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Unipart Dorman CLS LITE Operation & Maintenance Manual

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CLS LITE
Operation & Maintenance Manual
C64.65201
Issue 3
June 2019
INTELLIGENT ENGINEERING UNIQUE PEOPLE WORKING TOGETHER

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Summary of Contents for Unipart Dorman CLS LITE

  • Page 1 CLS LITE Operation & Maintenance Manual C64.65201 Issue 3 June 2019 INTELLIGENT ENGINEERING UNIQUE PEOPLE WORKING TOGETHER...

  • Page 2: Table Of Contents

    Pre Installation Checks ..................5 CLS LITE Variants ....................5 Detachable Alignment Scope ................6 INSTALLATION AND ALIGNMENT OF CLS LITE HEADS ON ALL STRUCTURES EXCEPT THE UNIPART DORMAN ASSISTED LIFT TRUNNION ..........8 Preparing and Mounting the Signal Head ............... 9 Backboard Arrangement ..................

  • Page 3: Document Control

    Unipart Dorman Colour Light C64.65201 Issue 3...

  • Page 4: Specifications

    Unipart Dorman for more information on these energy saving options. The CLS LITE can be installed anywhere a Classic CLS or Filament Head is currently fitted or by using the Unipart Dorman Assisted Lift Trunnion range as standalone maintenance free signals, where all work is carried out from ground level.

  • Page 5: Storage

    All activity on the CLS LITE, both mechanical and electrical, must only be carried out by staff deemed competent in these fields by their employer. It is the user’s sole responsibility to ensure that the CLS LITE is installed and/or maintained by certificated and competent staff.

  • Page 6: Pre Installation Checks

    SHALL BE APPLIED TO PROTECT THE WORKING RAILWAY. CLS LITE Variants There are two types of CLS LITE head and they are defined by the way they are mounted. The installation instructions are different and it is important that you identify which variant you are installing.

  • Page 7: Detachable Alignment Scope

    The other type can only be used with the Unipart Dorman GRP Post and Assisted Lift Trunnion and will be delivered with the Spigot Bracket attached. Where this method is employed, this document should be read in conjunction with the ALT Operations and Maintenance Manual C64.65976 which is available on the Unipart Dorman...
  • Page 8 Do not attempt to disassemble the scope to gain access to the internal lenses as this will disturb the optical alignment and the scope will need to be returned to Unipart Dorman for adjustment on the special to type jig C64.65201 Issue 3...

  • Page 9: Installation And Alignment Of Cls Lite Heads On All Structures Except The Unipart Dorman Assisted Lift Trunnion

    INSTALLATION AND ALIGNMENT OF CLS LITE HEADS ON ALL STRUCTURES EXCEPT THE UNIPART DORMAN ASSISTED LIFT TRUNNION C64.65201 Issue 3 Jun 2019...

  • Page 10: Preparing And Mounting The Signal Head

    Two removable lifting rings are fitted to assist in mechanical lifting. Once in the required position, the CLS LITE is secured to the base platform using suitable mounting hardware. Ensure the Lower Backboard extension is fitted in its operational position as detailed below.
  • Page 11 | 10 The backboard must be moved to its in-service position before aligning the signal as in the transit position; it obscures the holes in the backboard the scope looks through and the signal will not meet the 300mm backboard criterion Remove the Lower Backboard Extension from its stowage position above the aperture by removing the two 3mm Allen screws shown in blue below.

