ROBEL ROPOWER 70.02 User manual

Content
1
OPERATING MANUAL
ROPOWER
70.02 model 02
Hybrid Drive Unit

2
Robel Bahnbaumaschinen GmbH
Industriestraße 31
83395 Freilassing
Phone: ++49 (086 54) 609-0
Fax: ++49 (086 54) 609-445
E-Mail: [email protected]fo
Internet: www.robel.info
Translation of Original Operating Manual
Status: 31.01.2019
Version: V6
© 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.
Dimensions and weights are approximated.
Photographs show special layouts in some case.

Content
3
Content
1. General ................................................................................................................................... 6
1.1 About these instructions ................................................ 6
1.2 General Regulations....................................................... 6
1.3 Intended Audience for this Operating Manual............... 7
1.4 Liability Exclusions ......................................................... 7
1.5 Copyright ........................................................................ 8
1.6 Acceptance, Equipment and Operating Licence............ 8
1.7 Validity of these instructions.......................................... 8
2. Safety...................................................................................................................................... 9
2.1 Designated use............................................................... 9
2.2 Foreseeable misuse ....................................................... 9
2.3 Conventions of layout..................................................... 9
2.4 Design changes, original parts..................................... 10
2.5 Protective devices ........................................................ 10
2.6 Safety regulations ........................................................ 10
2.7 Qualifications of staff................................................... 11
2.8 Personal Protective Equipment ................................... 11
2.9 Instructions for particular types of hazards ................. 12
2.10 Accident prevention ..................................................... 16
2.11 First Aid......................................................................... 17
2.12 Fire safety..................................................................... 17
3. Technical data ...................................................................................................................... 18
3.1 Drive.............................................................................. 18
3.2 Electrical power (Output).............................................. 18
3.3 Electrical interface ....................................................... 18
3.4 Dimensions................................................................... 18
3.5 Fill quantities................................................................ 18
3.6 Weight .......................................................................... 18
3.7 Noise emissions and Vibration..................................... 19
3.7.1 Noise emissions................................................................. 19
3.7.2 Vibration.............................................................................. 19
3.8 Environmental conditions ............................................ 19

Content
4
4. Description of machine ........................................................................................................ 20
4.1 Structure....................................................................... 20
4.2 Overview of the machine.............................................. 20
4.3 Control elements.......................................................... 22
4.3.1 Petrol Engine...................................................................... 22
4.3.2 Indicating elements .......................................................... 23
4.4 Signs and Labels .......................................................... 24
4.4.1 Used signs and labels ....................................................... 24
4.4.2 Position on the product .................................................... 26
4.5 Workplace .................................................................... 27
4.6 Structure gauge............................................................ 27
5. Operating conditions ............................................................................................................ 28
5.1 Operating...................................................................... 28
5.2 Storage ......................................................................... 28
5.3 Transport ...................................................................... 31
6. Checking the machine.......................................................................................................... 33
6.1 Air filter......................................................................... 33
6.2 Engine oil level ............................................................. 35
6.3 Refilling the tank.......................................................... 37
6.4 Visual check.................................................................. 38
7. Putting the machine into operation ..................................................................................... 39
7.1 Setting up the machine................................................ 39
7.2Make electrical connections ........................................ 39
7.3 Starting the engine....................................................... 42
7.4 Engine running ............................................................. 46
7.5 Stopping the engine ..................................................... 47
7.6 Disconnecting the electrical link.................................. 48
7.7 Put away the machine ................................................. 49

