Lukas DUO Traversing System User Manual
Operating instructions
Rerailing Equipment
DUO Traversing System
84072058485 GB
Edition 07.2009
replaces 12.2008
(original operating instructions)
2
3
Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Functions and performance 9
4.1 Description 9
4.2 Hydraulic supply of jacks 10
5. Connection of hydraulic devices 10
5.1 Basic information 10
5.2 Coupling the quick-disconnect couplings 11
6. Operation 12
6.1 Setting up the DUO traversing system 12
6.2 Start-up 25
6.3 Control of the DUO traverse jack with anchor pin 26
6.4 Control of the DUO traverse jack with anchor jack 28
7. Dismantling the equipment / deactivation after operation 30
7.1 Hydraulic jacks 30
7.2 Hose lines 30
7.3 Other components of the traversing system 30
7.4 Hydraulic supply, control and separate load listing systems 30
8. Maintenance and service 31
9. Repairs 31
9.1 General information 31
9.2 Preventative service 32
9.3 Repairs 33
10. Troubleshooting 36
11. Technical data 38
11.1 Traverse jack 38
11.2 Roller carriage 40
11.3 Rerailing bridges 40
11.4 Distance bars 41
11.5 Recommendedhydraulicuids 42
11.6 Operating and storage temperature ranges 42
12. Notes 43
4
Hazard classes1.
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Pictogram
Damage /
injury to
human
device
- NOTE
Key word Denition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Death or major
injury
Potential death or
major injury
Minor or slight injury
Damage to the
equipment, damage
to the environment,
damage to
surrounding
materials
No injury / damage
to persons /
environment /
equipment
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
5
Product safety2.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design. Moreover, the operating
instructions are intended to ensure LUKAS products are used safely.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without restriction.
We further recommend that a qualied instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed.
Even if you have already received instructions on how to use the equipment, you should still
read through the following safety instructions once again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure.
Make sure that limbs or
clothing cannot become
trapped between the exposed
moving parts (e.g. piston
plate and jack).
Wear protective clothing,
safety helmet with visor,
safety shoes and protective
gloves
The department responsible
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is
to be shut down immediately
and secured.
In the event of malfunctions,
immediately shut down the
equipment and secure it. The
malfunction is to be repaired
immediately.
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical
supports must be used.
Inspect the equipment before
and after use for visible
defects or damage.
Inspect all lines, hoses and
screwed connections for
leaks and externally visible
damage. If necessary,
repair immediately. Squirting
hydraulic liquids can result in
injuries and res.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
6
Comply with all the
instructions regarding safety
and danger on the equipment
and in the operating
instructions.
Any method of operation
which impairs safety and/or
stability of the equipment is
prohibited.
Safety devices may never be
deactivated.
All the instructions regarding
safety and danger on the
equipment are to be kept
complete and in a legible
condition.
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
The maximum operating
pressure marked on the
equipment must not be
exceeded.
Before the equipment is
switched on / started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation
of the equipment.
When working close to live
components and cables,
suitable measures must
be taken to avoid current
transfers or high-voltage
transfers to the equipment.
The equipment is lled with
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic uids
can also have a negative effect
on biological systems.
Ensure adequate lighting when
you are working.
Always keep these operating
instructions within reach where
the equipment is used.
Only original LUKAS
accessories and spare parts
may be used for repairs.
During all work and transport
operations involving the
equipment, take care not to
trip and become caught in
hose loops.
The build-up of static
charge with the potential
consequence of spark
formation is to be avoided
when handling the equipment.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired by
the effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Ensure the proper disposal
of all removed parts, leftover
oil and uid, and packaging
materials.
7
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
WARNING / DANGER / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter "Proper use"). Any form of use beyond this is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such use.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are covered by the denition of proper use.
Never work when you are overtired or intoxicated.
8
Proper use3.
The components of the LUKAS DUO traversing unit are specially designed for rerailing
technology. In the event of derailments, the traversing unit is used to raise rail vehicles, move
them across the rails, thus allowing the vehicles to be rerailed.
A range of accessories such as base plates, stacking sets, etc. is available for specic
applications.
CAUTION!
To minimise the risk to the environment, remedy leaks as soon as possible.
