Lukas HP 25/ T700R User manual

Operating Instructions -
Re-railing Technology
84072376585 GB
HP Cylinders
(Translation of the original operating instructions)
Edition 12.2011

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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
8.2 Multistage sets 16
9. Dismantling the device / deactivation following operation 20
9.1 Hydraulic cylinder 20
9.2 Hydraulic unit 20
9.3 Hose lines 20
10. Maintenance and service 21
11. Repairs 22
11.1 General 22
11.2 Preventive maintenance 23
11.3 Repairs 24
12. Troubleshooting 25
13. Technical Data 27
13.1 Cylinder data 28
 13.2 Hydraulicuidrecommendations 30
13.3 Operating and storage temperature ranges 30
14. EC Declaration of Conformity 31
15. Notes 32

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Wear a helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
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 specic danger
and the possible consequences.
1. Hazard classes
Pictogram Damage / injury to Key word Denition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
device
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- NOTE
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment

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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.
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.
The equipment may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury.
We would like to point out to all users that they should carefully read and adhere to the
operating instructions in full before they use the equipment.
We further recommend that a qualied trainer train you in the use of the product.
WARNING / TAKE CARE!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes again.
Please ensure that no body
parts or clothing are caught
between the visibly moving
parts (e.g. piston guard plate
and cylinder).
Working under loads is
prohibited if they are raised
exclusively with hydraulic
devices. If this work is
unavoidable, adequate
mechanical supports are
additionally required.
Wear protective clothing,
a safety helmet with visor,
protective footwear and
gloves
Inspect the device before and
after use for visible defects or
damage
The responsible department
must be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the device must
be deactivated immediately
and secured!
Inspect all cables, hoses
and screwed connections
for leaks and externally
visible damage! If necessary,
repair immediately! Squirting
hydraulic uid can result in
injuries and res.
WARNING / TAKE CARE!
Ensure that the accessories used and the connected equipment are suitable
for the maximum operating pressure!

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The device is lled with a
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours are inhaled. Direct
contact with the skin should
be avoided for the same
reason. Please also note that
hydraulic uids can also have
an adverse effect on biological
systems.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired by
the effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
device can also heat up over a
long period of use.
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.
Any mode of operation which
impairs safety and/or stability
of the device is forbidden!
Comply with all stipulated
dates or dates specied in
the operating instructions
pertaining to regular tests /
inspections on the equipment.
Safety devices must never be
disabled!
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Before the device is switched
on / started up, and during its
operation, it must be ensured
that nobody is endangered by
the operation of the device.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you do not become
entangled in the looped hoses
and trip.
When working in the proximity
of live components and wires,
appropriate steps must be
taken to avoid current ow
or high-voltage discharge
through the device.
The build-up of static
charge with the potential
consequence of spark
formation is to be avoided
when handling the device.

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The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
WARNING / CAUTION!
The equipment is intended to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use is not considered
proper use. The manufacturer/supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!
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 uid, as well as
packaging materials.

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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.
HP cylinders in telescopic design offer long hoisting paths with a low retracted overall
height.
The accessories necessary for the particular application, such as base plate, multistage sets
etc., must be used during each deployment.
CAUTION!
Watch out vigilantly for any leaks in order to avoid threats to the environment.
Recommended accessories for HP cylinders:
- Base plate (Item 1)
- Multistage set (Item 2)
1 2

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4. Device designation
5. Functions and performance
25 THP 700
Design
Cylinder type
Cylinder variant
Total stroke
in [mm]
Cylinder variant:
HP = High pressure cylinder
Design:
(no information) = Single-stage design
T = Telescopic design
Special feature:
R = Hydraulic retraction
Special
feature
R/
5.1 Description
HP cylinders are double-acting hydraulic cylinders. Extension and retraction takes place
hydraulically. The direction of movement is controlled by pressurising the piston rod side or
the cylinder base side. Control of the pressurisation must be effected by an external control
unit (e. g. control panel) and a connected hydraulic unit (the use of a hand pump is possible
in exceptional cases).
Securing against unwanted lowering of the cylinders in the event of a hose breakage is
achieved by means of quick-stop couplings tted to the hose. If there is any doubt as to
which coupling sleeves are tted to your hose, please contact your authorised LUKAS dealer
or LUKAS directly before using the hose.
In addition to the quick-disconnect couplings, the HP cylinders are additionally equipped with
two connection blocks with integrated safety valve. These safety valves protect the cylinder
from damage caused by sudden load increase (e.g. something has additionally fallen onto
the part to be lifted, thus suddenly increasing the weight). If the specied maximum pressure
is exceed, the safety valves automatically open and hydraulic uid (protected) is squirted
out.
HP cylinders in telescopic design offer long hoisting paths with a low retracted overall
height.

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5.3 Hydraulic supply
5.4 Hose lines
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
specications, otherwise hazards may occur which are not the responsibility of LUKAS.
Ensure in particular that the maximum permissible operating pressure for the connected
LUKAS equipment is not exceeded.
NOTE:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
The pump unit and the HP cylinder are connected by hoses.
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.
A
B

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For dust protection, the supplied dust protection caps must be retted.
WARNING / CAUTION / ATTENTION!
Some quick-disconnect couplings have special functions and may therefore not
be unscrewed from the hydraulic lines and/or swapped!
NOTE:
It is only possible to connect devices when the hoses are depressurised.
CAUTION!
Always connect the return hose rst and then the supply hose!
Before coupling, remove the dust protection caps and then pull back and hold the locking
sleeve of the female coupling half (position X). Connect the male and female coupling together
and release the locking sleeve. Then turn the locking sleeve to position Y. The connection has
now been made and locked. Disconnection is carried out in the reverse order. Hoses can be
connected only when depressurised. For dust protection, the supplied dust protection caps
must be retted.
6.2 Coupling quick-disconnect couplings
The equipment is connected to the hydraulic pump via quick-disconnect-coupling halves
(male and female).
X
Y
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.
6. Connecting the equipment
WARNING / CAUTION / ATTENTION!
Prior to connecting the devices, ensure that all the components
being used are suitable for the maximum operating pressure
of the pump unit. In the case of doubt you must consult LUKAS
directly!

