ROBEL ROPOWER 70.02 Operating Manual Download Page 13 | Manualshive

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2. Safety

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While the engine is running, there is a risk of injury from rotat-
ing and hot parts.

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Only suitably trained and qualified persons may work on
the engine.

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Switch off the engine and allow it to cool down.

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Inspect the engine at regular intervals and immediately
rectify any faults (e.g. damage, leaks) that are found.

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Be vigilant for unusual noises, vibrations etc.

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Only carry out maintenance work when the engine is
switched off.

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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.

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Do not touch the spark plugs and spark plug cables while
the machine is operating.

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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.

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Only operate combustion engines in the open air. Only op-
erate in enclosed spaces with exhaust gas extraction sys-
tems.

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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.

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Allow the engine to cool down before refuelling, do not
pour fuel over a hot engine or silencer.

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Only refuel in a well-ventilated environment and with the
engine switched off.

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Do not smoke when handling fuel.

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Keep fuel away from naked flames and sparks.

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Avoid repeated or persistent contact with the skin and in-
halation of vapours.

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Take care not to spill fuel when refuelling.

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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

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Summary of Contents for ROPOWER 70.02

Page 1: ...Content 1 OPERATING MANUAL ROPOWER 70 02 model 02 Hybrid Drive Unit ...

Page 2: ...ion 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 ...

Page 3: ...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 Fi...

Page 4: ... 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 2 Make electrical connections 39 7 3 Starting the engine 42 7 4 Engine running 46 7 5 Stopping the engine 47 7 6...

Page 5: ...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 ...

Page 6: ... 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 o...

Page 7: ...liers 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 ...

Page 8: ... 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 Furthe...

Page 9: ...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 opera...

Page 10: ...r 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 affecte...

Page 11: ...al 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 wor...

Page 12: ...tor 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 mod...

Page 13: ...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 ai...

Page 14: ...njuries 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 ...

Page 15: ...ir 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 mea...

Page 16: ...nts 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 safe...

Page 17: ...volving 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 ...

Page 18: ... 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 ...

Page 19: ...orker 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 onl...

Page 20: ...or 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 ...

Page 21: ...4 Description of machine 21 Fig 2 Structure left side 1 Fuel tank 3 Rotor and stator DC 2 Main frame 4 Socket ...

Page 22: ...4 Description of machine 22 4 3 Control elements 4 3 1 Petrol Engine Fig 3 Handle of recoil starter 1 Handle of recoil starter Fig 4 Engine switch 1 Engine switch 2 Position ON I 3 Position OFF 0 ...

Page 23: ...l elements engine 1 Throttle lever 2 Fuel tap 3 Choke lever 4 3 2 Indicating elements Fig 6 LED Charge controller status 1 Description LED Status 2 LED LED green continuous Voltage O K LED red continuous Voltage not O K LED red flashing Error ...

Page 24: ...l Logo of manu facturer Fig 8 Type plate example Fig 9 Label Wear ear pro tection Fig 10 Label Observe operating instructions Fig 11 Label Fuel and tank capacity Fig 12 Label Do not turn machine onto this side Fig 13 Label Status LED charge controller Fig 14 Label AUTHOR ISED PERSONS ONLY ...

Page 25: ...4 Description of machine 25 Fig 15 Label Lift here Fig 16 Label LWA 96db Fig 17 Label Starting by instructed personnel only Fig 18 Label Earthing symbol Fig 19 Label Important instruction ...

Page 26: ...uct Fig 20 Signs and Label right side 1 Label Lift here 5 Label High voltage 2 Label Status LED charge controller 6 Label Fuel and tank capacity 3 Label Authorised persons only 7 Label Important instruction 4 Label Logo of manufacturer 8 Label Hot surface ...

Page 27: ...rn machine on this side 4 5 Workplace The user stands in front of the Hybrid Drive Unit when starting and stopping the engine After the engine has started the im mediate presence of the user is no longer necessary because the Hybrid Drive Unit does not offer any further operating op tions However the Hybrid Drive Unit must not be left running unattended 4 6 Structure gauge The Hybrid Drive Unit is...

Page 28: ...sumption The engine can be operated at high altitudes by making certain adjustments to the carburettor If the engine is to be continual ly operated at altitudes of 1 500 m or more above sea level arrange for your supplier to have the carburettor calibrated accordingly Even with the recommended carburettor setting the engine performance falls by around 3 5 for every 300 m increase in altitude above...

Page 29: ...n the carburettor by undoing the carburettor drain screw Drain the fuel into a suitable container 5 Replace the engine oil 6 Remove the spark plug and pour one tablespoon of clean engine oil into the cylinder 7 Crank the engine several revolutions to distribute the oil then screw the spark plug back in again 8 Pull the starter cord until a slight resistance is noticed 9 Then continue pulling until...

Page 30: ...5 Operating conditions 30 Fig 23 Aligning the two marks 1 Hole on recoil starter 2 Notch on the starter pulley 10 Cover the engine to keep out dust ...

Page 31: ...se in the back and shoulders A variety of other injuries may result Always transport the machine with suita ble equipment e g suitable trolley Lift the machine with suitable lifting equipment e g crane hoist tail lift or at least a four person team See chap 2 9 for further details on manu al handling This value is conservative and has been determined following the demands of the standard DIN EN 13...

Page 32: ...erating conditions 32 The centre of mass of the Hybrid Drive Unit is at the spot indi cated by the centre of gravity symbol Fig 24 Centre of mass Fig 25 Lifting the Hybrid Drive Unit Centre of mass Lifting ...

Page 33: ...uffler side See label on machine fuel tank 1 Unscrew the spark plug 2 Open the float drain screw on the carburettor and allow it to drain 3 Pull the starter cord the oil spurts out of the cylinder 4 Screw the spark plug and drain screw back in 5 Check the oil level and start the engine 6 1 Air filter NOTICE Risk of engine damage If the engine is operated without an air filter particles of dust can...

Page 34: ...r filter inserts to ensure they are clean and in good condition 2 Clean or replace the air filter inserts 4 and 5 if neces sary see Ch 8 2 3 Fig 26 Air filter 1 Wing nut 2 Air filter cover 3 Wing nut 4 Paper element 5 Sponge element 6 Gasket ...

Page 35: ...w it in 3 If the oil level is low top up with recommended oil to the lip of the oil filler neck NOTICE Risk of engine damage The use of non soluble oils or two stroke oils has an adverse effect on the service life of the engine Do not use non soluble oils or two stroke oils Use a high grade high detergent engine oil that meets or ex ceeds the requirements of SG or SF quality classification of the ...

Page 36: ...6 Checking the machine 36 Fig 28 SAE viscosity classes 1 Single grade oil 2 Multigrade oil 3 Ambient temperature ...

Page 37: ...lled or where petrol is stored Do not overfill the fuel tank there should be no fuel in the filler neck After refuel ling make sure the tank cap is closed properly and securely If the fuel tank is overfilled the heat generated by the en gine can cause the fuel to expand and leak through the openings in the fuel filler cap Be careful not to spill fuel when refuelling Check the leak tightness of the...

Page 38: ...pes of plastic Take care not to spill fuel when topping up Use vehicle petrol preferably unleaded or fuel with a low lead content in order to lim it combustion residues to a minimum Fill the fuel tank at least half full 1 Remove the fuel tank cap 2 Top up with fuel up to the bottom of the filler pipe Do not overfill 3 Wipe up petrol spillages before starting the engine 4 Screw on tank cap again 6 ...

Page 39: ...anu al handling This value is conservative and has been determined following the demands of the standard EN 13977 2011 However the operating company is entitled to conduct a risk assessment and to allow less persons if this is the outcome of the risk assess ment 1 Move the Hybrid Drive Unit to the installation site 2 Place the Hybrid Drive Unit on a level firm surface only 7 2 Make electrical conn...

Page 40: ...ections 1 Socket Hybrid Drive Unit 2 Plug of connector cable 3 Socket Example Hybrid rail head grinding machine 4 Plug of connector cable 3 Insert the plug of the connecting cable 4 into the socket of the working machine 3 4 Insert the plug of the connecting cable 2 into the socket of the Hybrid Drive Unit 1 5 Ensure cables are laid safely ...