Content
5
8. Maintenance......................................................................................................................... 50
8.1 Maintenance schedule................................................. 51
8.1.1 Engine.................................................................................. 51
8.1.2 Electrical system................................................................ 52
8.1.3 Machine .............................................................................. 52
8.2 Engine........................................................................... 52
8.2.1 Checking the engine oil level........................................... 53
8.2.2 Changing the oil................................................................. 54
8.2.3 Air filter................................................................................ 55
8.2.4 Cleaning the filter cup....................................................... 57
8.2.5 Spark plug maintenance.................................................. 58
8.2.6 Idle adjustment.................................................................. 61
8.3 Electrical System.......................................................... 62
8.4 Signs and labels ........................................................... 67
8.5 Cleaning and care ........................................................ 67
9. Troubleshooting.................................................................................................................... 68
9.1 Spark test ..................................................................... 69
9.2 Machine is not getting power....................................... 69
10. Environmental protection and disposal ............................................................................... 71
10.1 Environmental protection............................................. 71
10.2 Disposal........................................................................ 71
11. Appendix............................................................................................................................... 72
EC Declaration of Conformity

1. General
6
1. General
All personnel that operate or service the product must have
read and understood this operating manual.
The manual must be available to all participants at all times.
1.1 About these instructions
The following symbols are used to mark operating procedures,
lists and other elements of these instructions:
Symbol
Explanation
1. Action
2. Action
Operating procedure - the se-
quence of actions must not be
changed.
•List 1
–List 1.1
•List 2
List- Sequence may be
changed.
►Measure
►Measure
Measure - the sequence must
not be changed.
1.2 General Regulations
Appropriate legal requirements and accident prevention
measures for use of this appliance must generally be ob-
served. If they are not observed, the operator of the appliance
takes responsibility for any legal consequences.
In the event of differences between prevailing regulations that
apply to use of the machine and the manufacturer’s or sub-
contractor’s specifications, whichever limitations are the most
stringent must apply.
The buyer must make available all appliances and operational
or supporting materials to enable the delivered product to be
used and personnel to be trained. Enough safe and clear track
and work sections must be provided to allow personnel to learn
and practice how to use the goods delivered.
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.

1. General
7
1.3 Intended Audience for this Operating Manual
This operating manual contains important information for the
intended use of the product described therein.
The manual has been written exclusively for technically quali-
fied personnel.
Qualified personnel in this context are:
•Personnel who have demonstrated their suitability for
working with this product, whether through qualifications
or experience.
•Persons who are familiar with the safety concepts of ma-
chines and equipment;
•Maintenance and service personnel who have been special-
ly trained in the repair of machines and equipment.
Only people who are capable of reading this manual may work
on this machine. They must have read and understood this
manual, and have confirmed this with their signature.
The installation, maintenance and operation of the product
may only take place having regard to, and in strict conform-
ance with, the valid operating and safety standards and official
regulations, particularly those concerning safety, industrial
safety, environmental protection and the prescribed operating,
maintenance and safety instructions of manufacturers and
suppliers or other regulations.
1.4 Liability Exclusions
The manufacturer accepts no liability whatsoever for such
losses that may arise if the product is used for purposes other
than its intended use. If the product is operated without safety
devices, that is also deemed to be other than intended use.
Every use other than the specified use of this product is con-
sidered to be other than intended use and endangers the life
and limb of the operating and maintenance personnel as well
as the property of the operator. The manufacturer of the prod-
uct accepts no liability for injury to persons or damage to prop-
erty, whether of the operator or third parties, if: –
•The product is not used as intended,
•The operating and maintenance personnel have not read
and understood this operating manual and have used the
product for a purpose other than that intended,
•The operating and maintenance personnel are not suffi-
ciently qualified,
•The product is operated under conditions beyond the stat-
ed limits,
•The product is not maintained according to the specified
intervals as required,
•The product is not maintained using original spare parts,
•Components and attachments of the product are modified
without proper authority.
These grounds for exemption of liability for personal injury or
material damage shall not affect other grounds for exclusion.

