ROBEL 62.05L User manual

1
Content
OPERATING MANUAL
ROTAMP LIGHT
62.05L / Vers. 02
Vertical tamper

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Robel Bahnbaumaschinen GmbH
Industriestraße 31
83395 Freilassing
Telefon: ++49 (086 54) 609-0
Fax: ++49 (086 54) 609-445
E-Mail: [email protected]
Internet: www.robel.com
Translation of original operating manual
Status: 14.07.2020
Version 5 short
© 2020 Robel Bahnbaumaschinen GmbH
These operating instructions were issued taking into consideration
the latest technology at the time of printing.
They are subject to change due to new developments.
Dimensions and weights are approximate.
Some photos show special designs.

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Content
Content
1. General Information .................................................................................................................... 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 Information on particular types of dangers ..................11
2.10 Accident prevention ........................................................14
2.11 Fire safety ........................................................................16
3. Technical data............................................................................................................................17
3.1 Drive .................................................................................17
3.2 Dimensions......................................................................17
3.3 Filling Quantities .............................................................17
3.4 Weight..............................................................................17
3.5 Environmental conditions...............................................17
3.5.1 Temperature....................................................................... 17
3.5.2 Operating altitude.............................................................. 17
3.6 Noise emissions and vibration.......................................18
3.6.1 Noise emissions................................................................. 18
3.7 Vibration...........................................................................18
3.8 Digital tach/hour meter..................................................18

Content
4
4. Description of machine.............................................................................................................19
4.1 Design ..............................................................................19
4.1.1 Vertical tamper .................................................................. 19
4.1.2 Tamping pick...................................................................... 19
4.1.3 Guiding frame .................................................................... 19
4.2 General view ....................................................................20
4.3 Work station ....................................................................20
4.4 Petrol engine ...................................................................21
4.5 Signs and labels ..............................................................21
4.5.1 Signs and labels used....................................................... 21
4.5.2 Position on the product .................................................... 23
4.6 Digital tach/hour meter..................................................24
4.7 Accessories......................................................................24
5. Preparing the machine..............................................................................................................25
5.1 Digital inductive tach/hour meter .................................25
5.1.1 Operation ............................................................................ 25
5.1.2 Settings ............................................................................... 25
5.2 Checking/adjusting the carburetor setting...................27
5.2.1 Operation at high altitude (>800 m) .............................. 27
5.2.2 Operation at low altitude (<100 m)................................ 28
5.2.3 Adjusting idle...................................................................... 29
5.3 Checking the petrol engine ............................................29
5.3.1 Engine oil level ................................................................... 29
5.3.2 Air filter................................................................................ 31
5.3.3 Filling the tank ................................................................... 33
6. Operation....................................................................................................................................35
6.1 Starting the engine .........................................................35
6.2 Working with the tamper................................................37
6.2.1 Tamping (sleeper).............................................................. 37
6.2.2 Tamping (track panel)....................................................... 39
6.3 Stopping the engine........................................................40
6.4 Installing rail movement indicator (accessories) .........40
7. Transport and storage ...............................................................................................................41
7.1 Transport..........................................................................41
7.2 Storage.............................................................................42
8. Troubleshooting .........................................................................................................................44

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Content
9. Maintenance ..............................................................................................................................45
9.1 Maintenance schedule ...................................................46
9.2 Cleaning and care ...........................................................47
9.3 Engine ..............................................................................48
9.3.1 Cleaning the air filter ........................................................ 48
9.3.2 Cleaning the fuel filter ...................................................... 50
9.3.3 Maintaining the spark plug .............................................. 51
9.3.4 Idle adjustment.................................................................. 53
9.3.5 Reset carburetor to factory setting................................. 53
9.3.6 Changing the oil................................................................. 54
9.3.7 Changing fuel pipe ............................................................ 55
9.4 Rubber buffers.................................................................56
9.4.1 Checking the rubber buffers ............................................ 56
9.4.2 Replacing the rubber buffers........................................... 57
9.5 Centrifugal clutch ............................................................58
9.6 Tamping tool....................................................................59
9.6.1 Checking the tamping tool for wear ............................... 59
9.6.2 Replacing the tamping tool ............................................. 60
9.6.3 Changing bearings............................................................. 68
9.7 Signs and labels ..............................................................71
10. Environmental protection and disposal...................................................................................72
10.1 Environmental protection...............................................72
10.2 Disposal ...........................................................................72
11. Appendix.....................................................................................................................................73