Page 41: ...n 41 The connecting cable is equipped with special connectors Re fer to the following procedure for plugging in and locking the connector Fig 32 Plug in the connector Fig 33 Close the bracket Fig 34 bracket closed Operating the connector ...

Page 42: ...the engine run in enclosed or poorly ventilated spaces Risk to life from electric shocks The spark plug lead carries high voltage from the ignition coil to the spark plug Do not touch the ignition coil lead when the machine is operating People with heart pacemakers must not carry out any work on the ignition system See also engine manual from manufacturer 1 Set the throttle lever to idle Preparing...

Page 43: ... tap ON OPEN 2 Fuel tap The choke is needed in cold weather or when the engine is cold to enrich the mixture by narrowing the cross section of the suction inlet Do not use the choke when the engine is warm or the air temperature is high 3 Move the choke lever to the CLOSE position Fig 39 Choke position CLOSE 1 Position CLOSE 2 Choke lever ...

Page 44: ...ever to the left by about 1 3 from the MIN IDLE position Fig 40 Throttle lever to Position 1 3 1 Throttle lever 2 Position MIN idle 3 Position MAX fast 4 Position 1 3 5 Turn the engine switch to ON Fig 41 Turn the engine switch to ON 1 Engine switch 2 Position ON ...

Page 45: ... of the starter handle after the start up pro cess it can get damaged Do not allow the starter handle to snap back against the engine but move it back gently If the super capacitors are discharged com pletely increased resistance may be noticed when pulling the starter handle This is normal and this effect will disappear after a few at tempts Fig 42 Pull Handle of recoil starter 1 Handle of recoil...

Page 46: ...ove it back to OPEN to the right whilst the engine is warming up Fig 43 Move choke lever to the CLOSE Position 1 Position CLOSE 2 Choke lever 3 Position OPEN 4 Position CLOSE 2 Move throttle lever to the left MAX Fast highest RPM Fig 44 Move Throttle lever to position MAX 1 Throttle lever 2 Position MAX fast 3 Position MIN slow ...

Page 47: ...e engine after running at high speed and full power reduce the engine speed and let the engine run on idle for about a minute Also let the engine run at idle speed for about a minute to allow it to cool down 1 Switch off the working machine main switch in OFF posi tion 2 Move engine switch to the OFF Position Fig 45 Engine switch in Position OFF 1 Position OFF 2 Engine switch The engine stops 3 Mo...

Page 48: ...onductive object it can result in currents of up to several hundred amps There is a risk of severe burns from glowing metal particles and intense heat Wait at least two minutes before pulling the plug out of the socket Make sure that the contacts on the plug are not short circuited Fig 46 Disconnecting electrical link 1 Wait two minutes until the capacitors in the machine have discharged 2 Pull ou...

Page 49: ...table trolley Lift the machine with suitable lifting equipment e g crane hoist tail lift or at least a four person team See chap 2 9 for further details on manu al handling This value is conservative and has been determined following the demands of the standard DIN EN 13977 2011 However the operating company is entitled to con duct a risk assessment and to allow less persons if this is the outcome...

Page 50: ...are parts or parts of equal quality 1 Use only the recommended lubricants and when carrying out repairs use only original spare parts This is important firstly for warranty cases and secondly to enhance the operational reliability of your machine Correct ordering of spare parts is an essential contribution to a speedy delivery of spare parts and consequently to the eco nomic viability of the machi...

Page 51: ...ing machine Interval Component Maintenance work After each service or after every ten operating hours Engine oil Check oil level see Ch 6 2 Air filter Check 1 see Ch 8 2 3 Replace clean 1 see Ch 8 2 3 After the first month or after the first five operating hours Engine Oil Change oil see Ch 8 2 2 Every 25 hrs Air filter Replace 1 After each season or every 50 hrs Engine Oil Replace 2 see Ch 8 2 2 ...

Page 52: ...d dealer unless the operator has the necessary tools and maintenance data and staff with the necessary technical knowledge and skills Engine inspection and adjustment at regular intervals are the prerequisite for long lasting high performance Regular maintenance contributes to a long service life The required maintenance intervals and type of work to be carried out are described in the table in ch...

Page 53: ...ck clean Fig 47 Checking the engine oil level 1 Max oil level 2 Min oil level 3 Oil filler cap with dipstick 4 Oil filling opening 2 Insert the dipstick into the oil filling opening 4 but do not screw it in NOTICE Risk of engine damage The use of non soluble oils or two stroke oils has an adverse effect on the service life of the engine Do not use non soluble oils or two stroke oils 3 If the oil l...

Page 54: ... rubbish or pour it on the ground or into drains ROBEL suggests that you take the oil in a sealed container to your local waste oil collec tion point Drain the oil while the engine is still warm to ensure speedy and complete draining 1 Place a large container pan etc Fig 48 Changing the oil 1 Oil filler cap dipstick 2 Drain plug 3 Oil level 2 Remove the oil filler cap and the drain plug 3 Drain th...

Page 55: ...hout an air filter particles of dust can enter the combustion chamber Scoring of the en gine moving parts occurs pistons and cylinders The engine loses compression and hence performance Never leave the engine running without the air filter NOTICE Risk of damaging the air filter compressed air is used to clean the air filter the sensitive filter elements may be destroyed Brushing will press the dir...

Page 56: ...ion of household de tergent and warm water and then rinse thoroughly or clean in a non flammable solvent or in one with a high flash point 2 Allow the filter element to dry thoroughly 3 Dip the filter element in clean engine oil and then squeeze out excess oil The engine will smoke when first started if too much oil is left in the foam Foam filter element ...

Page 57: ...o not smoke or allow flames or sparks in the area Check for leaks after fitting the filter cup and ensure the area is dry before the en gine is started 1 Turn the fuel tap to OFF CLOSED 2 Remove the filter cup and O ring and wash in a non flammable solvent 3 Allow to dry thoroughly and then refit and tighten the cup securely 4 Turn the fuel tap to ON OPEN and check for leaks Fig 50 Cleaning the fi...

Page 58: ...of engine damage The engine can be damaged if the spark plug has the wrong heat rating Use a spark plug with the correct heat rating To ensure optimum engine performance the spark plug must be correctly adjusted and free from deposits CAUTION Risk of burns from hot silencer During engine operation the silencer will get hot If the engine was in operation a short time earlier be careful not to touch...

Page 59: ...ug if there is apparent wear or if the insulator is cracked or chipped Fig 52 Spark plug gap 1 Sealing washer 2 Spark plug gap 1 Measure the spark plug gap 2 with a feeler gauge 2 If necessary correct the spark gap by bending the earth electrode Spark plug gap 0 70 0 80 mm 0 028 0 031 Measuring adjusting the spark plug gap ...

Page 60: ...atisfactory then screw the spark plug back in by hand to avoid cross thread ing When installing a new spark plug tighten turn after it seats to compress the sealing washer When reinstalling the original spark plug tighten 1 8 to 1 4 turn after the spark plug seats to compress the sealing washer 2 After the spark plug is seated tighten it with a spark plug wrench to compress the sealing washer 3 At...

Page 61: ...and allow to warm up 2 Push throttle lever to the MIN position 3 While the engine is running adjust the idle adjustment screw in order to obtain the standard value for rpm Default rpm at idle 1 400 200 150 RPM Fig 53 Idle adjustment 1 Idle adjustment screw ...

Page 62: ... from glowing metal particles and intense heat Make sure that the socket is in good con dition Do not use the Hybrid Drive Unit if the socket or parts of the electrical system are damaged 1 Check the socket for damage before each use 2 Check the function of the cover Lift up the cover and let go The cover must close again by itself 3 Make sure that all wiring is in good condition Fig 54 Visual che...

Page 63: ...RNING Risk of burns due to short circuiting The super capacitors inside the electronics carry a voltage of up to 60 V even after the drive motor has been switched off Currents of up to several hundred amps can flow if the two poles of super capacitors are short circuited e g by connecting to an electrically conducting object There is a risk of severe burns from glowing metal particles and in tense...

