Moser Ro-V 280 Guide

Operating instructions aluminium trolley Ro-V 282
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Technical documentation
Ro-V 280 aluminium trolley for rail welders
Manufacturer:
Am Bahnhof 12c
09306 Rochlitz
Germany
Provisional release: 0date: March, 14th 2012
phone: [phone] fax: [phone] email:[e-mail]

Operating instructions aluminium trolley Ro-V 282
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contents
1. How to use this manual..............................................................................................3
2. Pleas note....................................................................................................................4
2.1 Foreword ...............................................................................................................4
2.2 Safety instructions .................................................................................................7
2.2.1 Use for intended purpose ...............................................................................7
2.2.2 Use of skilled personnel .................................................................................7
2.2.3 Working clothes..............................................................................................8
2.2.4 Operating safety instructions ..........................................................................8
2.2.5 Loads..............................................................................................................9
2.2.6 Entering and leaving the machine ..................................................................9
2.2.7 Safety notes in this manual ..........................................................................10
2.2.8 Preconditions for safety................................................................................11
2.2.9 Personnel .....................................................................................................11
2.2.10 Mechanical dangers .....................................................................................13
3. Description and explanation....................................................................................14
3.1 Technical specifications.......................................................................................14
3.2 General drawing ..................................................................................................15
3.2.1 Trolley in clearance profile German and Norwegian railway.........................16
3.3 Main frame/axle bridges ......................................................................................17
3.4 Rail wheels ..........................................................................................................18
3.4.1 Wheel profile ................................................................................................19
3.5 On track braking system......................................................................................20
3.5.1 Technical specifications................................................................................20
Maintenance and repair...................................................................................................22
3.6 General information .............................................................................................22
3.7 Regular checks and maintenance .......................................................................24
3.8 Self made repairs or attachments........................................................................26
4. Spare parts................................................................................................................27
5. Risk analysis.............................................................................................................29
6. Declaration of conformity ........................................................................................31
6.1 EG – Konformitätserklärung ................................................................................32

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1. How to use this manual
How to proceed correctly
• Read the entire handbook carefully.
• Familarize yourself particularly with the Safety Instructions
• Use the other chapters together

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2. Pleas note
2.1 Foreword
These operating instructions are designed to
•familiarize the operator with the trolley
•enable him to make full use of the machine
•enable safe and appropriate operation of the trolley
•prevent hazards
•reduce repair costs and downtimes
•improve the reliability and service life of the machine
These instructions should
•Be kept with the machine at all time
•Be supplemented with national accident prevention regulations where necessary
•Be known to the operators
•Be observed by the operators
Operating instructions cannot replace operator training
Please note, that these instructions are only meant to assist the operators. They can
merely reinforce existing skills
Prior to the first use of the machine, employers must provide proper Training for
operators, including general information on functions and safety precautions needed for
operation, such as giving the right signs by hand to other personnel and understanding the
directions given by others.

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Safety notes for the operation instructions
Not all operations require the same level of precaution. Therefore, a special
safety note precedes each individual description in these instructions. It is
marked by the symbol on the left.
These safety notes are, however merely of a complementary nature. The general safety
instructions as well as the safety requirements of the accident prevention regulations
and national regulations must also be observed.
Appropriate operation
It should be noted, that equipment of the same type may differ in small technical details,
which also have an effect on the operation. These differences result from client
specifications and national regulations. Any deviations found should be noted in your
instructions in order to avoid errors in the future.
Organisation of the operating instructions
We have made an attempt to arrange these instructions clearly and conveniently. You
should be able to find individual points and take action easily after reading chapter 1.
“How to use these operating instructions”
Illustrations in these operating instructions
These instructions have been provided with numerous photos, drawings and diagrams for
enhanced explanation.

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In some cases filler caps, covers or safety devices have been dismounted to improve
the illustration. We expressly point out, that these components must be mounted on the
device during normal operation.
Please note in addition, that these instructions have been compiled for your device from a
universal standard. The illustrations may therefore show components which do not form
part of the scope of supply for your device. The scope of supply is exclusively defined by
the provisions of the contract.