  • Page 12: Signal Alignment

    | 11 Correctly fitted backboard on a 3 aspect short housing signal head shown – 3 aspect tall and 4 aspect signals have the same arrangement) Signal Alignment General Notes GREAT CARE SHOULD BE TAKEN TO ALIGN THE SIGNAL IN STRICT ADHERENCE TO THE SIGNAL SIGHTING FORM REQUIREMENTS The Signal Sighting Form (SSF) will provide the definitive, signal specific alignment details and should always be consulted prior to commencement of work.
  • Page 13 | 12 These instructions refer to standard climbable structures such as posts/gantries and the Collis Fold Down Post system only. The Collis Post is easily identified by the use of a single, separate spring pot on the unit. This Method is not to be used for signal heads mounted on the Unipart Dorman Spigot Mount fitted into the GRP Post and installed in the ALT.
  • Page 14 | 13 4 Aspect and 3 Aspect tall Housings Use the threaded inserts in the inside of the frame in the positions shown below which correspond with the door stay mounting on the opposite side of the frame. C64.65201 Issue 3 Jun 2019...
  • Page 15 | 14 Scope fitted in a 4 aspect head – 3 aspect tall housing scopes are fitted in the same position These two variants require the removal and retention of the plastic module spacer fitted to the pivot bar to give enough clearance for the scope to be fitted. Alternatively, unlock the module and lift off the pivot bar then slide the spacers into the centre of the bar.
  • Page 16 | 15 The block needs to be repositioned on the opposite side of the frame where the door opening side is changed. Detailed instructions on swapping the door are in a later section of this document. Vertical adjustment of the head’s tilt angle is carried out by loosening the bolt on either side of the baseplate highlighted and tilting it about the pivot shaft.
  • Page 17 | 16 Horizontal adjustment is achieved by swivelling the head in the kidney slots on the fixed mounting as shown. Once the horizontal adjustment is complete tighten the mounting bolts to the torque value specific to the size and material of the fasteners used. C64.65201 Issue 3 Jun 2019...
  • Page 18 The Collis Post System requires the use of a remote viewing device which attaches to the signal head by using the Unipart Dorman scope mount or another suitable method. The signal is raised, the alignment checked and then lowered for adjustment as required.

  • Page 19: Installation And Alignment Of Cls Lite Heads Using The Unipart Dorman Assisted Lift Trunnion

    | 18 INSTALLATION AND ALIGNMENT OF CLS LITE HEADS USING THE UNIPART DORMAN ASSISTED LIFT TRUNNION C64.65201 Issue 3 Jun 2019...
  • Page 20 | 19 The following instructions are unique to the Unipart Dorman Assisted Lift Trunnion which is easily identified by the use of a single connection cover and a circular baseplate. Installation of the ALT is covered in its own O&M Document.

  • Page 21: Preparing And Mounting The Signal Head

    | 20 Preparing and Mounting the Signal Head Where the signal is to be installed in a Unipart Dorman ALT the standard CLS LITE base plate is replaced by a Spigot Bracket which fits into the GRP Post and where all of the angles are set during manufacture to enable signal alignment from ground level.
  • Page 22 | 21 A FOUR ASPECT HEAD WEIGHS UP TO 38 Kg AND SHOULD BE LIFTED OFF THE PALLET CAREFULLY To install the spigot, first slide the collar onto the post. Insert the post cable up through the bore of the spigot and connect the plug coupler.
  • Page 23 Maintenance Manual C64.65976 which is available on the Unipart Dorman website. Where the head is mounted on the Unipart Dorman GRP post installed in an ALT, the alignment and all adjustment is done from ground level as the head is fixed in the bracket with no adjustment facility.

  • Page 24: Backboard Arrangement

    | 23 The diagram above shows highlighted in green, that the vertical adjustment slot in the side bracket has been replaced with a simple through hole bolt securing the housing to the base plate and the E-Clip/Locking Plate on the pivot bar with a split pin arrangement.
  • Page 25 | 24 Using the existing Allen screws shown in green below, mount the plate at the bottom of the backboard. Correctly fitted backboard on a 3 aspect short housing signal head shown – 3 aspect tall and 4 aspect signals have the same arrangement) C64.65201 Issue 3 Jun 2019...