Page 64: ...4x screws of the cover 3 Remove the cover 4 Use a voltmeter to measure the voltage at the poles of the super capacitors and ensure that they are fully discharged 5 Unscrew the six screws including sealing washers on the heat sink Fig 56 Unscrew 6x screws on the heat sink ...

Page 65: ...ler marked yellow sealing washer item 8 7 Examine all sealing washers for signs of damage and re place if necessary Also replace the sealing washers if on visual inspection they appear to be over compressed Sealing washers 5 2x16 item 8 in parts list in total 16 EDP No 900 042 0274 Sealing washers 7 6x19 item 6 in parts list in total 10 EDP No 900 042 0260 Alternative Maintenance kit with all requ...

Page 66: ... is a risk of it loosening Use medium strength Loctite thread locker Fig 58 Left too little pretension centre too much pretension right optimum pretension Fig 59 Self retaining nuts on the heat sink Do not use Loctite where screws have self retaining nuts on the inside 1 Coat the threads of the screws with medium strength Loc tite thread locker 2 Insert the heat sink screws and sealing washers and...

Page 67: ...lace labels if necessary 8 5 Cleaning and care NOTICE Risk of damage Cleaning the machine with solvents aggressive or combus tible 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 machine Do not use any solvents or aggressive combustible clean ing fluids Do...

Page 68: ... stops at idle Idle too low Adjust idle see Ch 8 2 6 Engine does not reach full power 3 600 RPM Throttle lever is not in position MAX Turn throttle lever to Max position Refer to manual of engine manu facturer for other possible issues Engine gets hot poor perfor mance Fuel filter clogged Clean fuel filter Deployment at low altitude without adjustment of the car burettor jet Adjust carburettor jet...

Page 69: ...s are at particular risk Do not touch the spark plugs and spark plug cables while the machine is operating Use insulated pliers to perform the spark test People with heart pacemakers must not carry out any work on the ignition system 4 Using isolated pliers hold the spark plug against the frame to earth the side electrode then pull the recoil starter to check whether sparks are being produced 5 If...

Page 70: ...e ROBEL Discharge box 2 Check using a multimeter to see whether any voltage is present on the terminals 2 If there is no voltage 0V DC present 3 With the aid of the ROBEL discharge box accessory discharge the capacitor battery even if no voltage has been measured 4 Unscrew attachment screws 4 14x and remove the dark grey cover 5 from housing 3 5 Check wiring for breaks or loose cables 6 Check glas...

Page 71: ...ute the ground or get into the drains 10 2 Disposal The disposal of the product including machine parts engine oil and fuel will depend upon the local regulations for waste disposal If the product reaches the end of its life cycle ensure a safe and proper disposal particularly of parts or substances which are harmful for the environment These include among oth ers fuel lubricants and plastics 1 Si...

Page 72: ...11 Appendix 72 11 Appendix Fig 61 EC Declaration of conformity EC declaration of conformity ...

Page 73: ...Content 目录 1 产品说明书 ROPOWER 70 02 model 02 混合动力驱动系统 ...

Page 74: ... Freilassing 电话 49 086 54 609 0 传真 49 08654 609 445 电子邮箱 info robel com 网址 www robel com 产品说明书译文版日期 2019 年 1 月 31 日版本 V6 德国 Robel 轨道机械有限公司 2019 版权所有本产品说明书是按照打印时的技术现状编制的 Robel 公司保留在进一步发展的基础上进行修改的权利尺寸和重量都为近似值在某些情况下照片显示的为特殊布局 ...

Page 75: ... 验收设备及经营许可证 8 1 7 本说明书的有效性 8 2 安全 9 2 1 指定用途 9 2 2 可预见的误用 9 2 3 布局惯例 9 2 4 设计变更原装零件 10 2 5 防护装置 10 2 6 安全规程 11 2 7 工作人员资质 11 2 8 人身防护设备 PPE 12 2 9 关于特定类型危险的说明 13 2 10 事故预防 17 2 11 急救 18 2 12 消防安全 19 3 技术参数 20 3 1 驱动装置 20 3 2 电力输出 20 3 3 电气接口 20 3 4 尺寸 20 3 5 加油量 21 3 6 重量 21 ...

Page 76: ... 机器简介 23 4 3 控制元件 25 4 3 1 汽油发动机 25 4 3 2 指示元件 26 4 4 标志和标签 27 4 4 1 使用的标志和标签 27 4 4 2 产品上的位置 29 4 5 工作场所 30 4 6 结构限界 30 5 运行条件 31 5 1 操作 31 5 2 储存 32 5 3 运输 34 6 查机器 36 6 1 空气过滤器 36 6 2 发动机油位 38 6 3 重新加满油箱 40 6 4 目视检查 42 7 动机器 43 7 1 安装机器 43 7 2 进行电气连接 43 7 3 启动发动机 46 7 4 发动机运转 51 ...

Page 77: ...57 8 1 3 机器 57 8 2 发动机 58 8 2 1 检查发动机油位 59 8 2 2 换油 60 8 2 3 空气过滤器 61 8 2 4 清洗滤杯 64 8 2 5 火花塞维护 65 8 2 6 怠速调整 68 8 3 电气系统 69 8 3 1 目视检查 69 8 3 2 重新拧紧螺钉 70 8 3 3 安装具有正确预紧力的密封垫圈 73 8 4 标志和标签 74 8 5 清洁与护理 74 9 故障措施 75 9 1 火花试验 76 9 2 机器没电了 77 10 环境保护与处置 79 10 1 环境保护 79 10 2 处置 79 11 附录 80 欧共体声明 ...

Page 78: ...列表可以更改顺序度量度量度量顺序不得更改 1 2 总则一般情况下使用本产品必须遵守适用法律要求和事故预防措施如未遵守设备操作人员承担任何法律后果的责任如果适用于产品使用的现行法规与制造商或分包商的规范之间存在差异则以最严格的限制规定为准买方必须提供一切必要的机械设备和材料资源以便将交付的产品投入生产并培训员工买方还必须提供无限制安全和足够长的轨道和作业区段在这些区段上员工可以学习如何操作和使用交付的产品并进行实操训练产品制造商或供应商对买方的特定人员配置和操作环境没有影响因此对本手册的有效性不承担任何责任但是罗湃尔轨道机械有限公司及其客户服务部门乐于提供进一步的建议培训或其他咨询服务更多细节和条件可另行获取 ...

Page 79: ...严格遵循产品使用和安全方面的官方规定特别是涉及工作场所和环境的安全与保护以及制造商或供应商提供的操作维护和安全规定或其他指示才可以替换维护和操作本产品 1 4 责任免除制造商声明对于产品未按指定方式使用引起的任何损坏包括在没有安全措施的情况下使用机器制造商不承担任何责任本说明书并未指定除产品规定使用方式以外的危及操作和维护人员的生命健康以及操作方的物质财产的任何使用如果下列情况发生该产品的制造商声明对属于操作方或第三方的人员或财产的损害不承担任何责任该产品没有按照规定的方式使用操作和维护人员没有阅读和理解上述说明并将该产品用于其他用途操作或维护人员不具备足够的资格该产品已在超过限值的条件下使用该产品没有在规定的时间内进行保养使用非原装备件对产品进行了保养未经许可对产品部件或附件进行了更改这些对人身或物质财产损害的责任免除并不影响其他...

Page 80: ...的任何人 1 6 验收设备及经营许可证买方有责任检查所交付货物的条件配件性能特别是安全性能是否与所商定的有关规格以及合同中的规定相符买方必须为交付的货物配备一切必要的配件以符合有关的操作和安全规程规范法规或其他规定如灭火器急救箱信号和通讯设备附加报警装置防护服安全告示等除非另有约定货物交付时不提供此等性质的配件此外买方有责任证明所交付的货物已通过认证供有关当局使用制造商或供应商为此目的需提供的任何文件说明证明认证等应在供应合同中加以规定为取得操作认证所需的任何额外措施和费用都必须由买方承担 1 7 本说明书的有效性本产品说明书适用于以下 EDP 编号产品 EDP 参考编号 502 990 0002 ...