1. General
8
1.5 Copyright
Specific characteristics and particular attributes of the ma-
chine are the intellectual property of ROBEL Bahnbaumaschi-
nen 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. Its contents may not be
passed by company employees to anyone outside the busi-
ness.
1.6 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.
The buyer must equip the goods delivered with all fittings nec-
essary to meet relevant operational and safety regulations,
norms, statutory regulations or other regulations, e.g. fire ex-
tinguisher, first aid box, signal and telecommunications
equipment, additional warning devices, protective clothing,
safety notices etc.
Unless otherwise agreed, no fittings of this nature are provided
with the goods delivered.
Furthermore it is the buyer’s responsibility to demonstrate that
the goods delivered have been accredited for use by the ap-
propriate authority. Any documentation to be provided by the
manufacturer or supplier (descriptions, proof, attestations, etc.)
to enable this should be specified in the contract of supply.
Any additional measures and costs required to achieve opera-
tional accreditation must be borne by the buyer.
1.7 Validity of these instructions
This operating manual is valid for the product with the follow-
ing EDV numbers:
•EDP ref. No. 502 990 0002

2. Safety
9
2. Safety
2.1 Designated use
The Hybrid Drive Unit must only be used in combination with
Robel machines with suitable input electronics.
2.2 Foreseeable misuse
The Hybrid Drive Unit must not be used for devices and ma-
chines that require a different voltage/frequency
(e. g. not for 230 V/50 Hz AC or 400 V/50 Hz AC).
The Hybrid Drive Unit must not be connected to the mains sup-
ply.
The Hybrid Drive Unit must not be lashed down on the working
machine (e.g. Grinding Machine ROGRIND 13.49) with ropes or
straps.
2.3 Conventions of layout
This operating manual uses the following warning phrases and
symbols to ensure the personal safety and physical integrity of
the user and to protect the assets of the operator from dam-
age:
DANGER
Indicates that non-observance of the instruc-
tions results in death or severe injury of the
operator.
WARNING
Indicates that non-observance of the instruc-
tions may result in death or severe injury of
the operator.
CAUTION
Indicates that non-observance of the instruc-
tions may result in injury of the operator.
NOTICE
Indicates that non-observance of the instructions may result
in damage to the product or other assets belonging to the
operator.
Contains important information about the
machine, its operation or about a section of
the instructions on hand.

2. Safety
10
The warnings are structured as follows:
SIGNAL WORD
Type and source of danger!
Possible consequences when ignoring the
danger.
►Measure to avoid the danger.
2.4 Design changes, original parts
The manufacturer accepts no liability for unauthorised modifi-
cations to components and attachments to the product.
Original parts and accessories are specially designed for this
product. In certain circumstances the use of non-approved re-
placement parts can impair or have a detrimental impact on
the design characteristics of the product.
The manufacturer is not liable for any damage which is proven
to be attributed to the use of such parts or inferior operating
fluids.
2.5 Protective devices
Tampering with the safety devices can endanger the life of the
user and others!
►When operating the equipment, the user is also obliged to
actually attach the safety devices or to leave them in their
factory-installed positions.
►After completing his work, the person instructed to carry
out the maintenance must re-attach the safety devices.
2.6 Safety regulations
The handling requirements necessary for the protection of life,
health, property and the environment must be ensured as a
matter of priority.
►Before using the device, make sure you can prove that all
personnel affected have been made aware of the following
relevant regulations and provisions:
•statutory safety regulations
•stipulations of the respective building code and works rules
•stipulations of the respective professional and trade asso-
ciations
•industrial and environmental safety regulations
•approvals regulations
•internal company regulations
•All other applicable regulations, in addition to and in con-
cert with the manufacturer’s safety and operating regula-
tions
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.
Structure of the warnings

2. Safety
11
In addition to the information mentioned above the specific
safety regulations must be observed and adhered to.
2.7 Qualifications of staff
The operator was trained by the operating company in the
tasks assigned to him and informed of the potential dangers
arising from inappropriate behaviour.
•Extensive training in the product
•Knowledge of content of these operating and maintenance
instructions
•Knowledge of content of operating and maintenance in-
structions of suppliers’ and additional equipment
•Knowledge of national regulations and laws concerning the
machine and additional equipment
•Physical and mental fitness
•Power of concentration, sense of responsibility, reliability
•Necessary national requirements (qualifications, minimum
age)
•No influence of alcohol, medicines, drugs or fatigue, etc.
2.8 Personal Protective Equipment
Use the approved PPE during the operation and maintenance
of the product.
►Wear suitable hearing protection for
high-frequency noise.
►Wear steel-capped work shoes.
The PPE is defined by:
•Operating Manual
•National safety regulations
•Regulations of the professional associations
•Other applicable regulations
►In the event of any discrepancy between the existing regu-
lations applicable to the product owner and the instruc-
tions provided by the manufacturer and its suppliers, the
stricter regulation shall apply.
Operator
Requirements for the
operator

