Lukas HP Cylinders User Manual
Operating Instructions -
Re-railing Technology
HP Cylinders
(Translation of the original operating instructions)
84072376585 GB
Edition 12.2011
2
Contents Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Device designation 9
5. Functions and performance 9
5.1 Description 9
5.2 Controlling the operating movements 10
5.3 Hydraulic supply 10
5.4 Hose lines 10
6. Connecting the equipment 11
6.1 Hydraulic 11
6.2 Coupling quick-disconnect couplings 11
7. Operation 12
7.1 Installation 12
7.2 Commissioning 14
7.3 Hydraulic cylinder control 15
8. Use of accessories 16
8.1 Base plate 16
8.2 Multistage sets 16
9. Dismantling the device / deactivation following operation 20
9.1 Hydraulic cylinder 20
9.2 Hydraulic unit 20
9.3 Hose lines 20
10. Maintenance and service 21
11. Repairs 22
11.1 General 22
11.2 Preventive maintenance 23
11.3 Repairs 24
12. Troubleshooting 25
13. Technical Data 27
13.1 Cylinder data 28
13.2 Hydraulicuidrecommendations 30
13.3 Operating and storage temperature ranges 30
14. EC Declaration of Conformity 31
15. Notes 32
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1. Hazard classes
We distinguish between various categories of safety notes. The table below provides an
overview of the assignment of symbols (pictograms) and signal words to the specic danger
and the possible consequences.
Pictogram Damage / injury to Key word Denition Consequences
DANGER! Immediate danger
human
device
- NOTE
Wear a helmet with face protection
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 safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
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2. Product safety
LUKAS products are developed and manufactured to guarantee the best performance and
quality when used properly.
The safety of the operator is the most important consideration in product design. Moreover,
the operating instructions are intended to aid the safe use of LUKAS products.
The generally applicable, legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be implemented 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.
We would like to point out to all users that they should carefully read and adhere to the
operating instructions in full before they use the equipment.
We further recommend that a qualied trainer train you in the use of the product.
WARNING / TAKE CARE!
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 the following safety notes again.
WARNING / TAKE CARE!
Ensure that the accessories used and the connected equipment are suitable
for the maximum operating pressure!
Please ensure that no body
parts or clothing are caught
between the visibly moving
parts (e.g. piston guard plate
and cylinder).
Wear protective clothing,
a safety helmet with visor,
protective footwear and
gloves
The responsible department
must be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the device must
be deactivated immediately
and secured!
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, adequate
mechanical supports are
additionally required.
Inspect the device before and
after use for visible defects or
damage
Inspect all cables, hoses
and screwed connections
for leaks and externally
visible damage! If necessary,
repair immediately! Squirting
hydraulic uid can result in
injuries and res.
5
In the event of malfunctions,
immediately deactivate the
device and secure it. You
should have the malfunction
repaired immediately.
Observe all safety and danger
notices on the device and in
the operating instructions.
Do not carry out any changes
(additions or conversions) to
the device without obtaining
the prior approval of LUKAS.
All safety and danger notices
on the device must be kept
complete and in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the device is forbidden!
Safety devices must never be
disabled!
Before the device is switched
on / started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.
When working in the proximity
of live components and wires,
appropriate steps must be
taken to avoid current ow
or high-voltage discharge
through the device.
The device is lled with a
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours are inhaled. Direct
contact with the skin should
be avoided for the same
reason. Please also note that
hydraulic uids can also have
an adverse effect on biological
systems.
Comply with all stipulated
dates or dates specied in
the operating instructions
pertaining to regular tests /
inspections on the equipment.
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you do not become
entangled in the looped hoses
and trip.
The build-up of static
charge with the potential
consequence of spark
formation is to be avoided
when handling the device.
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
device can also heat up over a
long period of use.
6
Ensure adequate lighting when
you are working.
Always keep these operating
instructions within reach where
the device is used.
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.
Before transporting the
device, always ensure that the
accessories are positioned
such that they cannot cause an
accident.
Dispose properly of all
disassembled parts, oil and
left-over uid, as well as
packaging materials.
WARNING / CAUTION!
The equipment is intended to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use 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.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
7
3. Proper use
LUKAS-HP cylinders are especially designed for re-railing technology. In the event of derailed rail vehicles, they are used to lift the vehicles so that they can be re-railed, e.g. with an
additional transfer unit. Furthermore, they can be used to lift a rail vehicle in order to push a
towing device underneath it, for example.
HP cylinders in telescopic design offer long hoisting paths with a low retracted overall
height.
The accessories necessary for the particular application, such as base plate, multistage sets
etc., must be used during each deployment.
CAUTION!
Watch out vigilantly for any leaks in order to avoid threats to the environment.
Recommended accessories for HP cylinders:
- Base plate (Item 1)
- Multistage set (Item 2)
1 2
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4. Device designation
Cylinder variant
25 THP 700
Design
Cylinder type
Cylinder variant:
HP = High pressure cylinder
Design:
(no information) = Single-stage design
T = Telescopic design
Special feature:
R = Hydraulic retraction
Total stroke
in [mm]
R/
Special
feature
5. Functions and performance
5.1 Description
HP cylinders are double-acting hydraulic cylinders. Extension and retraction takes place
hydraulically. The direction of movement is controlled by pressurising the piston rod side or
the cylinder base side. Control of the pressurisation must be effected by an external control
unit (e. g. control panel) and a connected hydraulic unit (the use of a hand pump is possible
in exceptional cases).
Securing against unwanted lowering of the cylinders in the event of a hose breakage is
achieved by means of quick-stop couplings tted to the hose. If there is any doubt as to
which coupling sleeves are tted to your hose, please contact your authorised LUKAS dealer
or LUKAS directly before using the hose.
In addition to the quick-disconnect couplings, the HP cylinders are additionally equipped with
two connection blocks with integrated safety valve. These safety valves protect the cylinder
from damage caused by sudden load increase (e.g. something has additionally fallen onto
the part to be lifted, thus suddenly increasing the weight). If the specied maximum pressure
is exceed, the safety valves automatically open and hydraulic uid (protected) is squirted
out.
HP cylinders in telescopic design offer long hoisting paths with a low retracted overall
height.
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5.2 Controlling the operating movements
When the valve (A) is pressurised on the cylinder base side, the piston rod is extended. By
pressurising valve (B) on the piston rod side the piston rod retracts again.
B
A
5.3 Hydraulic supply
Only LUKAS motor pumps (or hand pumps in exceptional cases) may be used to drive the
devices.
If the pump unit is of a different make, you must make sure that it complies with LUKAS
specications, otherwise hazards may occur which are not the responsibility of LUKAS.
Ensure in particular that the maximum permissible operating pressure for the connected
LUKAS equipment is not exceeded.
NOTE:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
5.4 Hose lines
The pump unit and the HP cylinder are connected by hoses.
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