Lukas Double-acting Rope-lift cylinder User Manual

Operating Instructions Rerailing Equipment

Double-acting Rope-lift cylinder

(3.3)

(4.1)

(4.2)

84072/5355-85 GB Issue 2.2005

(4.3)

(3.2)

(3.1)

1 Rope-lift cylinder 2 Radius plate 3 Tilting set 4 Lifting belt 5 Holding rope 6 Shackle

Contents page

1 Safety instructions 3 2 Organisational measures 3 3 General safety instructions 4 4 Instructions for maintenance and service 5 5 Function of components 5

5.1 General

5.2 Connecting pieces

5.3 Hoses between the control table and cylinders

5.4 Quick-connect couplings

5.4.1 Hose pair compliant with 84072/1765

5.4.2 Connection of quick-connect couplings

6 Initial commissioning 7 7 Installation 7

7.1 Safety notes

7.1.2 General information for cylinder installation / operation

7.1.3 Note for cylinder retraction

8 Hydraulic connection and operation 7

8.1 General

8.1.1 Connection of the rope-lift cylinder

8.2 Cylinder operation

8.3 Uprighting of rolling stock

9 Accessories 8

9.1 Radius plates

9.2 Tilting set

9.3 Lifting belt

9.4 Holding rope

9.5 Shackle

10 Dismantling of components 9 11 Maintenance 9

11.1 Mechanical inspection

11.2 Hydraulic system leakage

11.3 Cylinder components

11.4 Oil recommendation

12 Malfunctions / trouble-shooting 10 13 Repair 11 14 Circuit diagram 11 15 Technical data 12

1 Safety instructions Designated use of the device

1.1 The cylinders described below may only be used together with LUKAS rerailing equipment

components. It is possible to use the device with equipment made by other manufacturers, however LUKAS must carry out the technical check and grant approval in each individual case.

1.2 The designated use of the device is exclusively the power supply and control of rerailing

equipment. Any other or additional use, such as the power supply and control of other hydraulic

systems is deemed to be contrary to the designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Designated use also includes conforming to the Operating Instructions as well as compliance with the inspection and maintenance directives (refer to Chapter 4 and Chapter 13).

1.3 The device has been constructed in accordance with the state of the art and the recognised

safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or result in damage to the device and to other material property.

1.4 Only use the device when it is in a technically perfect condition, as well as in accordance with

designated use, in awareness of safety and hazards and in compliance with the Operating Instructions. Any malfunctions, especially those which could affect the safety of the device, should therefore be rectified immediately.

1.5 Device designation

HP 25 / 800 R

Total stroke

in mm

Hydraulic retraction

High-pressure

cylinder

Rated

compression

force

in metric tons

2 Organisational measures

2.1 Always keep the Operating Instructions ready to hand at the location where the device is

used.

2.2 In addition to the requirements contained in the Operating Instructions, comply with and

provide instruction in the general legal provisions and other mandatory regulations that apply to accident prevention and environmental protection. This includes in particular the wearing of working or protective clothing, a helmet with visor or goggles and protective gloves.

2.3 The device may only be operated by persons who have received appropriate safety training,

otherwise there is a risk of injury. Particular attention must also be to paid to the influence of stress factors upon operators when the device is being used. These factors may cause a risk to life and limb of users or of third parties, or result in damage to the device and to other material property.

2.4 Comply with all safety instructions and hazard warnings on the device. Make sure that safety

instructions and hazard warnings displayed on the device are always complete and perfectly legible.

2.5 Obtain approval from the supplier before making any modifications, additions or conversions

to the device that may reduce safety. This also applies to the installation and adjustment of safety devices and valves.

2.6 Spare parts must conform to the technical requirements specified by the manufacturer.

This is always guaranteed for spare parts supplied by original equipment manufacturers. In the same way, only original LUKAS spare parts or LUKAS system components may be used.

2.7 Replace hydraulic hoses at the stipulated or suitable time intervals even if safety-relevant

defects cannot be detected. This must be done after 10 years at the latest.

2.8 Comply with the prescribed intervals or those specified in the Operating Instructions for

periodic checks/inspections.

2.9 Make sure that all packaging materials and removed parts are disposed of correctly.

3 General safety instructions

3.1 Check all parts for damage prior to commissioning.

3.2 Take the environmental conditions into account when using the device and adapt your

personal protective clothing to them. Also, do not forget that the cylinders may heat up over time. The environmental conditions may also cool them down considerably. Provision must also be made for these conditions by wearing suitable protective clothing.

3.3 Also note that noise from different sources may cause adverse effects and impede

communication during operation. Adverse effects during operation are also possible from exhaust fumes. Make sure that there is sufficient ventilation or that appropriate protective measures have been taken. The cylinders are connected by hoses that may also present a hazard of stumbling. Make sure that hoses are routed safely. Take particular account of the fact that escape routes should be provided.

3.4 Make sure that lighting is adequate during working, and that a clear view is provided of the

device so that work is carried out free of danger.

3.5 Make sure that persons cannot be placed in danger from the running device prior to switching

it on, starting it up and during its operation. Also, secure the device against being switched on or off without authorisation or accidentally.

3.6 Stop and secure the device immediately if there are any malfunctions. Have any defects

rectified immediately.

3.7 Always check that the accessories have been safely stowed away prior to transporting

the device. Bear the weight of the LUKAS rope-lift cylinders in mind during transportation.

3.8 Do not carry out any operation that degrades the device’s stability. Therefore, always use

a base plate (refer to Chapter 9.1). Also, make sure that the ground has sufficient load-bearing capacity.

3.9 After each use, check the device for any external damage and defects. Report any chan-

ges (incl. changes in the device’s working behaviour) to the relevant organisation/person immediately. If necessary, stop the device immediately and lock it. Check all lines, hoses and screwed connections for leaks and externally visible damage. Rectify any damage immediately. Splashing oil may cause injury and fires.

+ 8 hidden pages