard with a high level of risk that, if not avoided, may result in death
or serious injury.
WARNING
The signal word WARNING indicates a hazard with a medium level of risk that, if not avoided, may result in
serious injury.
CAUTION
The signal word CAUTION indicates a hazard with a low level of risk that, if not avoided, may result in minor
or moderate injury.
NOTICE
The signal word NOTICE indicates a hazard that, if not avoided, may result in damage to property or the
environment.
The info symbol indicates information (tips, recommendations, remarks, etc.) that may be helpful for
handling the product.
Situations with a risk of injury are additionally marked with a warning sign.
Table 1: Signal words and symbols

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2. Information about your safety
This chapter contains all the information relating to safety. Read all safety information thoroughly before using the machine and
follow it carefully when operating it. The safety instructions draw attention to hazards of possible personal injury, property damage
and environmental damage and contain information on how to avoid and prevent hazards. The presentation and content structure
of the safety instructions are based on the ISO 3864 and EN IEC/IEEE 82079 standards.
2.1 Intended use
The machine must always be operated in strict compliance with the specified operating conditions.
→ Chap. 5 Operating conditions
The GP 3600 P4 profile grinder is suitable for the accurate profile grinding of butt welds, running surfaces, rail head roundings and
the side surface of steel rails with vignole profile as well as groove profile in manual operation without the use of cooling lubricants.
Any other use of the machine or of its components, or any more extensive form of use, constitutes 'non-intended use'. The
machine can be used on flat-bottom rails from rail profile 46E1 as well as on grooved rails from rail profile 51Ri1. Please contact the
manufacturer to find out whether the machine can be used on smaller rail profiles.
The manufacturer accepts no liability for damage resulting from improper use.
2.2 Non-intended forms of use
Intended use exists if the machine is used for a different purpose that that described in → Chap. 2.1 Intended use.
Examples of intended use are:
•Grinding of other objects or materials than the defined rail profiles.
•Using the machine to drive other devices.
•Using the machine as a means of transport.
•Using the guidance system on the machine as wheels for transport.
2.3 Further regulations
In addition to the information in this operation manual, due compliance is mandatory with the statutory regulations for accident
prevention and environmental and occupational safety as well as the accident prevention regulations of the operating company.
Strict compliance is also required with the safety regulations issued by the railway authorities for working on and near the tracks.
2.4 General sources of hazard
The machine is designed to state-of-the-art standards. It is not possible to eliminate residual risks. Pay attention to the following
safety instructions when using the machine.

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2.5 Danger to life
2.5.1 Danger to life when working on railway tracks
During track construction work, there is always a risk of people being hit by passing trains, causing extremely severe injuries.
•Before working on the track bed, always ensure that the track has been closed off to permit that work. Never work on a track
that is open for rail traffic.
•Always proceed with great caution whenever the construction site is close to railway tracks open to rail traffic.
•Always set down equipment and materials in a place where they cannot collide with other rail vehicles.
2.5.2 Risk to life from electric shock
There is a risk of serious injury from electric shock when working on live parts and cables. This can lead to ventricular fibrillation,
cardiac arrest or respiratory paralysis with a fatal outcome.
•Never use the machine if a conductor rail at the work site is live.
•Never use this machine on a conductor rail that is electrically live at the time.
•Always ensure that there is no risk of electric shock.
2.5.3 Risk of injury
Risk of injury from the crushing of body parts
If people's limbs are under the grinding wheel or under the guide system when working with the machine, there is a risk of serious
injury from crushing possibly involving broken bones or even the severing of entire limbs.
•When operating this machine, never place hands or feet below the grinding head or under the guide system.
•Always wear sturdy protective work shoes of protection class S3.
•Always wear work gloves.
•Everyone except for the operator must maintain a safe distance of at least 5 metres from the machine while it is switched on.
Risk of injury from projectile gravel and dust when cleaning the air filter
Working with compressed air entails the risk of dust particles and splinters getting into the eyes. This can injure them or may even
cause blindness. Always wear safety goggles when working with compressed air and in the vicinity of others working with it.
Risk of injury from falling, slipping and sliding
When working on the track bed, there is a risk of slipping and falling on the gravel, causing injuries such as contusions or even
broken bones.
•When working with the machine, always maintain a firm stance.
•Do not work with the machine on a gradient of more than 10°.
•Wear work gloves in protection class S3.
Risk of damage to hearing
The A-weighted emission sound pressure level LPA at the workplace can be up to 74 dBA and the A-weighted emission noise level
LWA at the workplace can be up to 85 dBA. Exposure to noise can damage hearing and lead to short-term hearing loss and mental
overload. Always wear ear defenders when working with this machine.