2. Safety
12
2.9 Instructions for particular types of hazards
If the permissible per-person lifting weight is exceeded when
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.
►When lifting or carrying machinery or equipment, adhere to
the permissible per-person lifting weight.
It is the responsibility of the operating company to ensure that
the national safety regulations and guidelines of the trade as-
sociations in the respective countries are observed. The values
stated in the warning notices of these operating instructions
relate to regulations in Germany.
►Ensure that a risk assessment has been carried out and
that the following aspects with regard to operators and the
transport task have been considered:
–Frequency of transport
–Age
–Gender
–Operator’s state of health
–Uneven flooring
–Poorly lit worksites
–Bad weather
–Working under time pressure
–etc.
►Observe the relevant guidelines on lifting and transporting
heavy machinery or equipment.
►Mechanical aids to lifting are always the preferred method
of handling where possible, e.g. hoists, tail lift, rail trolleys
etc.
►Always use the handles to lift the modules.
►Always use two hands and address the modules symmetri-
cally.
►Do not twist the spine when handling.
►Do not carry any of the modules more than 10 meters
without a rest, or without using a mechanical aid.
►Contact your Health and Safety Advisor for more infor-
mation.
With some activities there is a risk of injuring muscles, ten-
dons, joints or bones if the necessary caution is not exercised
with the controls. An example is starting the engine by means
of the reversing starter.
►Pull the reversing starter vigorously but avoid jerky move-
ments.
►Avoid adverse movements and poor posture.
►Avoid static postures of the thumb and hand when using
the controls.
Danger due to manual
handling
Danger due to unergonomic
operation

2. Safety
13
While the engine is running, there is a risk of injury from rotat-
ing and hot parts.
►Only suitably trained and qualified persons may work on
the engine.
►Switch off the engine and allow it to cool down.
►Inspect the engine at regular intervals and immediately
rectify any faults (e.g. damage, leaks) that are found.
►Be vigilant for unusual noises, vibrations etc.
►Only carry out maintenance work when the engine is
switched off.
►Beware of hot components.
The spark plug lead carries high voltage to the spark plug.
Touching the spark plug or spark plug lead while the engine is
running can result in fatal electric shocks. People with heart
pacemakers are at particular risk.
►Do not touch the spark plugs and spark plug cables while
the machine is operating.
►People with heart pacemakers must not carry out any work
on the ignition system.
Risk of poisoning from toxic exhaust gases. The exhaust gases
contain carbon monoxide, a colourless, odourless, toxic gas
Breathing carbon monoxide can lead to severe brain injuries or
death.
►Only operate combustion engines in the open air. Only op-
erate in enclosed spaces with exhaust gas extraction sys-
tems.
►Do not breathe in exhaust gases.
Fuel is extremely combustible, and under certain conditions a
fuel-air mixture can be explosive.
There is a risk of injury and damage to property through the
mishandling of fuel.
►Allow the engine to cool down before refuelling, do not
pour fuel over a hot engine or silencer.
►Only refuel in a well-ventilated environment and with the
engine switched off.
►Do not smoke when handling fuel.
►Keep fuel away from naked flames and sparks.
►Avoid repeated or persistent contact with the skin and in-
halation of vapours.
►Take care not to spill fuel when refuelling.
►Only top up fuel with a suitable means of filling (e.g. fun-
nel).
►Wipe up any fuel spillages immediately.
Dangers from internal com-
bustion engines
Dangers from fuel

