Operating Instructions Re-railing Technology HP Cylinders 84072376585 GB Edition 12.
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.
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 specific danger and the possible consequences.
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.
In the event of malfunctions, immediately deactivate the device and secure it. You should have the malfunction repaired immediately. Do not carry out any changes (additions or conversions) to the device without obtaining the prior approval of LUKAS. Observe all safety and danger notices on the device and in the operating instructions. All safety and danger notices on the device must be kept complete and in a legible condition.
Ensure adequate lighting when you are working. Before transporting the device, always ensure that the accessories are positioned such that they cannot cause an accident. Always keep these operating instructions within reach where the device is used. Dispose properly of all disassembled parts, oil and left-over fluid, as well as packaging materials.
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.
4. Device designation HP 25 / T 700 R Cylinder variant Special feature Design Cylinder type Total stroke in [mm] Cylinder variant: HP = High pressure cylinder Design: (no information) = T = Single-stage design Telescopic design Special feature: R = Hydraulic retraction 5. Functions and performance 5.1 Description HP cylinders are double-acting hydraulic cylinders. Extension and retraction takes place hydraulically.
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 specifications, otherwise hazards may occur which are not the responsibility of LUKAS.
6. Connecting the equipment 6.1 Hydraulic On the device side, a quick-disconnect coupling sleeve is provided on the piston rod side of the valve, and a quick-disconnect coupling nipple on the cylinder base side of the valve; they are connected to the pump unit via two extension hoses. All LUKAS pairs of extension hoses are colour coded and are equipped with quick-disconnect couplings so that they cannot be mixed up when being connected.
7. Operation 7.1 Installation CAUTION / ATTENTION! Prior to installing the cylinders, the load to be lifted must be secured against slipping as prescribed in the respective applicable guidelines and regulations. The following must generally be observed when installing the cylinders: - Non-slip and even ground, so that the entire base area of the cylinder is lying on the ground.
- Please ensure that the load is applied centrally to the piston rod. NOTE: You may need to look for a more favourable load application point! Position the cylinder underneath the centre of gravity of the load, such that the load cannot tip over during lifting and endanger the operating staff or the cylinder itself. The load should always contact the middle of the piston area.
If several cylinders are used simultaneously, the load should be distributed as evenly as possible over all cylinders. Load share 1 Load share 2 Load share 2 Load share 1 Load share 1 < Load share 2 Load share 1 = Load share 2 WRONG RIGHT If several cylinders are used simultaneously, the load should be lifted synchronously by all cylinders. RIGHT WRONG 7.
7.2.1 Initial operation Before commissioning and following repairs, the device must be de-aerated. - Connect the equipment to the hydraulic pump (see chapter “Connecting the equipment”). - Fully extend and retract the device several times without load. NOTE: We recommend that during the de-aeration, the attached unit for the hydraulic supply should stand on a higher level than the cylinder. The connections on the hydraulic cylinder should face upwards. 7.2.
8. Use of accessories 8.1 Base plate Base plates are provided to: - Increase the base area of the cylinders, - Increase static stability, - Level out minor unevenness of the ground. Assembly of the base plate: Place the cylinder onto the base plate in such a way that the coupling connection is positioned in the corresponding recess in the centring tube. You must then tighten the three fixing screws on the centring tube. This way, the cylinders can be carried together with the base plate. 8.
Operation Schematic 2. Place the first cylinder attachment “C” centrally on the cylinder body using the fork lever. WARNING / CAUTION B C underneath the load! A 3. Lower the load onto this cylinder attachment and retract the piston. 4. Remove the standard piston guard plate from the cylinder if present. WARNING / CAUTION underneath the load! 5. Insert first piston attachment "D" with neck in piston centring device (use fork lever!). D C WARNING / CAUTION underneath the load! A 6.
Operation Schematic 7. Position the second cylinder attachment “E” using the fork lever. D E WARNING / CAUTION underneath the load! C A 8. Lower the load onto this cylinder attachment. 9. Insert second piston attachment "F" with neck into centring device of the first attachment (use fork lever!) WARNING / CAUTION underneath the load! E F D C A 10. Completely extend load again by means of piston.
Operation Schematic 11. Repeat these steps until you have either reached the desired height or until all cylinder and piston attachments have been mounted. WARNING / CAUTION underneath the load! WARNING / CAUTION / ATTENTION! Never use several multistage sets at the same time on one HP cylinder, as otherwise stability cannot be guaranteed! Dismantling of the multistage sets takes place in reverse order.
9. Dismantling the device / deactivation following operation WARNING / CAUTION / ATTENTION! Before dismantling the re-railing equipment, please ensure that the moved load is in a stable and firm position! 9.1 Hydraulic cylinder After completion of the work, the hydraulic cylinders must be retracted leaving only a few mm*) projecting. This relieves the hydraulic and mechanical strain on the device.