Page 81: ...频率的设备和机器例如不适用于 230 V 50 Hz AC 或 400 V 50 Hz AC 混合动力驱动系统不能连接干线电源混合动力驱动系统不能用绳索或扎带绑在作业机器上例如 ROGRIND 13 49 打磨机 2 3 布局惯例本说明书利用下列警告文字及符号来保障操作人员的安全以及保护其不会受到伤害并防止对运营公司的物质资产造成损害危险该符号表明不遵守产品说明书将导致操作人员死亡或严重不可逆的伤害警告该符号表示不遵守产品说明书可能导致操作人员死亡或严重不可逆的伤害小心该符号表示不遵守产品说明书可能导致操作人员轻微可逆的伤害 ...

Page 82: ...重要信息预警结构这些警告的结构如下警示词危险的类型和来源忽视危险时的可能后果采取措施规避危险 2 4 设计变更原装零件如擅自对产品部件和附件进行任何更改制造商概不负责原装零件和配件是专门为产品设计的使用未经批准的备件可能导致产品的结构特性发生变化或受损对于因使用此类零件或劣质操作液体而造成的任何损坏制造商不负任何责任 2 5 防护装置操作安全装置会对操作人员和他人的生命构成危险操作者有义务在操作过程中切实安装好指定防护装置或保持其预定出厂状态受委托进行维护的人员在完成工作后必须重新安装防护装置 ...

Page 83: ...业协会的规定职业与环境健康和安全条例审批规程公司内部规章制度制造商的安全和操作规程之外并与之一致的所有其他适用规定必要时负责操作的办公室必须针对产品的特殊作业制定额外的规程和措施以确保满足所有的安全要求除上述资料外还必须遵守和符合具体的安全规则 2 7 工作人员资质运营公司对操作人员就分配给他的作业任务进行了培训并告知操作人员不适当的行为可能带来的危险产品综合培训了解操作和维护说明的内容了解供应商及辅助设备的操作和维护说明的内容了解有关产品和辅助设备的国家法律和法规身心健康具有专注力责任感可靠性必要的国家要求资格最低年龄无酒精药物毒品疲劳等影响操作人员对操作人员的要求 ...

Page 84: ...2 安全 12 2 8 人身防护设备 PPE 在产品的操作和维护过程中使用认可的 PPE 佩戴适合高频噪音的听力保护装置穿钢顶工作鞋 PPE 根据下列项确定产品说明书国家安全条例专业协会规定其他适用规例如果适用于产品所有者的现行规定与制造商及其供应商提供的说明有任何不一致之处则较严格者适用 ...

Page 85: ...定运营公司有责任确保遵守其所在国家的安全条例和行业协会指南本产品说明书的警告留意述及的价值观与德国法规有关确保已进行风险评估并考虑到关于操作人员和运输作业的下列方面运输频率年龄性别操作人员健康状况地面不平整作业现场照明差天气不好在时间压力下工作等遵守起重及运输重型机械或设备的有关指南在可能的情况下机械起重工具始终是首选的搬运方式如起重机举升后厢板轨道自动车等始终用手柄来抬起模块始终使用两只手并对称地处理模块操作时不要扭转脊椎在没有休息的情况下或在没有使用机械辅助设备的情况下不得携带任何超过 10 米的模块联系您的健康和安全顾问以获得更多信息手动操作引起的危险 ...

Page 86: ...导致人身伤害的风险只有受过适当培训和有资质的人才能在发动机上工作关掉发动机让它冷却定期检查发动机发现任何故障如损坏泄漏等应立即纠正对不寻常的噪音振动等保持警惕仅在发动机关闭的情况下进行维护小心热部件火花塞引线给火花塞带来高电压当发动机运转时触碰火花塞或火花塞引线会导致致命的电击有心脏起搏器的人尤其危险机器运转时请勿触摸火花塞及火花塞电缆有心脏起搏器的人不得在点火系统上进行任何工作有毒废气中毒风险废气中含有一氧化碳这是一种无色无味有毒的气体吸入一氧化碳会导致严重的脑损伤甚至死亡只能在户外操作内燃机只有在安装排气排烟装置的情况下才可在密闭的空间内进行操作切勿吸入废气不符合人体工程学操作的危险内燃机危险 ...

Page 87: ... 操作燃料时不要吸烟保持燃料远离明火和火花避免反复或持续接触皮肤和吸入蒸气加油时注意不要弄洒燃油只用适当的方法来加油例如漏斗立即擦净任何燃油溢出物在启动发动机前确保所有的燃油溢出物已完全蒸发加油后确保油箱盖得严严实实在发动发动机之前至少站在离加油点 3 米远的地方在任何情况下如果燃油洒在发动机上了在这种情况下把溢出物全部擦掉燃油已经溢出到使用者或他们的衣服上在这种情况下更换衣服燃油正在漏出定期检查油箱盖和燃油管路是否有泄漏将燃料存放在儿童够不着的地方如果油箱过满产生的热量会导致燃料膨胀并通过油箱盖的开口逸出不要把油箱加得太满以至于燃油上升到加油管道中燃料危险 ...

Page 88: ...意外重新连接在电气系统上作业时请勿触摸任何带电的电线检查接地电缆的完整性及连接安全性检查接地电缆的连接表面是否清洁无腐蚀混合动力驱动系统配备超级电容器在内燃机运行时充电当开关箱盖打开时如果开关箱内的导体棒短路比如经由与导电物体的连接会产生高达数百安培的电流因灼热的金属颗粒和高温而有严重灼伤的风险不要使两极短路如果使用者没有持续佩戴适当的听力防护装置可能会对身体尤其是听力造成永久性损害佩戴听力保护装置接触热部件有受伤的危险请勿触摸发热部位在加热部件上工作之前请关掉机器至少冷却 30 分钟火灾危险这台机器应安装在离建筑物和其他设备至少一米远的地方电流危险超级电容器的危险噪音危险热危险 ...

Page 89: ...当会导致各种危险和损害严禁未经许可的人员操作机器操作人员必须为自己评估这个风险操作人员有责任采取措施防止未经许可的机器作业如果在维护工作中不小心按了按钮机器可能会在无意中启动这可能会导致严重的人身伤害在进行任何调整或维护之前机器必须关闭电机关闭并放置未经授权的或意外的重新启动所有的供能装置机械电气和液压必须关闭中和和防止重新连接 2 10 事故预防土木工程协会的事故预防规例亦适用于本说明书须仔细阅读和遵守始终遵守通用的和内部的事故预防规定必须考虑与产品所承担的特定作业任务相关的可能事故风险并提供相应说明启动前必须检查产品是否处于正常状态设备辅助装置工具附件防护装置等是否齐备且完好环境损害风险违例操作的危险维护不当的危险 ...

Page 90: ...安全间隙要求邻近轨道上的交通确保所有保护设备安装牢固遵守所有操作上必要的安全措施操作液体机油润滑脂等泄漏必须立即去除以防止发生火灾或滑倒的危险手边应备有适当的油封剂和清洗剂离开产品前请检查机器已妥善关闭机器已固定以防止意外移动工具和配件已安全储存只使用状况良好的机器设备和工具即使是小缺陷也应立即纠正以防变成大缺陷 2 11 急救请确保能在紧急情况下提供下列急救措施确保急救箱处于良好状态在任何时候都是齐备和干净的向贵方办事处的医疗服务机构或医生咨询急救措施和相应设备立即补充已用完的物资储存急救设备急救箱毯子等和容易取到的灭火器携带保护事故现场的材料 ...

Page 91: ...2 消防安全燃料机油油漆和清漆引起的火灾会释放出有毒的蒸气因闷火烧焦的电缆也会释放出有毒的蒸气在尽可能合理的范围内每个人都有责任避免任何可能引起火灾或加剧火灾蔓延的事情一般来说发生任何火灾都只能用干粉灭火器来扑灭一般要求必须遵守下列消防安全措施只使用经认可的防火级别的灭火器粉末型灭火器确保灭火器每隔一定时间检查一次并贴上测试标签最迟每 2 年检查一次注意到期日使用完灭火器后立即更换 ...

