Lukas Telescopic Rams User Manual

Operating Instructions
Rerailing Equipment

Double-acting
Telescopic Cylinders

84072/0000-85N GB
Issue 1.2005

replaces issue 9.2004

1

Contents Page

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

5.1 General

5.2 Coupling connectors

5.3 Hoses between control desk and cylinders

5.4 Quick-connect couplers

5.4.1 Hose pair acc. to 84072/1765

5.4.2 Single hose, red

5.4.3 Connection of quick couplers

6 Initial Commissioning 7
7 Installation 7

7.1 Safety notes

7.1.2 General instructions for the installation / operation of the cylinders

7.1.3 Note for retracting the cylinder

8 Hydraulic connection and operation 8

8.1 General

8.1.1 Connection of telescopic cylinders

8.2 Operation of cylinders

9 Zubehör 8

9.1 Base plates

9.1.1 Mounting the base plates

9.2 Stacking sets

9.2.1 Attributes of stacking sets

9.2.2 Installation / operation of the stacking sets

10 Dismantling of components 9
11 Maintenance 9

11.1 Mechanical check

11.2 Hydraulic system leakage

11.3 Cylinder components

11.4 Oil recommendation

12 Problems / trouble shooting 10
13 Repair 11
14 Hydraulic diagram 11
15 Technical data 12

2

1 Safety instructions

Basic operation and designated use of the machine

1.1 The cylinders described below may only be used in combination with components from

LUKAS rerailing equipment. It is possible to operate them with devices from other manufacturers

-- however, this requires technical testing/approval by LUKAS in each individual case.

1.2 The machine is intended exclusively for driving and controlling rerailing equipments. Any

other use, e.g. driving and controlling other hydraulic equipment, is not according to specifications.
The manufacturer/supplier will not accept any liability for damage as a result thereof. The risk is
entirely to be borne by the user.
Use according to specifications also means that the operating instructions are observed and that the
conditions for inspection and maintenance are to be met (see also chapters 4 and 13).

1.3 The machine has been built in accordance with state-of-the-art standards and the recognized

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

1.4 The machine must only be used in technically perfect condition in accordance with its

designated use and the instructions set out in the operating manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine. Any functional disorders,
especially those affecting the safety of the machine/plant, should therefore be rectified immediately.

1.5 Device designation

HP 25 T - 450 R

min. push capacity

in tonnes

high-pressure

cylinder

total stroke

in mm

hydraulic piston

retractiontelescopic design

2 Organizational measures

2.1 The operating instructions must always be at hand at the place of use of the machine, e. g.

by stowing them in the tool compartment or tool-box provided for such purpose.

2.2 In addition to the operating instructions, observe and instruct the user in all other generally

applicable legal and other mandatory regulations relevant to accident prevention and environmental
protection. This also applies for wearing protective clothing, helmet with visor or goggles and
protective gloves.

2.3 In order to avoid injuries, the machine must only be operated by a specially trained operator who

has undergone safety training. It is also important to consider the influence of stress factors on the
operator when working at the machine. These may constitute a risk to life and limb of the user or of
third parties, or cause damage to the machine and to other material property.

2.4 Observe all safety instructions and warnings attached to the machine. Make sure that safety

instructions and warnings attached to the machine are always complete and perfectly legible.

2.5 Never make any modifications, additions or conversions which might affect safety without the

supplier’s approval. This also applies to the installation and adjustment of safety devices and valves
as well as to welding work on load-bearing elements.

3

2.6 Spare parts must comply with the technical requirements specified by the manufacturer. Spare

parts from original equipment manufacturers can be relied to do so. It is only allowed to use
original LUKAS spare parts or LUKAS system components.

2.7 Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant

defects have been detected. This has to be done after 10 years at the latest.

2.8 Adhere to prescribed intervals or those specified in the operating instructions for routine checks

and inspections.

2.9 Make sure to dispose properly of packing material and dismounted parts!

3 General safety instructions

3.1 Check all parts for possible damage before starting up.

3.2 When operating the machine, pay attention to the ambient conditions, making sure that you

wear suitable personal protective clothing. Also pay attention to the fact that the cylinders could heat
up after a while. They may also cool down considerably depending on the ambient conditions. This
must likewise be borne in mind by wearing suitable protective clothing.

3.3 Also be aware that possible noise could result from various sources during operation which may

impede communication.
During operation, there may also be impairment from exhaust fumes. Make sure that there is sufficient
ventilation or that protective measures are taken.
Since the cylinders are coupled with hose pipes, they may constitute a tripping risk. Ensure that the
hose pipes are safely installed. This is especially important due to the fact that escape routes must
be provided.

3.4 When working, make sure there is sufficient lighting and a clear view of the machine, so as to

guarantee safe working conditions.

3.5 Before switching on/starting up and while operating the machine, please ensure that nobody

will be endangered when the machine starts running. Also, secure the machine against unauthorised
or accidental switching on/off.

3.6 In the event of malfunctions, stop the machine immediately and lock it. Have any defects

rectified immediately.

3.7 Before setting the machine in motion always check that the accessories have been safely

stowed away! During transport, the weight of the LUKAS telescopic cylinders must be taken into
account.

3.8 Avoid any operation that might be a risk to machine stability! For this reason, a base plate (refer

to chapter 9.1) must be used. Also check that the foundation has sufficient load-bearing capacity.

3.9 Check the machine at least after every operation for obvious damage and defects. Report any

changes (incl. changes in the machine’s working behaviour) to the competent organization/person
immediately. If necessary, stop the machine immediately and lock it. All lines, hoses and screwed
connections have to be checked for leaks and obvious damage. Repair damage immediately.
Splashed oil may cause injury and fire.

3.10 All safety equipments have to be checked for completeness and flawless condition:

- instruction markings and warning signs (safety instructions)

- check safety cover (e.g. motor-safety covers, heat protection etc.) if they are available and if they
are in a good condition.

4