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2.2 Safety instructions
2.2.1 Use for intended purpose
This aluminium trolley has been designed to carry different kinds of loads, especially rail
welding and mounting equipment to the construction site.
Make sure the loading capacity must not be exceeded.
It is not allowed to transport persons on the trolley!
The trolley must not be used on open road traffic only on construction sites!
It is assumed that all work takes place under suitable physical conditions, so that all the
loads are fixed properly.
The trolley is designed to be lifted manually by 2 operators.
Caution! The trolley is not designed to be lifted by cranes or excavators and it is not
designed to be lifted under load!
2.2.2 Use of skilled personnel
Unauthorized people must not enter the machine and keep out of its working range.
The machine must be operated, maintained, serviced and repaired by personnel, who
have been properly trained/ instructed and are able to give proof of the skills related to it.
Besides this technical know-how, the personnel must also be aware of all the applicable
safety and accident prevention regulations and act accordingly. In addition, the company
operating the machine must have assigned that personnel to their respective tasks.

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2.2.3 Working clothes
Always wear suitable working clothes. Loose wide clothes as well as necklaces and
jewelery which might become entangled in machine components are not permitted.
Always wear sturdy, comfortable, flat footgear for a safe, firm footing on the machine.
Open, loose sandals or high thick-soled footwear are not permitted.
2.2.4 Operating safety instructions
The operator must
•Check if the load bed panel is in proper condition and not bend or cracked
•Visually inspect if the trolley is damaged, bent or broken in any way.
•Visually inspect if all mechanical connectors are as supposed to and not bent or
damaged
•Make sure that there are no mechanical hindrances between the wheel and the
braking pads
•check the insulation and remove any electrical bridge between both rails/wheels
•Do not use the trolley if a defect is detected.
•Notify the supervisor in charge and the operator relying on him of the detected
defects
•Make sure that the spring loading break is applied when leaving the trolley by
means of loosening the manual hand grip (282a) or releasing the foot braking lever
(282b)
•Ensure safe parking of the machine according to relevant provisions at the end of
operation
•Ensure correct setting to the rail tracks
•The operator has to generate a warning signal if necessary.

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It is not allowed to transport people under any circumstances on the
trolley.
It is not permitted to propel the trolley in any other way than manually. The
trolley may not be towed or pushed by vehicles and it is not intended being
coupled to any other rail vehicles!
It is not allowed to transport stuff on the trolley while operation on the
road!
The trolley must not be used on open road traffic only on construction
sites!
The trolley must not be left on track without supervision of the operator
Any signals necessary for communication between operator and others staff working with
the trolley have to be agreed on beforehand.
2.2.5 Loads
The loads carried by the construction trolley must not exceed the maximum permissible
limit. The mass centre of the load to be transported should be in or near the middle of the
trolley. Loads must not exceed the trolley outline dimensions.
2.2.6 Entering and leaving the machine
Unauthorized personnel may not enter the trolley.
Personnel may not enter the machine, until the permission has been given by the operator
and the machine is at a standstill.
Maintenance and repair work has to be done by authorized and skilled staff and the
permission to enter the machine has to be given by the operator and supervisor. The
trolley has to be placed in a safe position outside the track.

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Safety notes in this manual
In this manual you find “safety notes” in each chapter
corresponding to the possible hazards!
They are indicated by the general warning sign in the margin.
To make sure those note are clear and avoid them being
interpreted differently in different countries, the notes have been
written as text and translated into the respective national language.
General mandatory sign
Wear safe working clothes
No unauthorized entry
Warning
Warning of crushing hazards
Warning of hand injuries
Warning of dangerous voltage
Warning of noxious or irritating substances
Warning of substances contributing to fire hazards
Hazard caused by pressurised components
Warning of environmental damage

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2.2.7 Preconditions for safety
The machine may be used for its intended purpose.
Safety precautions for its operation as well as a safe environment must be ensured by the
user of the machine.
Note
This list briefly summarizes the detailed safety notes given in these instructions.
This list does not relieve you of your duty to familiarize yourself with
•The detailed safety notes in this instructions
•The relevant accident prevention regulations
•The instructions regarding safety at work
•Internal regulations
•The relevant environmental regulations
•Other specific national regulations
2.2.8 Personnel
All people entrusted with operation and maintenance of the construction
trolley must:
•Possess proof of an adequate professional qualification
•Have been trained and/ or instructed on the machine
•Have been assigned to their area of responsibility
•Know and comply with the accident prevention regulations applying to their
assignment
•Wear safe working clothes

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After maintenance operation check that:
•Screw connections have been firmly tightened
•No tools / objects clutter the working area
ono electrical bridges are between the opposite rail wheels
Before starting the machine, make sure that:
•The machine is in safe condition, ready for operation
•All people have left the danger area
•The warning signal “Start” is given
During operation, make sure that:
•dangerous spots are within the closed- off safety area
Ensure that at the end of a shift:
•the machine is handed over properly, or:
•the machine is properly brought to a stop
•the machine is secured to prevent unauthorized restarting
•the trolley is taken off track and out of the clearance profile
At change of shifts
•Inform the staff taking over of unusual occurrences, in the event of safety-relevant
occurrences in writing.