Page 92: ... RPM 3 600 RPM 下输出最大值 4 1 kW 燃料汽油至少 91 ROZ 相当于 86 辛烷值转速 3 600 RPM 时的油耗大约 1 7 l h 排放值符合欧 II 及 CARB EPA III 级 3 2 电力输出标称电压 56 V 标称电流连续 80 A 标称电流间歇 125 A 3 3 电气接口触点数八极 1 5 mm2 两极 16 mm2 防护等级 IP 55 防止极性反转 3 4 尺寸长度 840 mm 宽度 500 mm 高度 450 mm 高度带升降梁 570 mm ...

Page 93: ...排放及振动 3 7 1 噪音排放由于作业时的噪音超过了适用于人的噪音标准因此必须佩戴适当的听力保护装置也请参见国家法律法规以及基本的健康和安全要求评估人员适用的噪音水平需要考虑到每个工人的实际工作环境比如呆在不同的地方机器处排放声压级 LpA 0 dB A 声压级 LpA 不确定度 dB A 声功率级 LWA 97 4 dB A 声功率级 LWA 不确定度 1 5 dB A 作业人员不是站在机器旁边 3 7 2 振动振动总 hAV 值 5 86 m s2 总振动值不确定度 1 3 m s2 关于振动的数值仅供参考因为这不是一台手持的机器 ...

Page 94: ...3 技术参数 22 3 8 环境条件操作温度范围 10 至 40 运输温度范围 20 至 50 储存温度范围 20 至 50 ...

Page 95: ...4 机器简介 23 4 机器简介 4 1 结构该混合动力驱动系统包括以下部件驱动电机转子定子及多个超级电容器在超级电容器中缓冲电能这样即使在高电流消耗的情况下也能保证稳定的电源电压 4 2 机器简介图 1 结构右侧 1 举升点 4 起动器手柄 2 连接电缆 5 化油器 3 发动机 6 手柄 4x ...

Page 96: ...4 机器简介 24 图 2 结构左侧 1 燃油箱 3 转子和定子直流 2 主机架 4 插座 ...

Page 97: ...4 机器简介 25 4 3 控制元件 4 3 1 汽油发动机图 3 反冲起动器手柄 1 反冲起动器手柄图 4 发动机开关 1 发动机开关 2 位置 ON 打开 1 3 位置 OFF 关闭 0 ...

Page 98: ...4 机器简介 26 图 5 发动机控制元件 1 油门杆 2 燃油开关 3 阻风门杆 4 3 2 指示元件图 6 LED 状态充电控制器 1 LED 状态描述 2 LED LED 绿灯常亮电压正常 LED 红灯常亮电压不正常 LED 红灯闪烁故障 ...

Page 99: ...4 机器简介 27 4 4 标志和标签 4 4 1 使用的标志和标签图 7 标签制造商徽标图 8 型式标牌示例图 9 标签戴耳保护装置图 10 遵守操作说明书标签图 11 燃料及油箱容量标签图 12 不要把机器转到此侧标签图 13 LED 状态充电控制器标签图 14 仅限获授权人士标签 ...

Page 100: ...4 机器简介 28 图 15 此处为起重装置标签图 16 LWA 96 db 标签图 17 仅限专业人员启动标签图 18 接地符号标签图 19 重要说明标签 ...

Page 101: ...4 机器简介 29 4 4 2 产品上的位置图 20 标志和标签右侧 1 此处为起重装置标签 5 高压标签 2 LED 状态充电控制器标签 6 燃料及油箱容量标签 3 仅限获授权人士标签 7 重要说明标签 4 制造商徽标标签 8 热表面标签 ...

Page 102: ... 仅限受过训练的人员标签 2 型式标牌 7 96 dB 标签 3 热表面标签 8 遵守操作说明书标签 4 接地符号标签 9 标签戴耳保护装置 5 不要在此侧转动机器标签 4 5 工作场所当启动和停止发动机时使用者应站在混合动力驱动系统的前面发动机启动后不再需要使用者即时在场因为混合动力驱动系统不提供任何进一步的操作选项但是混合动力驱动系统不能在无人照管的情况下运行 4 6 结构限界混合动力驱动系统不受轨道限制可以安装在结构限界之内或之外 ...

Page 103: ...动机损坏风险如果发动机在较低的高度运行而不调整化油器设置由于混合气过稀它将显示低性能容易过热并最终遭受严重损害根据低海拔调整化油器设置在海平面以上的高海拔地区燃料空气的混合物变得过浓由于空气中氧含量较低这会导致发动机性能下降和油耗增加通过对化油器进行一定的调整发动机可以在高空运行如果发动机要在海拔 1500 米或以上的高度持续运转请联系供应商对化油器进行相应的校准即使化油器具备推荐设置海平面以上的海拔高度每增加海拔 305 米发动机性能会下降 3 5 左右然而如果没有上述修改性能损失会更大 ...

Page 104: ...5 运行条件 32 5 2 储存存放机器的温度范围为 20 至 50 1 确保储存场所干燥无灰尘警告火灾和爆炸的危险在某些条件下汽油是高度易燃和易爆的禁止在工作区域吸烟或允许产生火焰或火花图 22 放油 1 放油螺钉 2 滤杯放油 1 将燃油开关调至 OFF 关闭取出滤杯并倒空 ...

Page 105: ...的燃油排到一个合适的容器里 3 重新安装滤杯并拧紧 4 通过拆卸化油器放油螺钉来排出化油器的燃油将燃油排入合适的容器中 5 更换发动机机油 6 拆下火花塞将一汤匙干净的机油倒入汽缸中 7 把发动机转动几圈把机油分配出去然后再把火花塞拧回来 8 拉起动绳直至感觉到轻微的阻力 9 然后继续拉直到起动器皮带轮上的缺口与反冲起动器上的孔对齐见下页图示图 23 对齐这两个标记 1 反冲起动器孔 2 起动器皮带轮缺口 10 盖好发动机以防灰尘进入 ...

Page 106: ...保持机器处于水平状态防止燃料溢出警告有受伤的危险这台机器太重了单靠一个人是无法操作的肌肉骨骼或肌腱可能会受伤特别是背部和肩部可能会导致多种其他伤害始终用合适的设备运送机器例如合适的手推车用合适的起重设备如起重机升降机举升后厢板或至少一个四人小组来抬起机器参见第 2 9 章关于手动操作的更多细节此值为保守值根据 DIN EN 13977 2011 标准的要求确定但是运营公司有权进行风险评估如果这是风险评估的结果也有权允许减少参与人员运输机器的温度范围是 20 到 50 1 将混合动力驱动系统移动到储存场所 2 将混合动力驱动系统放置在平整坚固的表面上 ...

Page 107: ...5 运行条件 35 混合动力驱动系统的质心位于重心符号所标示的位置图 24 质心图 25 抬起混合动力驱动系统质心抬起 ...

Page 108: ...程序留意发动机损坏风险发动机油可能泄漏到气缸室内发动机将无法启动不要将发动机向消声器倾斜参见机器上的标签油箱 1 拧下火花塞 2 打开化油器上的浮子放油螺钉以排油 3 拉起动绳油从汽缸里喷出来 4 旋上火花塞然后旋回放油螺钉 5 检查机油油位并启动发动机 6 1 空气过滤器留意发动机损坏风险如果发动机在没有空气过滤器的情况下工作灰尘颗粒会进入燃烧室导致发动机磨损加剧发动机的活动部件活塞和气缸上出现刻痕发动机会失去压缩功能进而丧失其性能切勿在没有空气过滤器的情况下运转发动机 1 检查空气过滤器滤芯以确保其清洁和良好状态补救办法空气过滤器检查 ...

Page 109: ...6 查机器 37 2 清洁或更换空气过滤器滤芯 4 和 5 如有必要的话请参见第 8 2 3 章图 26 空气过滤器 1 翼形螺母 2 空气过滤器盖 3 翼形螺母 4 纸质滤芯 5 海绵滤芯 6 密封垫 ...

