ROBEL 22.28/01 User manual

Vers.2 / Stand 26.10.2009 O:\BU_M&W 050 DOKU\Gruppe_2\2228\2228_01-E-V2_nform.doc
Operating Manual
Switch Blade Lining Device
22.28 / 01
Robel Bahnbaumaschinen GmbH
Industriestraße 31,
Postfach 3222,
83398 Freilassing
83395 Freilassing
e-mail:
Internet:
[email protected]
www.robel.info
Telefon/Phone/Téléfone
Telefax/Fax
(08654) 609-0
[phone]
This operating manual was issued taking into consideration
the latest technology at the time of printing.
They are sbject to change do to new developments.
Weights and measurements approximate.
Some photos show special designs.

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Contents
1TECHNICAL DATA..............................................................1
2SAFETY...............................................................................3
2.1 General Dangers ....................................................................................3
2.2 Danger Warnings ...................................................................................3
2.3 First Aid ..................................................................................................3
3APPLIANCE DESCRIPTION ...............................................5
3.1 Intended Use ..........................................................................................5
3.2 Components...........................................................................................5
4OPERATION......................................................................11
4.1 Pre-Operation Checks .........................................................................11
4.2 Preparing for Alignment......................................................................12
4.3 Aligning ................................................................................................13
5MAINTENANCE.................................................................17
5.1 Cleaning and maintaining ...................................................................17
5.2 General .................................................................................................18
5.3 Hydraulics ............................................................................................18

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6APPENDIX A .....................................................................19
6.1 Intended Use ........................................................................................19
6.2 Liability Exclusions .............................................................................19
6.3 Copyright ..............................................................................................19
6.4 General Specifications ........................................................................20
6.5 Acceptance, Fittings and Operating Licence ....................................20
6.6 Safety Regulations...............................................................................21
6.7 Protecting and Using the Appliance...................................................21
6.8 Intended Audience for Operating Instructions..................................22
6.9 Accident Prevention ............................................................................23
6.10 Safety Principles ..................................................................................24
6.11 Specific Dangers..................................................................................24
6.12 Dangers from Hydraulic Power...........................................................24
6.13 Dangers from Heat...............................................................................24
6.14 Other Dangers –Safety Equipment....................................................25
6.15 Fire Hazards .........................................................................................25
6.16 Fire Prevention.....................................................................................26
APPENDIX: EC-DECLARATION OF CONFORMITY

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1 TECHNICAL DATA
Stroke.
max 150 mm
Pushing force
max. 250 KN
Hydraulic system pressure
max. 700 bar
Hydraulic oil Panolin HLP 46 Synth.
1.3 litre
Hand pump
two-stage
Cylinder
single-acting
Dimensions in mm
Length
Width
Height
Weight in
kg
Appliance with hand pump
- basic configuration
930
125
500
60
Strut, long
990
90
55
9.3
Strut, short
730
90
115
7.5
Wedge, long
210
90
120
4.8
Wedge, short
160
65
200
1.9
Accessories:
2 clamps for S49/S54 profile
155
110
90
7.0
2 clamps for UIC 60 profile
180
110
90
7.4
2 clamps for R65 profile
190
110
90
7.4

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2 SAFETY
2.1 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.
2.2 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. These instructions use specific naming conventions
throughout to differentiate between different types of danger and the degree of
consequences that might arise if instructions are not followed. In particular they are:
DANGER indicates that not following the instructions could
lead to death or serious injury to the operator and to
substantial damage to the operator’s assets.
CAUTION indicates that non-compliance with the
instructions may cause injuries of the operator and damage
to the property of the owner.
NOTE contains important information about the machine, its
operation or about a section of the manual on hand.
2.3 First Aid
Aim to keep the First Aid kit in good order at all times.
Your work place’s medical service or doctor should therefore be consulted about
First Aid measures and equipment.