The DUO traversing unit consists of:
- Rerailing bridge (Item 1)
- Traverse jack (Item 2)
- Roller carriage (Item 3)
- Adjustable distance bars (Item 4) [optional]
2
3
4
1
NOTE:
Suitable lifting gear (e.g. LUKAS HP jack) and accessories are necessary in
order to raise rail vehicles and either move them while raised or place them on
to the DUO traversing unit.
3
9
Functions and performance4.
4.1 Description
4.1.1 Rerailing bridge
The rerailing bridge is placed across the rails and acts as the base and traverse support for
the LUKAS roller carriages and the LUKAS traverse jacks.
If one bridge is not long enough, a second bridge can be bolted on by means of connecting
elements.
The anchor pin or the integrated anchor jack of the traverse jack can be xed in the openings
at the top of the rerailing bridge. The rerailing bridges are transported by means of the pull-out
carrier handles mounted on the sides.
4.1.2 Roller carriages
The LUKAS roller carriages are designed for carrying heavy loads. The special rollers on the
underside of the roller carriage make it possible to move the carriage by hand or with the aid
of traverse jacks. The roller carriages are specically designed to match the LUKAS rerailing
bridges, thus ensuring optimum traversing of the load.
The upper sliding plate is simply placed on the roller carriage yet it can be rotated and shifted
laterally with respect to rolling direction in order to minimise the danger of a jack placed on
the plate tilting or the supported load tipping the roller carriage during operation.
4.1.3 Traverse jack
LUKAS traverse jacks are designed for the purpose of traversing the LUKAS roller carriages
on the rerailing bridges. The traverse jack is a double-acting hydraulic cylinder. The end of
the piston rod is attached to the mounting points provided in the roller carriage. This makes it
possible to move the roller carriage in the retract and extend direction of the traverse jack.
Two versions of the traverse jacks are available. The one version has a xed pin for locking
the traverse jack in the xing points of the LUKAS rerailing bridge while instead the other
version features an integrated single-acting anchor jack that performs the same function as
well as lateral guide plates.
The advantage of the version with the anchor jack is that the jack can be hydraulically adjusted
without the user having to enter the danger zone. The prerequisite for this function is that the
rerailing bridge is aligned approximately horizontal and the load is raised such that there is no
danger of the roller carriage rolling away to the side. Nevertheless, it is still essential to rmly
secure the load.
The anchor jack is always extended when in no-load position to ensure anchorage in the
rerailing bridge is always retained even in the event of pressure loss in the hydraulic system.
The anchor jack is retracted when pressure is applied, thus making it possible to shift the
traverse jack.
4.1.4 Distance bars
The distance bars are used when a load is raised at two or more points and is then to be
shifted in one direction by means of roller carriages. They are always used in pairs to connect
the roller carriages. Most distance bars feature a rough adjustment and ne adjustment
facility to allow them to be adjusted precisely to the distance between the lifting points.
Versions are also available that cannot be adjusted.
The bars are attached to the securing points in the roller carriages.
10
4.2 Hydraulic supply of jacks
Only LUKAS motor pumps or suitable LUKAS hand pumps may be used to drive the
equipment.
If an other-make pump assembly or hand pump is used, it is necessary to make sure that it
is designed in accordance with LUKAS specications otherwise hazardous situations could
occur for which LUKAS cannot be held responsible. Particular care must be taken to ensure
that the maximum permissible operating pressure of the connected LUKAS devices is not
exceeded.
NOTE:
Before you use pumps of a different manufacturer, you must contact LUKAS or
an authorised dealer.
The connection between the pump assembly or hand pump and the hydraulic jacks is made
by hose lines.
Connection of hydraulic devices5.
5.1 Basic information
Double-acting, hydraulically operated implements are tted with a male quick-disconnect
coupling on the pressure supply side (jacks: jack bottom end) and a female quick-disconnect
coupling on the return side (jacks: piston rod end); a pair of extension hoses connect them
to the control unit.
Single-acting, hydraulically operated implements are tted with a male quick-disconnect
coupling on the pressure supply side; an extension hose line connects it to the pump
assembly or control unit.
All LUKAS extension hose pairs/lines are colour-coded and equipped with quick-disconnect
couplings to minimise the possibility of misconnection.
WARNING / DANGER / CAUTION!
Before connecting equipment, make sure that all the components
used are suitable for the maximum operating pressure of the
pump unit. In cases of doubt, you must consult LUKAS directly!