1. General Information
6
1. General Information
Staff operating and maintaining this product must have read
and understood these operating instructions.
All those involved must have access to the operating instruc-
tions 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 product must generally be observed. If
they are not observed, the operator of the appliance takes re-
sponsibility for any legal consequences.
In the event of differences between prevailing regulations that
apply to use of the product and the manufacturer’s or sub-
contractor’s specifications, whichever limitations are the most
stringent must apply.
The buyer must provide all necessary machinery, equipment
and material resources for putting the delivered product into
operation and training staff. He must also make available un-
restricted, safe and sufficiently long track and work sections,
on which staff can learn how to operate and use the delivered
product and practise these tasks. Since the manufacturer or
supplier of the product has no influence over the buyer’s par-
ticular staffing and operating circumstances, no responsibility
is accepted for the effectiveness of the instructions.
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.

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1. General Information
1.3 Intended Audience for this Operating Manual
This manual contains the information needed to use the prod-
uct they describe correctly.
The manual has been written exclusively for technically quali-
fied personnel. Qualified personnel in this context are:
•Personnel who can prove that they are qualified to use this
product either through training or experience,
•Personnel familiar with the safety concepts that relate to
machinery and equipment,
•Maintenance and service personnel who are specially
trained to repair machines, appliances and its accessories.
Only persons who can read and understand this manual are
allowed to use the product. They should sign to indicate that
they have read and understood the manual.
Replacement, maintenance and operation of the product
should only occur where official regulations are strictly fol-
lowed for its use and safety, especially where they relate to
safety and protection of the workplace and environment as
well as the operating, maintenance and safety regulations or
other instructions supplied by the manufacturer or supplier.
1.4 Liability Exclusions
The manufacturer declares himself to be exempt from any
responsibility for damage arising when the product is not used
in a designated way. This also includes use of the machine
without safety mechanisms.
Any use of the product other than that specified above is not
designated and endangers the lives and health of operating
and maintenance personnel as well as the material property of
the operator. The manufacturer of the product declares himself
free from liability for damage to people or property belonging
to the operator or a third party if:
•the product is not used as specified,
•operating and maintenance personnel have not read and
understood the aforementioned directions and have used
the product for other purposes,
•operating or maintenance personnel are not sufficiently
qualified
•the product has been used under conditions exceeding
limiting values,
•the product has not been serviced within the time speci-
fied,
•the product has not been serviced using other than original
spare parts,
•product components or attachments have been altered
without authorisation.
These exclusions from liability for damage to people or materi-
al property do not affect other exclusions.

1. General Information
8
1.5 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. 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
These operating instructions apply to products with the follow-
ing EDP nos.:
•EDP-No. 899 990 0005
•EDP-No. 980 620 5190

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2. Safety
2. Safety
2.1 Designated use
The vibratory tamper 62.05L has been designed and manufac-
tured for is used in track construction to compact the ballast
bed under the sleepers
2.2 Foreseeable misuse
The vertical tamper must not be used for demolition work or
the like.
2.3 Conventions of layout
These instructions make use of the following warning texts and
symbols to keep the operator safe and injury-free and prevent
damage to the material assets of the operating company:
DANGER
Indicates that non-compliance with the in-
structions will result in death or severe (irre-
versible) injuries of the operating personnel.
WARNING
Indicates that non-compliance with the in-
structions may result in death or severe (irre-
versible) injuries of the operating personnel.
CAUTION
Indicates that non-compliance with the in-
structions may result in minor (reversible) inju-
ries of the operating personnel.
NOTICE
Points out that non-compliance with instructions may result
in damage to the product or other assets of the operating
company.
Contains important information about the
product, 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 will not be liable if any unauthorised chang-
es to product components and attachments are made.
Original parts and accessories have been designed specifically
for this product. The use of non-approved spare parts may re-
sult in structural features of the product being changed or im-
paired.
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
Danger to life for the operator and others from manipulation of
the safety devices!
►The operator is obliged to actually fit the designated pro-
tective devices during operation or to leave them in the
predetermined factory position.
►The person commissioned to carry out maintenance must
refit the protective devices after completing his work.
2.6 Safety regulations
The necessary requirements for protecting life, health, material
property and the environment when handling the product must
take precedence!
►Before using the product, make sure you can prove that all
personnel affected have been made aware of the following
relevant regulations and provisions:
•Statutory national safety regulations
•Provisions of the respective building code and works rules
•Provisions of the respective professional and trade associa-
tions
•Occupational and environmental health and safety regula-
tions
•Approvals regulations
•Company-internal regulations
•All other applicable regulations, in addition to and in con-
cert with the manufacturer’s safety and operating regula-
tions
Structure of the warnings

