Operating Instructions Rerailing Equipment 84072/5355-85 GB Issue 2.2005 Double-acting Rope-lift cylinder 3 (4.1) (4.3) 4 (3.3) (4.2) 1 5 3 2 (3.1) 6 1 2 3 4 5 6 (3.
Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 page Safety instructions Organisational measures General safety instructions Instructions for maintenance and service Function of components 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 Initial commissioning Installation 7.1 Safety notes 7.1.2 General information for cylinder installation / operation 7.1.
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.
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.
3.10 Check all safety equipment for completeness and perfect condition: - Instruction markings and warning signs (safety instructions) Check that safety covers (e.g. motor safety covers, heat shields etc.) are fitted and that they are in good condition. 3.11 It is not permitted to work under loads if they are raised solely by hydraulic cylinders. If such work is unavoidable, then additional mechanical supports are required. 3.12 Do not place hoses under mechanical strain (pulling, bending etc.). 3.
5.2 Connecting pieces In addition to the quick-connect couplings, these cylinder models are fitted with two connecting blocks with a safety valve to prevent damage to the cylinder under external load. If the specified maximum pressure is exceed, the safety valves automatically open and oil (protected) is squirted out. 5.3 Hoses between the control table and cylinders Connection is normally made with 10 m hose pairs red/blue (order no. 84072/1765).
Important! Some quick couplers have special functions and therefore must not be unscrewed from the hoses and/or interchanged. To avoid dirt from entering when the couplings are disconnected, fit dust protection caps on the plug and socket or, if the couplings are connected, fit the dust protection caps together. 6 Initial commissioning The cylinders must be vented prior to being used for the first time. - Extend the pistons approximately halfway when they are free from any load.
.2 Cylinder operation This must be carried out in accordance with the operating instructions of the motor pump used. 8.3 Uprighting of rolling stock With the uprighting system, overturned rolling stock can be turned back to its normal position so that it may be rerailed. The lifting belt (4) is fastened to the vehicle framed by means of a holding rope (5) and shackle (6).
.2 - 9.3 - Tilting set (3) comprising: Swivel base (3.1) Radius plate (3.2) Piston guard plate (3.3) Telescopic cylinder HP 25 / T 450 R (has to be ordered separately) Lifting belt (4) comprising: Lifting belt with plastic rope (4.1) Rope roller (4.2) Pressure piece (4.3) 9.4 Holding rope (5) 9.5 Shackle (6) 10 Dismantling of components Dismantle the components in the reverse order of the installation sequence.
11.2 Hydraulic system leakage - Check equipment for oil loss and replace any defective seals. Important: Carry out the following procedures over an oilpan; dispose of used oil in accordance with regulations. 11.3 Cylinder components Remove any oil remaining in the piston chamber and piston ring zone by fully unscrewing the two quick-connect couplings from the connecting blocks of all lifting cylinders and carefully draining the oil. Flush and fill up with new hydraulic oil.
13 Repair Only original LUKAS spare parts as listed in the spare parts list may be used for renewal of all LUKAS rerailing equipment components as it is important that any appropriate special tools, assembly notes, safety aspects and checks must be used and applied. Refer to Section 2.6 and Chapter 4 of these Operating Instructions.
15 Technical data HP 25 / 800 R 84072/5355N 53 MPa (530 bar) 1893 mm 800 mm 266 kN 3.1 l -20 ... +55 °C Dia. 115 x 1093 mm 23.5 kg © Copyright 2005 LUKAS Hydraulik GmbH Order no. Permissible pressure Length, extended Total stroke Lifting force Oil requirement Ambient temperature Dimensions dia.