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7. Operation
7.1 Installation
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. If there is any doubt as to the load-bearing capacity of the ground, suitable
wooden or metal underplates must be used to increase the contact area.
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.
ATTENTION!
Hydraulic uids may produce a lubricating lm on the ground!
CAUTION / ATTENTION!
When using wooden underplates, care must be taken that particularly hard
wood without damage is used, so that the underplate cannot crack. Additional
clamping together of other woods with metal straps is not sufcient!
ATTENTION!
Use an additional non-slip underplate between the piston guard plate and the
load to be lifted, as a lubricant lm may be present at the contact point of the
load!
- The ground must be a continuous surface (no gratings, gravel etc.)
- Never place cylinders on a yielding underplate
- Never use cylinders without a piston guard plate, in order to avoid damage to the
piston and achieve safe power introduction
WRONG RIGHT

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NOTE:
You may need to look for a more favourable load application point!
- Please ensure that the load is applied centrally to the piston rod.
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. Side loads should be
avoided!
WRONG RIGHT
Load Load
WRONG RIGHT
Load Load
It is usually not possible to make the load contact the full area of the cylinder piston. We
also recommend the use of suitable piston guard plates for this reason, as otherwise
there is a risk of damage to the piston rod or the cylinder. A convex piston guard plate
distributes the load evenly over the piston area again.

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7.2 Commissioning
If several cylinders are used simultaneously, the load should be distributed as evenly as
possible over all cylinders.
WRONG RIGHT
Load
share 2
Load share 1 = Load share 2
Load
share 1
Load
share 1
Load
share 2
Load share 1 < Load share 2
If several cylinders are used simultaneously, the load should be lifted synchronously by
all cylinders.
WRONG RIGHT
WARNING / CAUTION / ATTENTION!
Always keep a sufcient distance away from the hydraulic cylinder when
pressurising it, in particular when commissioning the equipment after
installation!
ATTENTION!
Each time before putting into operation, make sure that the hydraulic
connections to the cylinders are properly made and in full working order.
Incorrectly made connections or defective couplings can lead to a safety valve
responding (e.g. on the coupling nipple in the case of hoses with safety quick-
disconnect coupling nipple)!

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7.2.2 Checking the pump unit
See separate operating instructions for the corresponding unit (or hand pump).
NOTE:
Before working on the pump unit or connecting/disconnecting hoses, always
make sure that the pump unit is switched off or disconnected from the supply
in the case of electric pumps, and that the control valves have been set to
depressurised recirculation.
7.3 Hydraulic cylinder control
Movement of the cylinder piston cannot be directly controlled by the cylinder. Extending
and retracting the cylinder must be controlled via a separate control unit or the connected
hydraulic unit.
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.

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8.2 Multistage sets
Multistage sets consist of:
- Cylinder attachments (Fig. right, item 1),
- Piston attachments (Fig. right, item 2),
- Fork lever (Fig. right, item 3)
Application case for multistage sets:
Multistage sets enable an increase in load lifting
height beyond the stated cylinder stroke. For space
reasons, cylinders with large strokes often cannot be
used due to their large overall height. Multistage sets
make it possible to use cylinders with small overall
height to lift loads very high.
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3
NOTE:
Multistage sets are specically designed for individual cylinders.
To nd out which multistage set is suitable for your cylinder, please contact your
authorised dealer or LUKAS directly.
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 cou-
pling connection is positioned in the corresponding recess in the
centring tube. You must then tighten the three xing screws on
the centring tube. This way, the cylinders can be carried together
with the base plate.
Installation / operation of the multistage sets:
1. Raise the load with the cylinder "A", using the standard
piston guard plate "B".
Operation Schematic
A

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2. Place the rst cylinder attachment “C” centrally on the
cylinder body using the fork lever.
Operation Schematic
WARNING / CAUTION
underneath the load!
B
A
C
3. Lower the load onto this cylinder attachment and retract
the piston.
4. Remove the standard piston guard plate from the cylinder
if present.
5. Insert rst piston attachment "D" with neck in piston
centring device (use fork lever!).
WARNING / CAUTION
underneath the load!
WARNING / CAUTION
underneath the load!
D
A
C
6. Completely extend load again by means of piston.

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7. Position the second cylinder attachment “E” using the
fork lever.
8. Lower the load onto this cylinder attachment.
WARNING / CAUTION
underneath the load!
Operation Schematic
E
A
C
D
9. Insert second piston attachment "F" with neck into
centring device of the rst attachment (use fork lever!)
10. Completely extend load again by means of piston.
WARNING / CAUTION
underneath the load!
E
A
C
D
F

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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.
WARNING / CAUTION
underneath the load!

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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 rm 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.
NOTE:
When hydraulic cylinders are in storage, fluctuations in ambient temperature
can cause the pistons to move slightly. This phenomenon is due to the
difference in the expansion of the hydraulic fluid enclosed on the piston side
and the rod side.
*) 1 mm = 0.04 in.
9.2 Hydraulic unit
9.3 Hose lines
Upon completion of work, the unit must be deactivated.
First of all, decouple the pressure hose then the return hose as described in chapter
“Connecting the equipment”.
Ensure that you replace the dust protection caps onto the mono-coupling halves.