Page 110: ...失效的风险确保发动机有足够的机油发动机停机时在水平地面检查机油油位图 27 检查油位 1 加油口盖量油尺 2 注油口 3 最大油位 1 拆下加油口盖把量油尺擦干净 2 将量油尺插入开口但不要拧入 3 如果油位低加推荐的油到加油颈的边沿留意发动机损坏风险不溶性油或二冲程油的使用对发动机的使用寿命有不良影响不要使用不溶性油或二冲程油请使用满足或超过美国汽车制造商的 SG 或 SF 质量等级要求的高级高清洁度发动机油 SG 和 SF 质量等级的发动机油的容器上应有相应标识 ...

Page 111: ...6 查机器 39 建议在所有温度下采用通用型机油 SAE 10 W 30 如果使用的是单级的油选择适合于使用区域的平均温度的粘度图 28 SAE 粘度等级 1 单级油 2 多级油 3 环境温度 ...

Page 112: ...护排油化油器调整关掉发动机让它冷却后再加油禁止吸烟在通风良好的区域以及发动机停机后加油不要在发动机加油或储存汽油的地方吸烟或允许产生火焰或火花油箱不要加得太满加油口颈部不应有燃油加油后确保油箱盖正确安全地关闭如果油箱加得过满发动机产生的热量会导致燃油膨胀并通过加油口盖的开口泄漏加油时小心不要弄洒燃油检查油箱嘴的密封性以免燃油泄漏如果不能防漏则更换油箱嘴一定要马上把洒出来的燃油擦干净如果燃油已经泄漏一定要确保在启动发动机之前该地区是完全干燥的且燃油蒸气已散逸避免反复或长时间接触皮肤或吸入蒸气放在儿童够不着的地方汽油 ...

Page 113: ...1 留意发动机损坏风险受污染的汽油会导致发动机损坏不要使用任何不清洁的机油汽油混合物或汽油避免污垢灰尘或水进入油箱油漆有损坏的风险燃油会攻击油漆和某些类型的塑料制品加油时注意不要把燃油溅出来使用车用汽油最好是无铅或含铅量低的燃油以尽可能减少燃烧残留物至少要把油箱加到半满 1 拆下油箱盖 2 将燃油加到注油管的底部不要加得太多 3 在发动发动机之前把溢出的汽油擦干 4 再次拧紧油箱盖 ...

Page 114: ...6 查机器 42 6 4 目视检查 1 确保所有的接线都处于良好状态图 29 目视检查接线 ...

Page 115: ...送机器例如合适的手推车用合适的起重设备如起重机升降机举升后厢板或至少一个四人小组来抬起机器参见第 2 9 章关于手动操作的更多细节此值为保守值根据 DIN EN 13977 2011 标准的要求确定但是运营公司有权进行风险评估如果这是风险评估的结果也有权允许减少参与人员 1 将混合动力驱动系统移动到安装位置 2 将混合动力驱动系统放置在平整坚固的表面上 7 2 进行电气连接 1 确保工作机器已按照适用的说明书准备好并且工作机器的主开关已关闭注意跳闸危险工作机器的电缆可能造成跳闸危险这可能会导致各种各样的伤害确保电缆不会造成跳闸危险 ...

Page 116: ...7 动机器 44 2 提起提升式插座盖图 30 提升式插座盖图 31 进行电气连接 1 混合动力驱动系统插座 2 连接电缆插头 3 插座例如混合轨头打磨机 4 连接电缆插头 3 将连接电缆 4 的插头插入工作机器 3 的插座中 ...

Page 117: ...7 动机器 45 4 将连接电缆 2 的插头插入混合动力驱动系统 1 的插座中 5 确保电缆安全敷设连接电缆配有专用连接器要插入和锁定连接器请参阅下面的程序图 32 插入连接器图 33 合上支架图 34 支架闭合操作连接器 ...

Page 118: ...7 动机器 46 图 35 关上锁图 36 连接器锁定 7 3 启动发动机警告有中毒的危险发动机废气中含有有毒气体一氧化碳不要让发动机在密闭或通风不良的地方运转触电引起生命危险火花塞引线将高压从点火线圈输送到火花塞当机器运转时请勿触摸点火线圈引线有心脏起搏器的人不得在点火系统上进行任何工作 ...

Page 119: ...7 动机器 47 请参阅制造商提供的发动机说明书 1 将油门杆设置为空转图 37 发动机视图 left rear right 2 将燃油开关 2 设置为 ON 打开图 38 开式燃油开关 1 燃油开关 ON 打开 2 燃油开关在寒冷天气或发动机很冷的情况下为通过缩小吸入口的横截面来增加混合气浓度必须使用阻风门当发动机处于高温下或空气温度较高时不要使用阻风门准备启动 ...

Page 120: ...7 动机器 48 3 将阻风门杆移动到 CLOSE 关闭位置图 39 阻风门位置 CLOSE 关闭 1 CLOSE 关闭位置 2 阻风门杆 4 将油门杆从 MIN 怠速位置向左移动大约 1 3 图 40 油门杆调到 1 3 位置 1 油门杆 2 MIN 怠速位置 3 MAX 快速位置 4 1 3 位置 ...

Page 121: ... 动机器 49 5 将发动机开关调至 ON 打开图 41 将发动机开关调至 ON 打开 1 发动机开关 2 ON 打开位置注意受伤风险便你在启动过程后松开反冲起动器手柄也会对手指手和手臂造成伤害不要让起动器手柄猛地弹回到发动机而应轻轻地向后移动留意反冲起动器有损坏的风险即便您只是在启动过程后松开起动器手柄它仍可能被损坏不要让起动器手柄猛地弹回到发动机而应轻轻地向后移动 ...

Page 122: ...7 动机器 50 如果超级电容器完全放电当拉动起动器手柄时可能会注意到阻力增加这是正常的这种增加在几次尝试后就会消失图 42 拉起反冲起动器手柄 1 反冲起动器手柄 6 轻轻地拉起动器手柄直到您感觉到阻力然后通过起动器手柄用力拉起动绳发动机启动 ...

Page 123: ...发动机运转 1 如果将阻风门杆设置为 CLOSE 关闭以启动发动机则在发动机升温时逐渐将其移回 OPEN 打开右侧状态图 43 将阻风门杆移动到 CLOSE 关闭位置 1 CLOSE 关闭位置 2 阻风门杆 3 OPEN 打开位置 4 CLOSE 关闭位置 2 将油门杆移动到左边的 MAX Fast 最高转速图 44 将油门杆移动到 MAX 位置 1 油门杆 2 MAX 快速位置 3 MIN 慢速位置 ...

Page 124: ...7 动机器 52 7 5 发动机停机另见发动机制造商产品说明书留意发动机损坏风险如果在高速运转时突然停止发动机可能会损坏发动机以高速全功率运行后关闭之前应降低发动机转速让发动机空转约一分钟让发动机以怠速运行约一分钟以便其冷却 1 关掉工作机器主开关处于关闭位置 2 将发动机开关移动到关闭位置图 45 发动机开关处于关闭位置 1 CLOSE 关闭位置 2 发动机开关 ...

Page 125: ...LOSE 关闭位置 7 6 断开电气连接危险严重灼伤风险即使在内燃机停机后插座触点仍持续携带 60 伏直流电约 2 分钟如果插座上有短路例如比如经由与导电物体的连接会产生高达数百安培的电流灼热的金属颗粒和高温有导致严重灼伤的风险因此在把插头从插座上拔出来之前至少要等两分钟确保插头上的触点没有短路图 46 断开电气连接 1 等两分钟直至机器里的电容器都已放电 2 从插座上拔下工作机器的插头 3 确保插座上的挡板向下折叠 ...

Page 126: ...的肌肉骨骼或肌腱可能会受伤特别是背部和肩部可能会导致多种其他伤害始终用合适的设备运送机器例如合适的手推车用合适的起重设备如起重机升降机举升后厢板或至少一个四人小组来抬起机器参见第 2 9 章关于手动操作的更多细节此值为保守值根据 DIN EN 13977 2011 标准的要求确定但是运营公司有权进行风险评估如果这是风险评估的结果也有权允许减少参与人员 1 将混合动力驱动系统移动到储存场所 2 将混合动力驱动系统放置在平整坚固的表面上 ...