  • Page 26: Alignment At The Alt

    | 25 Alignment at the ALT General Notes GREAT CARE SHOULD BE TAKEN TO ALIGN THE SIGNAL IN STRICT ADHERENCE TO THE SIGNAL SIGHTING FORM REQUIREMENTS The Signal Sighting Form (SSF) will provide the definitive, signal specific Alignment details and should always be consulted prior to commencement of work The signal should not be aligned to a target board when using the Assisted Lift Trunnion.
  • Page 27 | 26 Using the alignment scope to provide visual cues, the signal is adjusted horizontally by rotating the base within the kidney slots and vertically by adjusting the angle of the ALT using the securing and adjustment nuts and the spherical washer sets shown in red.

  • Page 28: Instructions Common To Both Variants

    INSTRUCTIONS COMMON TO BOTH VARIANTS Electrical Connection To reduce the amount of spares that need to be held, all CLS LITE Modules have the splitter cable for the second Yellow module attached. If the signal only uses a single Red Yellow Green module the splitter cable will have a blanking cap fitted and it will be secured to the main plug coupler using a cable tie or fitted in the bracket on the inside of the door.
  • Page 29 | 28 The main connector is plug coupled and connected by aligning the keyway and lug inside the connector shells with a slight push to get the worm drive to engage and then turning the friction locking collar by hand until an audible ‘click’ is detected and the two indicator spots are aligned.
  • Page 30 | 29 in the door bracket as shown. This stowage option can also be used where the feed cable is fitted with a blanking cap, The RYG Plug Couplers are stowed in their brackets in the positions shown in green below.

  • Page 31: Changing The Door Opening Side

    The instructions below are illustrated using a 4 aspect head but the procedure is also the same for both 3 aspect configurations. Unipart Dorman recommends that where the installation requires the door to be swapped, the signal alignment procedure is carried out using the camera attachment C64.65201 Issue 3...

  • Page 32: Door Preparation

    | 31 or if there is insufficient space to fit the camera, the procedure is undertaken when the door is removed Do not reposition the adaptor block on the scope as this will invalidate the scope alignment which can only be reset on the manufacturing jig Door Preparation Note the assembly order of any fasteners removed in the instructions below, to ensure correct re-assembly sequence.
  • Page 33 | 32 Lift the door off its hinges (shown in green) by driving out both of the two part hinge pins (shown in magenta below). Once the door is off, using an 8mm socket, remove the 4 x rubber doorstops (shown in red) fitted inside the door flange and retain.

  • Page 34: Frame Preparation

    | 33 Frame Preparation Remove the frame earth strap and fit it to the corresponding stud on the opposite side of the frame (shown in blue above). Move the two hinges to the opposite side of the frame. Do not tighten at this stage to allow later door/frame alignment.

  • Page 35: Refitting The Door

    | 34 Refitting the Door Rehang the door onto the frame using the two part hinge pins ensuring the short pins are fitted at the bottom of both hinges. Adjust the hinges on the mounting for satisfactory door operation and to give approximately 1mm clearance between the inner face of the door and the rolled edge on the frame.

  • Page 36: Signal Husbandry

    | 35 Signal Husbandry If the signals require any cleaning to be carried out, the only mediums approved are water and proprietary detergents. Do not use any solvent based or abrasive cleaning material as this may irreparably damage the signal. Using a lint free cloth moistened with the water detergent solution, carefully wipe the lens clean and using a dry second cloth remove any water spotting etc.
  • Page 37 | 36 The module can then be swung out and if required is unhooked from the top bar for removal. C64.65201 Issue 3 Jun 2019...

  • Page 38: End Of Life Disposal

    End of Life Disposal Wherever possible the component parts and complete assemblies of the Unipart Dorman CLS LITE are designed to be disposed of in accordance with the requirements of the Waste Electronic and Electrical Equipment Regulations 2006. Please contact Unipart Dorman for full details of the procedure to be undertaken when a signal is permanently withdrawn from service for disposal.

  • Page 39: Contact Us

    This document either in whole or part, must not be reproduced, or disclosed to others, or used for any purpose other than that for which it is supplied without Unipart Dorman’s written permission; or if any part is furnished by virtue of a contract with a third party, as expressly authorized under that contract.

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