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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.
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.
•Comprehensive training on 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
product 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
The approved personal protective equipment has to be used
when operating and maintaining the product.
►Wear protective gloves!
►Wear ear protection!
►Wear steel-capped work shoes
The protective equipment is determined by:
•These instructions
•National safety rules
•Rules of the professional trade associations
•etc.
►If there are differences between the prevailing regulations
within the operating company's scope of validity and those
of the manufacturer and his suppliers, whichever regula-
tions are the most stringent shall be applied.
2.9 Information on particular types of dangers
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.
Operator
Requirements for the
operator
Danger due to heavy weight

2. Safety
12
►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.
►Carry out an assessment. Consider the following aspects
with regard to operators and the transport task:
–Frequency of transport
–Age
–Gender
–Operator’s state of health
►Observe the relevant guidelines on lifting and transporting
heavy machinery or equipment.
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.
When the engine is running, there is a risk of injury from rotat-
ing and hot components.
►Only authorised technical personnel may work on the com-
bustion engine.
►Switch off the engine and allow it to cool down.
►Check the engine regularly and rectify any faults found
straight away (e.g. damage, leaks).
►Listen out for unusual noises or vibrations, etc.
►Only perform maintenance with the engine switched off.
►Watch out for hot components.
The ignition cable carries high voltage to the spark plugs. Le-
thal electric shocks may result if the ignition cable or spark
plug is touched when the engine is running. Wearers of pace-
makers are particularly at risk.
►Do not touch the ignition cable or spark plug when the en-
gine is running.
►Wearers of pacemakers must not carry out any work on the
ignition system.
Danger of poisoning from exhaust gases. The exhaust gases
contain carbon monoxide, a colourless, odourless and toxic
gas. If breathed in, carbon monoxide can lead to severe brain
injuries or even death.
Danger due to unergonomic
operation
Danger from combustion en-
gines

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2. Safety
►Only operate combustion engines outdoors. Operate in
enclosed spaces only if exhaust fume extraction is in-
stalled.
►Do not breathe in exhaust fumes.
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,
►Refuel in a well-ventilated area with the engine stopped.
►Do not smoke when handling fuel.
►Keep fuel well away from naked flames and sparks.
►Avoid repeated or prolonged contact with skin or breathing
of vapour.
►Be careful not to spill fuel when refuelling.
►Refill fuel only with suitable filling devices (e.g. funnel).
►Wipe up spills immediately.
If the fuel tank is overfilled, heat subsequently generated may
cause the fuel to expand and emerge through openings in the
filler cap.
►Do not overfill the tank so that fuel rises up into the filler
neck.
Some parts may be live and may cause severe to fatal injuries
when getting in contact with them.
►Work on the electrical system only by authorised electrical
engineers.
►Rectify faults (contact faults, external damage to cables or
housings, etc.) straight away.
►Before working on the electrical system: Shut off the power
supply to the system, switch off the drive and disconnect
the power supply.
►During work on the electrical system: Do not touch any live
lines.
►Check earthing cables are securely seated and complete.
►Check that the connecting surfaces of the earthing cables
are clean and free from corrosion.
Permanent damage, especially to hearing, if the operator does
not constantly wear personal hearing protection.
►Wear ear protection.
Risk of injury from touching hot parts.
Danger from fuel
Danger from electrical
voltage
Danger from noise
Danger from heat

2. Safety
14
►Do not touch heated parts.
Prior to work on heated parts, switch off engines and allow
hot parts to cool down for at least 30 minutes.
Risk of fire
►Place the machine at least one metre away from buildings
and other equipment.
►Make sure that there is no flammable material near the
engine and that no objects are placed on the engine when
it is running.
►Only cover and/or reload the machine when it has cooled
down.
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.
►During the work process, incorporate vibration-free activi-
ties with mainly dynamic demands on muscles.
The majority of the components and parts used are subject to
special regulations for collection and disposal.
►Dispose of components according to material groups
(steel, plastics, oils, etc.).
►Collect waste oil in line with the relevant regulations and
dispose of it accordingly.
Unauthorised start-up and misuse can result in dangers and
damage of any kind.
►Unauthorised start-up by unauthorised persons is strictly
prohibited.
►It is up to the operating company to assess this risk.
►It is the responsibility of the operating company to imple-
ment appropriate measures against unauthorised start-up.
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.
►Consider the potential risks of accidents in association with
the special tasks of the product and provide for appropriate
training.
►Check that the product is in proper working order before
putting it into service:
Danger from vibration
Risk of environmental
damage
Danger arising from
unauthorised start-up