2. Safety
14
►Make sure that any fuel spillages have completely evapo-
rated before starting the engine.
►After refuelling make sure the tank is tightly capped.
►Stand at least 3 m away from the refuelling point before
starting the engine.
►Under no circumstances should you start the engine if:
•Fuel was spilled on the engine. In that case, mop up the
spillage completely.
•Fuel has spilled on to the user or their clothes In that case,
change the clothes.
•Fuel is leaking out. Regularly check the tank cap and fuel
pipes for leaks.
►Store fuel out of reach of children.
If the fuel tank is overfilled, the heat generated can cause the
fuel to expand and escape through the openings in the fuel
cap.
►Do not fill the fuel tank so full that the fuel rises into the
filler pipe.
There may be live parts inside the product, which if touched
could cause severe or fatal injuries.
►Only authorised qualified electricians are permitted to work
on the electrical system.
►Any faults (faulty contacts, external damage to cable or
housing etc.) should be rectified immediately.
►Before working on the electrical system: Switch off the
drive, de-energise the system, disconnect the power supply
and secure against accidental reconnection.
►While working on the electrical system: Do not touch any
live wires.
►Check that the earthing cable for integrity and secure con-
nection.
►Check that the connecting surfaces of the earthing cable
are clean and free from corrosion.
The Hybrid Drive Unit is equipped with supercapacitors that are
charged when the combustion engine is running.
If there is a short circuit of the conductor bars inside the switch
box when the cover is open (e.g. through connection with a
conductive object) it can result in currents of up to several
hundred amps. Risk of severe burns from glowing metal parti-
cles and intense heat.
►Do not short circuit the two poles.
Dangers from electric current
Dangers from supercapaci-
tors

2. Safety
15
Risk of permanent damage, particularly to hearing, if the user
does not continuously wear suitable hearing protection.
►Wear hearing protection.
Risk of injury from touching hot parts.
►Do not touch hot parts.
►Prior to work on heated parts, switch off the machine allow
to cool down for at least 30 minutes.
Fire hazard
►The machine should be set up at least one metre away
from buildings and other equipment.
►Make sure that there are no inflammable materials in the
vicinity of the motor and that no objects are placed on the
motor when it is running.
►Do not cover or load the machine until it has properly
cooled down.
Most of the parts and components built into the product are
subject to special regulations regarding their disposal.
►Components must be sorted and properly disposed of ac-
cording to their material groups (steel, plastics, oils etc,).
►Waste oil and hydraulic fluid must be collected and dis-
posed of in accordance with the relevant regulations.
Unauthorised operation and improper use can lead to all kinds
of dangers and damage.
►The operation of the machine by unauthorised persons is
strictly forbidden.
►The operator must assess this risk for himself.
►The operator is responsible for taking measures to prevent
unauthorised operation of the machine.
The machine can start up unintentionally if buttons are acci-
dentally pressed during maintenance work. This can result in
serious injuries.
►Before carrying out any adjustments or maintenance, the
machine must be switched off (motor off) and secured
against unauthorised or accidental restarting. All energy
supplies (mechanical, electrical and hydraulic) must be
switched off, neutralised and secured against reconnec-
tion.
Dangers from noise
Dangers from heat
Risk of environmental dam-
age
Dangers from unauthorised
operation
Dangers from improper
maintenance

2. Safety
16
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.
►Consideration must be given to the possible accident risks
in connection with the particular tasks undertaken with the
product and appropriate instruction provided.
►Before starting up, the product must be checked that it is
in proper condition:
•completeness and integrity of equipment, aids, tools, ac-
cessories, protective devices etc.
•Inspection and servicing works properly completed on
schedule
•Topped-up consumables (fuels, lubricants etc.)
•Compliance with all conditions necessary to carry out the
works without risk to the user and other people, property
and the environment.
►Watch out for special risks posed by the product and in its
working area, particularly:
–persons and obstacles,
–adherence to safety clearances,
–traffic on adjacent tracks,
–secure fitting of all protective equipment,
–compliance with all operationally necessary safety
measures.
►Leaking operating fluids (oil, grease, etc.) must be removed
immediately to prevent a fire hazard or risk of slipping.
Keep suitable oil binding agents and cleaning agents at
hand.
►Before leaving the product check that:
•the machine has been properly shut down
•the machine has been secured to prevent accidental
movement
•tools and accessories have been stored securely
►Only machines, equipment and tools that are in good order
are used.
►Rectify even small defects immediately, to prevent them
becoming larger.