Page 127: ...导致发动机意外启动的风险在开始维护工作前关停发动机为了防止意外重新启动关闭发动机开关拔下火花塞盖留意有损坏的风险使用不符合质量要求的零件会损坏发动机只使用原装备件或同等质量的零件 1 只使用推荐的润滑剂在进行维修时只使用原装备件这一点首先对于质保很重要其次对于提高机器的运行可靠性也很重要正确订购备品备件对于快速交付备品备件进而提高机器的经济可行性至关重要 2 向我们订购备件时请提供以下资料机器类型机器编号组装备件描述和编号数量运输方法发货地址 ...

Page 128: ...计划表中的规范要求只有在紧急情况下即在没有备用部件的情况下才对空气过滤器和火花塞执行所描述的清洁程序 8 1 维护计划表 8 1 1 发动机 1 为了确定保养间隔时间对连接的工作机器的运行时间计数器进行评估间隔时间部件维护工作每次保养之后或每十个运行小时之后发动机油检查油位参见 6 2 章空气过滤器检查 1 参见第 8 2 3 章更换清洁 1 参见 8 2 3 章第一个月后或头 5 个运行小时后发动机油换油参见第 8 2 2 章每 25 小时空气过滤器更换 1 每季度后或每 50 小时发动机油替换 2 参见第 8 2 2 章空气过滤器检查火花塞检查更换调整参见第 8 2 5 章 ...

Page 129: ...火花塞更换参见第 8 2 5 章每 2 年燃油管线替换 1 在尘土飞扬的环境中使用时应增加维护频次 2 在高负荷和高室外温度下每 25 小时更换一次机油 3 维护工作只可由 Robel 或合资格的专业人员进行 8 1 2 电气系统间隔时间部件维护工作每次使用之前插座检查是否状况良好目视检查参见第 8 3 章检查连接器盖参见第 8 3 章第 1 个月后或头 5 个运行小时后 A1 外壳的所有螺钉拧紧螺钉参见第 8 3 章 8 1 3 机器间隔时间部件维护工作每次使用之前标志和标签检查状态是否正常目视检查必要时更换参见第 8 4 章 ...

Page 130: ...机应由授权经销商维护除非操作人员拥有必要的工具和维护数据并具备必要的技术知识和技能发动机定期检查和调整是维持持久高性能的先决条件定期维护有助于延长使用寿命所需的维护间隔时间和需进行的工作类型在第 8 1 章的表格中有所描述也请参见发动机制造商的产品说明书 Robel 建议定期更换空气过滤器和火花塞以符合维护计划表中的规范要求只有在紧急情况下即在没有备用部件的情况下才对空气过滤器和火花塞执行所描述的清洁程序 ...

Page 131: ...油位降得太低则会有发动机润滑失效的风险确保发动机有足够的机油发动机停机时在水平地面检查机油油位 1 拆下加油口盖 3 把量油尺擦干净图 47 发动机油位检查 1 最大油位 2 最小油位 3 带量油尺的加油口盖 4 注油口 2 将量油尺插入注油口 4 但不要拧入留意发动机损坏风险不溶性油或二冲程油的使用对发动机的使用寿命有不良影响不要使用不溶性油或二冲程油 3 如果油位低加推荐的油至加油口边沿推荐油 SAE 15W40 4 再次放上带量油尺 3 的加油口盖 ...

Page 132: ...警告有被污染的风险皮肤与旧机油反复长时间接触可能会导致皮肤癌戴上防护手套每次接触用过的油后立即用水和肥皂彻底洗手以符合环保规例的方式处置用过的发动机油不要把用过的油和垃圾一起倒在地上或排入下水道 Robel 建议您将机油盛放在一个密封的容器中然后送到到您当地的废油收集点在发动机仍处于温热状态时排放机油以确保快速和彻底的排放 1 放置一个大容器盘等图 48 换油 1 加油口盖量油尺 2 放油塞 3 油位 ...

Page 133: ...荐油 SAE 15W40 6 重新安装加油口盖并拧紧 8 2 3 空气过滤器污浊的空气过滤器会限制空气流向化油器为防止化油器故障应定期清洗空气过滤器在灰尘极多的环境下操作发动机时应增加过滤器清洗频率警告火灾和爆炸的危险如果用汽油或低闪点溶剂清洗空气过滤器可能会发生火灾或爆炸不要使用汽油或低闪点溶剂清洗空气过滤器滤芯留意发动机磨损加剧的风险如果发动机在没有空气过滤器的情况下运行颗粒物灰尘易进入燃烧室发动机活动部件活塞和气缸出现划痕发动机会失去压缩功能进而丧失其性能没有空气过滤器时切勿运行发动机 ...

Page 134: ...8 保养维护 62 留意有损坏空气过滤器的风险如用压缩空气来清洗空气过滤器敏感的滤芯可能会被破坏刷毛会把污物压进纤维里不要使用压缩空气来清洗或干燥空气过滤器不要用刷子来清除污垢备件空气过滤器 EDP 参考编号 900 085 0090 1 拆下机翼螺母和空气过滤器盖 2 取出空气过滤器滤芯件并将其分开 3 仔细检查这两个滤芯是否有孔洞和撕裂如损坏应更换 ...

Page 135: ...8 保养维护 63 图 49 空气过滤器 1 翼形螺母 2 空气过滤器盖 3 翼形螺母 4 纸质滤芯 5 泡沫滤芯 6 密封垫 1 用家用洗涤剂与温水的混合溶液清洗滤芯然后彻底冲洗或者在不易燃的溶剂中清洗或者在高闪点溶剂中清洗 2 让滤芯彻底干燥泡沫滤芯 ...

Page 136: ...上轻拍滤芯数次以去除多余的污垢 2 如果污染太重更换纸质滤芯 8 2 4 清洗滤杯警告火灾和爆炸的危险在某些条件下汽油是高度易燃和易爆的禁止在该区域吸烟或允许产生火焰或火花安装滤杯后检查是否有泄漏并确保在发动机启动前该区域是干燥的 1 将燃油开关调至 OFF 关闭位置 2 拆下滤杯和 O 形环并在不易燃的溶剂中清洗 3 彻底干燥然后重新安装滤杯并拧紧 4 将燃油开关调至 ON 开位置并检查是否有泄漏图 50 清洗加油口盖 1 O Ring 2 滤杯 3 有溶剂的容器 4 燃油开关处于关闭位置纸质滤芯 ...

Page 137: ...的间隙且无沉淀推荐火花塞 BP6ES NGK BPR6ES W20EP U W20EPR U 日本电装备件火花塞 BP6ES EDP 参考编号 900 280 0061 该推荐火花塞具有正确的热额定值可确保发动机有正常的运行温度留意发动机损坏风险如果火花塞热值错误发动机可能会损坏使用具有正确热值的火花塞为了确保最佳的发动机性能火花塞必须正确调整且无沉积物注意有被热消音器灼伤的风险发动机运转时消音器会变热如果发动机不久前还在运转小心不要触碰消音器 ...

Page 138: ...8 保养维护 66 1 拔出火花塞连接器 2 正确清洁火花塞的环境 3 使用合适的火花塞扳手 1 拆卸火花塞图 51 拆卸火花塞 1 火花塞扳手 4 目视检查火花塞如果有明显的磨损或绝缘体破裂或有缺口则丢弃该火花塞图 52 火花塞间隙 1 密封垫圈 2 火花塞间隙拆下火花塞火花塞间隙测量调整 ...