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2. Safety
•Equipment, devices, tools, accessories, safety equipment,
etc. are complete and intact.
•Inspection and maintenance work has been carried out
professionally and on schedule.
•Operating fluids have been topped up (fuel, lubricants, etc.)
•All prerequisites for carrying out work safely have been met
with regard to you and other persons, material property
and the environment.
►Beware of the particular dangers of the product and your
work area, especially:
•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 perform the following checks:
•It has been shut down properly.
•It is secured against moving unintentionally.
•Tools and accessories are stowed away safely.
►Use only machines, appliances and tools that work proper-
ly.
►Rectify smaller faults straight away in order to avoid larger
faults.
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.
►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.
First Aid

2. Safety
16
2.11 Fire safety
Poisonous vapours are released when fuels, oils, paints or var-
nishes catch fire.
In addition, all measures required to prevent the development
or spreading of a fire must be taken in individual cases.
With smouldering fires in electrical equipment toxic vapours
are released from charring cables, also with fires of fuels, oil or
paints.
►Everybody is obliged, as far as possible and reasonable to
refrain from any actions that may cause a fire or favour the
spreading of a fire. In addition, all measures required to
prevent the development or spreading of a fire must be
taken in individual cases.
►In general, any fires that occur are to be fought only with
powder extinguishers.
The following fire safety measures must be adhered to.
►Use only approved fire extinguishers (powder-type extin-
guishers) of the prescribed fire protection class.
►Check the fire extinguishers periodically and ensure that
they are provided with an inspection label (at least every 2
years, check the expiry date!).
►After using a fire extinguisher, replace it straight away.
General

17
3. Technical data
3. Technical data
3.1 Drive
Type: Dolmar 4300, air cooled one-cylinder four-stroke engine
RPM
7,500 RPM
Output at 7,500 U/min
1.5 kW
Fuel
Petrol, min. 91 ROZ
(equivalent to 86 oc-
tane)
Unleaded petrol
(E10 or less)
Alkylate based petrol
(four stroke)
Consumption per operational hour
approx. 0.9 l/h
Exhaust emissions
in accordance with
CARB Tier 3,
EPA Phase 2,
EU level 2
3.2 Dimensions
Length
1,080 mm
Width
510 mm
Height
410 mm
3.3 Filling Quantities
Fuel
0.6 l
Motor: Engine oil SAE 10W-30
0.06 l
Tamping pick: Engine oil SAE 10W-30
0.06 l
3.4 Weight
Tamper
19.6 kg
3.5 Environmental conditions
3.5.1 Temperature
Temperature range - operation
-20°C to 50°C
Temperature range - transport
-20°C to 60°C
Temperature range –storage
-20°C bis 60°C
3.5.2 Operating altitude
With standard valve equipment and carburet-
tor factory setting
100 m to 800 m,
ideal 400 m
For adjusting the operating altitude see chapter 5.2

3. Technical data
18
3.6 Noise emissions and vibration
Since the noise level criterion for personnel is exceeded when
working, suitable ear protection must be used (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)
3.6.1 Noise emissions
Sound pressure level LpA
113.6 dB(A)
Sound power level LWA
109.0 dB(A)
3.7 Vibration
Total vibration (vector sum of three directions)
7.7 m/s2
3.8 Digital tach/hour meter
Value
Range
Revolutions per minute (RPM)
0...60,000 U/min (UPM)
Max. value of revolutions per minute
ever reached (RPM)
0...60,000 U/min (UPM)
Operating hours
0…99,999 hours
Value
Resolution
Revolutions per minute (RPM)
1 U/min (UPM)
Max. value of revolutions per minute
ever reached (RPM)
1 U/min (UPM)
Operating hours
0.1 hour
Range
Resolution

19
4. Description of machine
4. Description of machine
4.1 Design
4.1.1 Vertical tamper
The vertical tamper consists of a petrol engine which drives a
shaft using an unbalance to produce the vibrations.
Mounted on the engine is the "engine stop" button for cutting it
off.
4.1.2 Tamping pick
The tamping pick consists of two parts. The tamping tool is
located on its bottom side.
4.1.3 Guiding frame
The guiding frame is fixed to the vibrator with damping via
eight rubber-metal buffers.
The throttle handle is fitted on the right-hand side.

4. Description of machine
20
4.2 General view
Fig.
1:
General view
1
Petrol engine
2
Protective cover
3
Guiding frame
4
Throttle handle
5
Rubber buffer
6
Tamping tool
7
Tamping pick
4.3 Work station
The operator stands behind the machine and grabs the han-
dles with both hands. For information on working ergonomical-
ly see chapter 6.2.1.