2. Safety
17
2.11 First Aid
Please ensure the following to be able to provide First Aid in an
emergency:
►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.
►Immediately replenish used up material.
►Store First Aid equipment (First Aid kit, blankets etc.) and
fire extinguishers within easy reach.
►Carry material for securing accident sites.
2.12 Fire safety
Fires involving fuels, oil, paints and varnishes release toxic
vapours.
Charring of cables from smouldering fires can release toxic
vapours.
►As far as is reasonably possible, everyone has the respon-
sibility of avoiding anything that could cause a fire or help
it to spread.
►In general, any fires that occur are to be fought only with
powder extinguishers.
The following fire safety measures must be adhered to.
►Only use approved fire extinguishers (powder-type extin-
guishers) of the prescribed fire protection class.
►Ensure that fire extinguishers are checked at regular inter-
vals and are marked with a test tag (every 2 years at the
latest, note expiry date!).
►After using a fire extinguisher, replace it without delay.
General

3. Technical data
18
3. Technical data
3.1 Drive
Type: HONDA GX200, Air cooled one-cylinder four-stroke en-
gine
Max. RPM
3,600 RPM
Max. output at 3,600 RPM
4.1 kW
Fuel
Petrol, min. 91 ROZ
(equivalent to 86
octane)
Consumption at 3,600 RPM
approx. 1.7 l/h
Emission values
Complies with Euro
II and
CARB/EPA Stage III
3.2 Electrical power (Output)
Nominal voltage
56 V
Nominal current (continuous)
80 A
Nominal current (intermittent)
125 A
3.3 Electrical interface
Number of contacts
eight poles 1.5 mm2
two poles 16 mm2
Protection Class
IP 55
•protected against polarity reversal
3.4 Dimensions
Length
840 mm
Width
500 mm
Height
450 mm
Height (with lifting beam)
570 mm
3.5 Fill quantities
Fuel
3.1 l
Engine: Engine oil: SAE 15W40
approx. 0.6 l
3.6 Weight
Hybrid Drive Unit
49.5 kg

3. Technical data
19
3.7 Noise emissions and Vibration
3.7.1 Noise emissions
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).
Assessment of the noise level for personnel
requires consideration of the actual working
environment for each worker (e.g. staying at
different places/machines).
Emission sound pressure level LpA
0 dB(A)*
Uncertainty of sound pressure level LpA
- dB(A)
Sound power level LWA
97,4 dB(A)
Uncertainty of sound power level LWA
1,5 dB(A)
*) Worker is not standing next to machine.
3.7.2 Vibration
Vibration total value hAV
5.86 m/s2
Uncertainty of vibration total value hAV
1.3 m/s2
The figures on vibration are for information
only, as this is not a hand-held machine.
3.8 Environmental conditions
Temperature range operation
-10°C to 40°C
Temperature range transport
-20°C to 50°C
Temperature range storage
-20°C to 50°C

4. Description of machine
20
4. Description of machine
4.1 Structure
The Hybrid Drive Unit comprises the components: drive motor,
rotor, stator and a number of supercapacitors.
Electrical energy is buffered in the supercapacitors, so that a
stable supply voltage is also assured even at high current con-
sumption.
4.2 Overview of the machine
Fig.
1:
Structure (right side)
1
Lifting point
4
Starter handle
2
Connecting cable
5
Carburettor
3
Engine
6
Handle (4x)