11
5.2 Coupling the quick-disconnect couplings
The device connects to the hydraulic pump by means of individually coded quick-connect
coupling halves (plug and socket).
X
Before coupling, remove the dust protection caps, then pull back and hold the locking sleeve
of the female coupling (position X). Connect the nipple and female coupling and let go of
the locking sleeve. To conclude, turn the locking sleeve into position Y. The connection is
now in place and secure. Uncouple in reverse order. Hoses can be connected only when
depressurised. To protect against dust, the accompanying dust protection caps must be
replaced.
CAUTION!
Always connect the return hose rst and then the supply hose.
NOTE:
Coupling of the devices is only possible when the hoses are depressurised.
To protect against dust, the accompanying dust protection caps must be replaced.
WARNING / DANGER / CAUTION!
Some quick-disconnect couplings have special functions. Therefore it is not
permitted to screw them off the hoses or to swap them.
12
Operation6.
6.1 Setting up the DUO traversing system
6.1.1 General information
The DUO traversing system consists of several individual components. By correspondingly
conguring the individual components, several different complete systems can be built up.
While not all individual components are required for some of these complete systems, you
may need several of the individual components to make up other systems.
In addition to the individual components of the DUO traversing system, you will need suitable
hydraulic jacks for lifting the load and at least one suitable hydraulic unit or hand pump to
supply the pressure.
6.1.2 Preparing to set up the traversing system
DANGER / CAUTION!
Before the individual components of the DUO traversing system can be set up,
the load to be raised must be secured in accordance with applicable guidelines
and regulations to prevent it slipping.
Check the individual components for visible damage before setting up the traversing
system.
You must pay attention to the following points while setting up the components of the
traversing system:
- Make sure that the load is placed centred on to the piston rod or roller carriage plate.
NOTE:
It may be necessary to select a more favourable load application point!
Position the jack/roller carriage under the centre of gravity of the load so that the load
cannot tilt during the lifting and traversing operation thus posing a danger to the operating
personnel or the equipment itself. The load must always rest centred on the surface of
the piston or roller carriage plate. Avoid off-centre loads!
Load
WRONG RIGHT
Load
13
In the majority of cases it is not possible to rest the load over the entire surface of the
jack piston. We therefore recommend using suitable piston guard plates otherwise the
piston rod or jack may be damaged. A convex piston guard plate evenly distributes the
load over the surface of the piston.
Load
WRONG
If several jacks/roller carriages are used simultaneously, the load should be distributed
as evenly as possible over all jacks/roller carriages.
Load
share 1
Load share 1 < Load share 2
WRONG RIGHT
The following points must be observed while setting up jacks:
- Non-slip, at ground so that the entire base of the jack rests on the ground. If there is
doubt concerning the load bearing capability of the ground, use suitable wooden or metal
base supports in order to increase the contact area.
Load
share 2
Load
share 1
Load share 1 = Load share 2
Load
RIGHT
Load
share 2
WRONG
CAUTION!
Hydraulic uid can leave an oily lm on the ground!
- The ground must provide support over the entire area (no grids, rubble, etc.)
- Never place jacks on ductile (non-rigid) base
RIGHT
14
- To avoid damaging the piston and to ensure safe force application, never use jacks
without a piston guard plate
CAUTION!
Use an additional non-slip base between the piston guard plate and the load
to be lifted as there may also be a greasy lm at the contact point on the
load!
- Make sure that the load is applied centred on to the piston rod.
6.1.3 Setting up the rerailing bridges
The bridge is placed across the tracks and carefully supported by wooden planks. Please
ensure that:
- The rerailing bridge and the supporting wooden planks are placed on rm and
stable ground
DANGER / CAUTION!
When using wooden supports make sure that undamaged, hardwood is
used to rule out the possibility of the base splintering. It is not sufcient to
additionally strap together other pieces of wood with metal straps!
- The maximum load of the bridge is not exceeded:
Bridge height Support width Max. load
[mm] [m] [kN]
[in.] [ft.] [lb]
65 0 200
2.56 0 44,964
140 0 700
5.51 0 157,374
184 0 1200
7.24 0 269,784
* fully supported
*
*
0,5 60
1.64 13,489
1 20
3.28 4,496
*
*
1 500
3.28 112,410
1,43 400
4.69 89,928
*
*
1 900
3.28 202,338
1,43 650
4.69 146,133
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