10. Maintenance and service A visual inspection must be carried out after every use, but at least once a year. Every three years or if there is any doubt regarding the safety or reliability of the equipment, a functional test must also be performed. (Please also observe the relevant valid national and international regulations pertaining to service intervals of hydraulic equipment).
11.1 General points 11. Repairs Servicing may only be carried out by the manufacturer or personnel trained by the manufacturer and by authorised LUKAS dealers. Only LUKAS replacement parts may be used to replace all components (see replacement parts list) since special tools and compliance with, assembly instructions, safety aspects and inspections are required (see also chapter "Maintenance and Servicing").
11.2 Preventive maintenance 11.2.1 Maintenance instructions The exterior of the device must be cleaned from time to time. In order to protect it from corrosion, a suitable agent must be applied to the metallic surfaces. (In case of doubt, contact your authorised LUKAS dealer or LUKAS directly!) 11.2.2 Function and load test If there is any doubt regarding the safety or reliability of the equipment, a function and load test must also be performed. 11.2.
11.3 Repairs 11.3.1 Couplings The couplings must be replaced if: - There is external damage, - The lock does not function correctly, - Hydraulic fluid continues to leak in a coupled/uncoupled state. WARNING / CAUTION / ATTENTION! Never repair couplings: they must be replaced with original LUKAS parts! During assembly, tighten the coupling to the torque stated in the corresponding replacement parts list for the cylinder. Procedure: 1. Remove the coupling. 2.
12. Troubleshooting Trouble Check Cylinder piston Are the hoses moves slowly or connected jerkily when activated properly? Cause Solution Air in the hydraulic Deaerate pump system system Does the pump unit work? Cylinder defective Remove the cylinder from service and repair it (have it repaired) Piston on the cylinder Quick-stop Let the cylinder piston is not retracting function on the extend a little, then cylinder effective let it retract slowly.
Trouble Damage on the surface of the hydraulic hose lines Check Hydraulic fluid leaks on the piston rod Hydraulic fluid leak at Increase load? overpressure valve Coupling on the cylinder piston side properly coupled or defective? Leak in the couplings Is the coupling damaged? Cause Solution Replace hoses Mechanical damage or contact with aggressive agents Defective rod seal Have trouble repaired by authorised dealer, specially trained Damage to the LUKAS staff or piston directly by LUKAS Load incre
If it is not possible to rectify the malfunctions, inform an authorised LUKAS dealer or the LUKAS customer service department immediately! The address for the LUKAS customer service department is: LUKAS Hydraulik GmbH Weinstrasse 39, Postfach 2560, Phone: Fax.: D-91058 Erlangen D-91013 Erlangen (+49) 09131 / 698 - 348 (+49) 09131 / 698 - 353 13.
13.1 Cylinder data Type Ref.No. [kN] [lbf.] [kN] Compression force (piston 2) [lbf.] [kN] Compression force (piston 3) [lbf.] [mm] max. stroke (piston 1) [in.] [mm] max. stroke (piston 2) [in.] [mm] max. stroke (piston 3) [in.] [mm] Total piston stroke [in.] [mm] Length (extended) [in.] [mm] Dimensions D x H *** [in.] [kg] Weight incl. hydraulic fluid filling [lbs.] [MPa]* Max. operating pressure [psi.] [l]** Operating fluid quantity [gal.
Type Ref.No. Compression force (piston 1) HP50/T185R HP50/T400R HP65/T400R 840728265N 840728065N 840721065N 504 504 703 [kN] HP65/T500R 840721064 703 [lbf.] 113,309 113,309 158,049 158,149 Compression force (piston 2) [kN] 1066 1066 1665 1665 [lbf.] 239,658 239,658 374,326 374,326 max. stroke (piston 1) [mm] [in.] [mm] [in.] [mm] [in.] [mm] [in.] [mm] 89 3.50 96 3.78 185 7.28 423 16.65 220 x 238 195 7.68 205 8.07 400 15.75 804 31.65 220 x 404 253 9.96 250 9.84 503 19.80 955 37.
13.2 Hydraulic fluid recommendations Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil code HL 5 HM 10 HM 22 HM 32 HF-E15 Viscosity rating VG 5 VG 10 VG 22 VG 32 VG 15 Remarks A B C D E Oil temperature range -24 .... +30°C -18 .... +50°C -8 .... +75°C +5 .... +80°C -8 .... +70°C Oil temperature range -11.2 .... +86°F -0.4 .... +122°F +17.6 .... +167°F +41.0 .... +176°F +17.6 ....
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15. Notes Please dispose of all packaging materials and dismantled parts properly. LUKAS Hydraulik GmbH A unit of the IDEX Corporation Phone: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.com Made in GERMANY HP_Zylinder_BA_GB_84072376585_1211.