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2.2.9 Mechanical dangers
•Crushing hazards in the zones of moveable machine elements, such as:
braking ridges, loose panels and axle components
•Danger of being caught in running or spreading drives or parts
•Danger of hand injuries in the zones of moveable machine elements
•danger of being overrolled

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3. Description and explanation
3.1 Technical specifications
Dimensions road 693 x 1900 x 805 mm (L x W x H ab. rail)
Dimensions rail 693 x 1900 x 805 mm (L x W x H)
wheelbase 530 mm
gauge 1435mm/ 1000mm (option)
Wheel running diameter 94 mm
tare weight 27 kg
loading capacity 750 kg
Gross vehicle weight 777 kg
Max. wheel load 200 kg
Max. velocity 5 km/h, manually
Max track distortion 10 ‰
Max. inclination for parking break
without additional provisions 70 ‰ (loaded trolley)
load bed dimensions 1700 x 650 mm (L x W)

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3.2 General drawing
valid standard: EN 13977 (hand moved trolleys)
Illustration 1: General drawing

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3.2.1 Trolley in clearance profile Norwegian railway
Illustration 1: Clearance gauge JBV NO1

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3.3 Main frame
The trolley chassis and load bed is an aluminium construction in one piece:
For transport and stocking, the trolley may be stacked and fixed by lashing straps
The assembled components are able to carry the full load capacity while operating on
track.
Illustration 2: trolley components
Pos. amount(pc) description
1 1 frame/load bed
2 4 wheel
3 1 handle bar
4 2 braking cartridge
5 1 braking lever
6 1 braking armature

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All elements of the trolley are welded constructions. Excepted the handle bar and braking
components, the components are made in aluminium. All wheels are insulated by plastic
bushes to avoid electrical connection and signal failures between both rails. The braking
pads are also made of insulating material.
The trolley frame is a welding construction consisting of the load bed and U-shaped wheel
carriages. Herein are mounted the running wheels and also the braking mechanism.
Underneath the load bed, the main braking lever which operates both braking cartridges is
installed.
The load bed is build by a anti slip aluminium panel. On the underside, the panel is
additionally strengthened by 2 U-profiles.
The handle bar is made of galvanized steel. Both ends are plugged into the foreseen tubes
that there are no additional connections necessary to assemble and activate the trolley.
3.4 Rail wheels
The 4 rail wheels are made of identic design and material.
The wheel body is made of mould aluminium, flange and the running plane have a finished
surface. Inside each wheel are 2 sealed ball bearings to ensure a smooth rolling
movement and 2 insulating bushes. Optionally, the wheels may be delivered in full heat
resistant plastic body.
Illustration 3: Rail wheel
Illustration 4: rail wheel, option with
plastic body, section

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3.4.1 Wheel profile
The wheel can be changed or dissembled easily. It is possible to equip the trolley with
different wheel profiles according to the operating system. The axles are of high quality
and can be removed by loosening the axle nut. For safety, the nut is secured against
loosening. This must be replaced every time after a change/removal of a wheel.
Because of weight reasons, the wheels are made of aluminium and underlay a high wear
on running surface and wheel flange.
The rail wheel profile is ORE DIN EN 13715 S1002/h32/e32,5/6,7%
The running diameter is 94 mm.
The wear of the rail wheel has to be checked before using the trolley.
The wear of the running surface and the flange should be less than the
regulations set by the operating company.
The wheel diameter has to be larger then the check mark on the wheel
side!
If the running surface reaches the groove the wheel has to be replaced!

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Transport and setting on track
The trolley can be lifted manually. It is possible to transport them onto a trailer or inside a
van as it is possible to stow them using a minimum of space.
Don´t lift the complete trolley under load! Don´t handle the trolley by
crane or excavator!
Use capable equipment to fix the trolley components for transport on a
load bed or inside a van.
Before loading or moving the trolley on track, make sure that the braking mechanism is in
full function!
3.5 On track braking system
3.5.1 Technical specifications
Illustration 5: brake wiring and working system