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Summary of Contents for Lukas HP 25/ T700R
- Page 1 Operating Instructions - Re-railing Technology HP Cylinders 84072376585 GB Edition 12.2011 (Translation of the original operating instructions)
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Page 3: Table Of Contents
Contents Page 1. Hazard classes 2. Product safety 3. Proper use 4. Device designation 5. Functions and performance 5.1 Description 5.2 Controlling the operating movements 5.3 Hydraulic supply 5.4 Hose lines 6. Connecting the equipment 6.1 Hydraulic 6.2 Coupling quick-disconnect couplings 7. -
Page 4: Hazard Classes
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. Pictogram Damage / injury to Key word Definition Consequences Death or major... -
Page 5: Product Safety
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. - Page 6 (additions or conversions) to device and secure it. You the device without obtaining should have the malfunction the prior approval of LUKAS. repaired immediately. Observe all safety and danger All safety and danger notices notices on the device and in on the device must be kept the operating instructions.
- Page 7 Ensure adequate lighting when Before transporting the you are working. device, always ensure that the accessories are positioned such that they cannot cause an accident. Always keep these operating Dispose properly of all instructions within reach where disassembled parts, oil and the device is used.
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Page 8: Proper Use
3. Proper use LUKAS-HP cylinders are especially designed for re-railing technology. In the event of de- railed 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. -
Page 9: Device Designation
Securing against unwanted lowering of the cylinders in the event of a hose breakage is achieved by means of quick-stop couplings fitted to the hose. If there is any doubt as to which coupling sleeves are fitted to your hose, please contact your authorised LUKAS dealer or LUKAS directly before using the hose. -
Page 10: Controlling The Operating Movements
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. -
Page 11: Connecting The Equipment
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. -
Page 12: Operation
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. - Page 13 - 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.
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Page 14: Commissioning
If several cylinders are used simultaneously, the load should be distributed as evenly as possible over all cylinders. Load Load Load share 2 share 1 Load share 1 share 2 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... -
Page 15: Hydraulic Cylinder Control
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. -
Page 16: Use Of Accessories
NOTE: Multistage sets are specifically designed for individual cylinders. To find out which multistage set is suitable for your cylinder, please contact your authorised dealer or LUKAS directly. Multistage sets consist of: - Cylinder attachments (Fig. right, item 1), - Piston attachments (Fig. right, item 2), - Fork lever (Fig. - Page 17 Operation Schematic 2. Place the first cylinder attachment “C” centrally on the cylinder body using the fork lever. WARNING / CAUTION underneath the load! 3. Lower the load onto this cylinder attachment and retract the piston. 4. Remove the standard piston guard plate from the cylinder if present.
- Page 18 Operation Schematic 7. Position the second cylinder attachment “E” using the fork lever. WARNING / CAUTION underneath the load! 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! 10.
- Page 19 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.
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Page 20: Dismantling The Device / Deactivation Following Operation
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. -
Page 21: Maintenance And Service
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). -
Page 22: 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"). -
Page 23: Preventive Maintenance
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. -
Page 24: Repairs
- 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. -
Page 25: Troubleshooting
12. Troubleshooting Trouble Check Cause Solution Cylinder piston Are the hoses Air in the hydraulic Deaerate pump moves slowly or connected system system jerkily when activated properly? Does the pump unit work? Cylinder defective Remove the cylinder from service and repair it (have it repaired) Piston on the cylinder... - Page 26 Hydraulic fluid leaks Defective rod seal Have trouble repaired on the piston rod by authorised dealer, specially trained Damage to the LUKAS staff or piston directly by LUKAS Hydraulic fluid leak at Increase load? Load increase Secure the load and overpressure valve (e.g.
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Page 27: Technical Data
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, D-91058 Erlangen Postfach 2560, D-91013 Erlangen Phone: (+49) 09131 / 698 - 348 Fax.:... -
Page 28: Cylinder Data
13.1 Cylinder data Type HP10/T280R HP25/T185R HP25/T450R Ref.No. 840724665N 840721565N 840723765N [kN] Compression force (piston 1) [lbf.] 23,381 67,671 67,671 [kN] Compression force (piston 2) [lbf.] 67,671 146,133 146,133 [kN] Compression force (piston 3) [lbf.] 146,133 [mm] max. stroke (piston 1) [in.] 3.54 3.54... - Page 29 Type HP50/T185R HP50/T400R HP65/T400R HP65/T500R Ref.No. 840728265N 840728065N 840721065N 840721064 [kN] Compression force [lbf.] 113,309 113,309 158,049 158,149 (piston 1) [kN] 1066 1066 1665 1665 Compression force [lbf.] 239,658 239,658 374,326 374,326 (piston 2) [mm] max. stroke (piston 1) [in.] 3.50 7.68 7.80...
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Page 30: Hydraulic Fluid Recommendations
13.2 Hydraulic fluid recommendations Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range Oil code Viscosity rating Remarks -24 ..+30°C HL 5 VG 5 -18 ..+50°C HM 10 VG 10 -8 ..+75°C HM 22 VG 22 +5 .. -
Page 31: Ec Declaration Of Conformity
14. EC Declaration of Conformity... -
Page 32: Notes
A unit of the IDEX Corporation Weinstrasse 39, D-91058 Erlangen 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.indd © Copyright 2011 LUKAS Hydraulik GmbH...
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