Page 139: ...隙火花塞间隙 0 70 0 80 毫米 0 028 0 031 留意发动机损坏风险一个松动的火花塞可能会变得非常热过分拧紧火花塞可能会损坏气缸盖的螺纹将火花塞拧紧至规定扭矩 1 确保密封垫圈 1 合乎要求然后用手将火花塞旋回以避免螺纹错扣安装一个新的火花塞时在火花塞就位后拧紧圈以压紧密封垫圈重新安装原来的火花塞时在火花塞阀座后拧紧 1 8 到 1 4 圈以压紧密封垫圈 2 火花塞就位后用火花塞扳手拧紧火花塞压紧密封垫圈 3 连接火花塞连接器安装火花塞 ...

Page 140: ...8 保养维护 68 8 2 6 怠速调整 1 启动发动机并进行预热 2 将油门杆推到 MIN 最小值位置 3 发动机运转时调整怠速调节螺钉以获得标准 rpm 值怠速下的默认 rpm 1 400 200 150 RPM 图 53 怠速调整 1 怠速调节螺钉 ...

Page 141: ... 8 3 1 目视检查警告有严重受伤的风险如果插座上有短路例如比如经由与导电物体的连接会产生高达数百安培的电流灼热的金属颗粒和高温有导致严重灼伤的风险确保插座处于良好状态如果插座或电气系统的部件损坏请不要使用混合动力驱动系统 1 每次使用前检查插座是否损坏 2 检查护盖的功能掀开盖子放开盖子必须自己再合上 3 确保所有的接线都处于良好的状态图 54 目视检查接线转子定子和超级电容器都是免维护的 ...

Page 142: ...压紧并用中等强度的乐泰螺纹锁固胶紧固有些螺钉只能通过对外壳内部的锁紧螺母施加反作用力来拧紧如果按步骤更换螺钉工作就会简化也能防止组件在内部不受控制地移动警告因短路而导致灼伤的风险即使在驱动电机关闭后电子元件内部的超级电容器仍携带有高达 60 伏的电压如果超级电容器的两极短路比如因连接到导电物体可能会产生高达数百安培的电流灼热的金属颗粒和高温有导致严重灼伤的风险只有由经过培训的工作人员才能打开电气箱打开盖子前利用放电箱 EDP 编号 502 693 0001 给超级电容器放电使用电压表检查超级电容器是否已放电上述工作正在进行时确保电机不会启动 ...

Page 143: ...8 保养维护 71 1 连接放电箱等待显示电压下降直到电压最终消失 2 拧下盖子的 14 个螺钉图 55 拧下盖上的 14x 螺钉 3 拆下盖子 4 用电压表测量超级电容器两极的电压确保它们完全放电 5 拧下散热片上的六个螺钉包括密封垫圈图 56 拧下散热片上的 6 x 螺钉 ...

Page 144: ... 中间板的 4x 紧固螺钉标记为红色密封垫圈第 6 项和控制装置的 2x 紧固螺钉标记为黄色密封垫圈第 8 项 7 检查所有密封垫圈是否有损坏的迹象必要时进行更换如经目视检查发现密封垫圈过度压紧也应更换密封垫圈 5 2 16 零部件清单第 8 项共 16 个 EDP 编号 900 042 0274 密封垫圈 7 6 19 零部件清单第 6 项共 10 个 EDP 编号 900 042 0260 备选办法维护工具包包括进行此等维护所需的所有部件 EDP 编号 502 991 0002 ...

Page 145: ...8 保养维护 73 8 3 3 安装具有正确预紧力的密封垫圈密封垫圈必须用适当的预紧力压紧见下面的图示如果预紧力过低或过高螺纹连接就不会是紧封状态并且有松动的危险使用中等强度的乐泰螺纹锁固胶图 58 左预紧力过小居中预紧力过大右最佳预紧力图 59 散热片上的自锁螺母切勿在螺钉内部有自锁螺母的地方使用乐泰胶安装散热片螺钉 ...

Page 146: ...锁固胶 6 插入散热片螺钉和密封垫圈并用正确的预紧力拧紧 7 在螺钉的螺纹上涂上一层中等强度的乐泰螺纹锁固胶 8 插入散热片螺钉和密封垫圈并用正确的预紧力拧紧 8 4 标志和标签定期检查所有标志是否存在且完好无损必要时更换标签 8 5 清洁与护理留意有损坏的风险用溶剂腐蚀性或易燃的清洗剂清洗机器可能会造成损坏使用高压清洗器会导致水进入电机消音器空气过滤器化油器和机器的铰接式接头而造成损坏不要使用任何溶剂或腐蚀性的易燃的清洗液不要用汽油清洗不要使用高压清洗器或喷水器进行清洗 1 定期清洗机器使其不会因污垢而造成停产 2 只用湿布清洁机器只使用水如有必要使用不添加任何化学添加剂的温和清洁剂安装中间板螺钉安装控制装置螺钉装盖 ...

Page 147: ...点火线圈必要时更换燃油过滤器堵塞 Clean fuel filter 清洁燃油过滤器空气过滤器堵塞 Clean carburettor compressed air 清洁化油器压缩空气发动机浸水关闭燃油开关将油门杆移动到全油门启动机器如有必要拆下火花塞清洁并干燥工作机器插头插不进连接工作机器发动机空转停机怠速过低调整怠速参见第 8 2 6 章发动机功率不足 3600 RPM 油门杆不在 MAX 位置将油门杆调至 MAX 位置其他可能出现的问题请参阅发动机制造商说明书发动机发热性能差燃油过滤器堵塞清洁燃油过滤器在低海拔下部署而不调整化油器喷嘴根据高度调整化油器喷嘴参见第 5 章发动机运行不平稳低功率空气过滤器堵塞清洁空气过滤器参见第 8 2 3 章在高海拔下部署而不调整化油器喷嘴根据海拔高度调整化油器喷嘴参见第...

Page 148: ...堵塞等修理或更换受影响的部件 9 1 火花试验火花塞是否产生火花 1 拆下火花塞盖清洁火花塞底座周围的污垢然后拧下火花塞 2 将火花塞插入火花塞盖 3 打开点火开关警告致命危险火花塞引线给火花塞带来高电压当发动机运转时触碰火花塞或火花塞引线会导致致命的电击有心脏起搏器的人尤其危险机器运行时不要触摸火花塞和火花塞电缆用绝缘钳进行火花试验戴有心脏起搏器的人不得在点火系统上进行任何工作 4 使用绝缘钳将火花塞固定在机架上使侧面电极接地然后拉动反冲起动器检查是否产生火花 5 如果没有火花就更换火花塞如果火花塞是好的重新安装火花塞并根据说明书中的指示尝试启动发动机 ...

Page 149: ...7 9 2 机器没电了 1 检查机器的连接电缆参阅相应机器的说明书图 60 混合动力驱动系统 70 02 概览 1 混合动力驱动系统与相应机器之间的连接电缆 2 插座端子 3 机壳 4 连接螺钉 14x 5 盖子警告致命危险触电致死性伤害只有熟练的电动才能承担产品电气装置上的工作只使用 Robel 的放电箱以便超级电容器放电 2 用万用表检查端子 2 上是否有电压如果没有电压 0V 直流电 ...

Page 150: ...9 故障措施 78 3 借助 Robel 放电箱配件即使没有测得电压电容器电池也可放电 4 拧下连接螺钉 4 14x 并从机壳 3 上拆下深灰色盖子 5 5 检查接线是否断裂或电缆是否松动 6 检查玻璃管保险丝必要时更换 7 如果玻璃管保险丝正常则故障的根本原因很可能在于充电控制装置有缺陷更换充电控制装置或联系 Robel 售后 ...

Page 151: ... 和适当回收处置的法律规定并遵守使用者所在国家适用的环境法 2 特别要注意的是在维修和保养工作中应确保水污染物质如油脂和机油不得污染地面或进入下水道 10 2 处置该产品包括机械零件发动机油和燃料的处理将取决于当地的废物处理条例产品寿命周期结束时应确保进行安全和适当的处理特别是对环境有害的部件或物质的处理其中包括燃料润滑剂和塑料 1 由于存在潜在的环境污染的风险应将产品交给经批准的专业公司处理 2 在任何情况下检查哪些材料可用于回收利用并将这些材料交由适当的废物管理公司处理 ...

Page 152: ...11 附录 80 11 附录图 61 欧共体声明欧共体声明 ...

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