Page 3 22.38 / 02 HYDRAULIC RAIL BENDER SAFETY General Dangers The appliance is safe by current technical standards. The appliance’s safety mechanisms are in accordance with current safety regulations. For further information see Appendix A. Danger Warnings All of the following remarks and instructions aim to protect the personal safety and physical integrity of the operator from danger and to protect the appliance operator’s assets from damage.
Page 5 22.38 / 02 HYDRAULIC RAIL BENDER APPLIANCE DESCRIPTION Intended Use The hydraulic rail press is for shaping rails. Components Hooks Piston Piston guard Bending unit Handles Stop valve Pump lever Lever extension handle Fit the appropriate hooks to the appliance for each type of rail.
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Page 6 22.38 / 02 HYDRAULIC RAIL BENDER Stop valve Pump lever Lever extension handle Oil filler Connection for manometer...
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Page 7 22.38 / 02 HYDRAULIC RAIL BENDER Detail of Handle & Hook Hook Bending unit Handle with bolt Fastening bolt Nuts for bolts (covered)
Page 8 22.38 / 02 HYDRAULIC RAIL BENDER Hooks for grooved rails (contoured inserts not shown!) Please note: The photograph is for guidance only TRANSPORT AND STORAGE To avoid damaging the appliance during transport and in storage, the piston should be pushed in until it is fully retracted.
Page 9 22.38 / 02 HYDRAULIC RAIL BENDER OPERATION Checks before commissioning The appliance is delivered filled with oil and ready to operate. • Before using the appliance, check for visible signs of damage (cracks, defective hooks, loose nuts and bolts on the hooks). •...
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Page 10 22.38 / 02 HYDRAULIC RAIL BENDER Air in the hydraulic system prevents the piston from staying retracted: • Position the rail bender horizontally. • Carefully pump the piston as far as possible (max. 110 mm). Danger of tilting! Make sure the device is always in a stable position! •...
Page 11 22.38 / 02 HYDRAULIC RAIL BENDER Changing Hooks Please note: The photograph is for guidance only Hook Bending unit Handle with bolt Fastening bolt Nuts for bolts (covered) Damage! • Hooks should only be replaced in matching pairs of the same type! •...
Page 12 22.38 / 02 HYDRAULIC RAIL BENDER Positioning the Rail Bender Danger of injury! • This is a two-person operation • Fingers can become trapped both above and below the pump lever. Tilting the rail bender during positioning can damage the appliance prevent successful...
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Page 13 22.38 / 02 HYDRAULIC RAIL BENDER For grooved rails: Pressure pad at plunger (1x) Position on standard rails Position on grooved rails A is parallel with B piston contoured insert When positioning the rail bender (see illustration above) •...
Page 14 22.38 / 02 HYDRAULIC RAIL BENDER Shaping Danger of crushing injury in the area of pump lever • Pump carefully! Damage of the base of piston! • Never apply full pressure to the piston without having an object (i.e. a rail) to shape. This would force the piston inside the bending unit against the cylinder base at full force and could break the base of the piston.
Page 15 22.38 / 02 HYDRAULIC RAIL BENDER MAINTENANCE • Please always use the recommended lubricants and, in the event of repairs, use genuine replacement parts at all times. In addition to complying with the terms of guarantee this is also important for the added operational safety of your machine.
Page 16 22.38 / 02 HYDRAULIC RAIL BENDER Cleaning and maintaining • Clean the hydraulic rail bender regularly in order to prevent a loss of production caused by excessive soiling. • Clean the hydraulic rail bender only with a damp cloth. Use only water and if necessary a mild cleaning agent without chemical supplements.
Copyright Specific characteristics and constructional peculiarities of the machine are the intellectual property of ROBEL Bahnbaumaschinen GmbH. The copyright on this operating manual remains the property of ROBEL Bahnbaumaschinen GmbH. It may not be reproduced either in full or in part, published or otherwise exploited for competitive purposes, whether for payment or not.
Enough safe and clear track and work sections must be provided to allow personnel to learn and practice how to use the goods delivered. ROBEL Bahnbaumaschinen GmbH together with its customer service organizations are however happy to provide further advice, training or other consultative services.
Page 19 22.38 / 02 HYDRAULIC RAIL BENDER Safety Regulations All requirements relating to handling of the appliance in order to protect life, health, material property and the environment must be guaranteed as a priority! • Before setting up the appliance, provide proof that all personnel concerned have been made aware that all relevant: −...
Page 20 22.38 / 02 HYDRAULIC RAIL BENDER Intended Audience for Operating Instructions These instructions contain the information needed to use the appliance they describe correctly. The instructions are written exclusively for technically qualified personnel. Qualified personnel in this context are: ▪...
Page 21 22.38 / 02 HYDRAULIC RAIL BENDER • Be aware of the dangers specific to use of the appliance in your area of work, especially regarding: − People and obstacles, − Adherence to safety guidelines, − Work on neighbouring rails, −...
Page 22 22.38 / 02 HYDRAULIC RAIL BENDER 7.12 Dangers from Hydraulic Power Work on the hydraulic part of the appliance may only be performed by personnel who are specially qualified to do so. The appliance’s hydraulic equipment must be checked regularly and any faults found must be addressed immediately, e.g.
Page 23 22.38 / 02 HYDRAULIC RAIL BENDER 7.15 Fire Hazards Poisonous or carcinogenic substances may result from burning hydraulic oil! As a rule all fires should only be extinguished with a dry-powder extinguisher. 7.16 Fire Prevention • No naked flames or easily flammable materials on or in immediate proximity of the appliance! •...
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