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3 APPLIANCE DESCRIPTION
3.1 Intended Use
The aligning device is for re-shaping deformed switch blades including flexible
switch blades.
3.2 Components
The shaping arm consists of a yoke-shaped hollow box with a hydraulic hand pump
mounted on top which supplies the cylinder screwed on to the bending arm.
External hydraulic equipment can also be attached using the hose’s quick-change
connection.
A double wheel flange is incorporated under the shaping arm and, on the opposite
side, there is a built-in extension tube. By attaching the long strut to this tube, the
device can easily be pushed on to the rail.
The appliance also has two struts (short and long) and two wedges (short and long)
together with appropriate clamps.
Fit the relevant clamp to the appliance for each rail type.

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1
Shaping arm
2
Clamps
3
Hydraulic cylinder
4
Quick-change connection
5
Handle
6
Pump handle
7
Hydraulic oil tank vent / filler
8
Extension tube for strut
9
Safety bolt

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Safety bolt closed
Safety bolt open
6
Pump handle
9
Safety bolt
10
Pump valve
The switch blade aligning appliance should NOT be carried
by the pump handle!

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3.2.1 Detail of Quick-Change Connection
4
Quick-change connection (screw fastening)
11
Safety cap
3.2.2 Transporting to Rails
12
Strut
13
Safety bolt

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3.2.3 Struts
13
Safety bolt
14
Shorter strut
15
Longer strut
3.2.4 Wedge Configuration
16
Short wedge
17
Long wedge
Bending point is indicated by a white cross!

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3.2.5 Detail of Clamps
For UIC 60
For S54 / S49

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4 OPERATION
The aligning device is used to re-shape deformed switch blades including flexible
switch blades.
It is placed on the heads of stock rails and switch blades. Switch blades should only
be shaped when cold and with points not locked.
•During aligning do not touch the switch blade –keep your
distance
4.1 Pre-Operation Checks
•Before using the appliance check it for visible signs of damage (cracks,
hydraulic hose, defective clamps, quick-change connection screw loose.)
•Check that there is sufficient hydraulic oil in the tank.
•Fill with hydraulic oil if the level in the tank is less than half:
To do this, unscrew the cap (for
venting and filling the hydraulic oil
tank) in an anti-clockwise
direction;
After filling with hydraulic oil,
screw shut in a clockwise direction
and, to vent, twist clockwise a
further ½ turn.
The hydraulic cylinder should be
vented with the pump valve turned
in an anti-clockwise direction.
•The clamps should be separated far enough from each other so that there is
enough space for the switch blade between the clamps.

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4.1.1 Changing the Clamps
•Flip the safety ring to the right and pull the retaining pin out of the bolt (19) with
the safety ring (18) to the right.
•Place an alternative clamp on to the bolt so that markings point towards the
shaping arm.
4.2 Preparing for Alignment
•Inspect the deformed switch blade and mark the defective area with chalk.
•Establish whether the deformation has increased the curve (reduced the
radius) or decreased the curve (increased the radius).
The first is the most usual occurrence.
However, a combination of both may also occur.

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4.3 Aligning
Danger!
•It is essential that points are carefully and correctly re-
locked on completion of any alignment work
4.3.1 Case I: Increasing the Radius
Where the switch blade deformation reduces the radius.
•Switch blades should only be shaped when points are not
locked
X
Wedge
Y
Strut

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•Place the aligning device in the space between sleepers at a distance of
between 1 and 1.5 metres from the site of the fault (in the direction of the fault).
−Completely retract the hydraulic cylinder.
−Turn the pump valve (10) on the hydraulic pump to shut.
Smaller gaps: The aligning device does not have sufficient force.
Larger gaps: The switch blade deformation is springy and the tip of the blade
is already touching the stock rail.
•Introduce a wedge at the damaged spot. This should completely fill the gap
between switch blade and stock rail or the aligning device’s stroke cannot be
used fully.
•Place the strut approximately half way between the fault and the first spot
where the blade is to be clamped, at as close as possible to a right angle to the
switch blade (see illustration).
•Using the hydraulic pump, extend the cylinder and bend the switch blade
against the fault.
•Having identified the best spot, place the switch blade under bending tension
for at least 60 seconds.
•Opening the pump valve (10) on the hydraulic pump releases the switch blade.
•After removing the aligning device, check the resulting appearance.
•If the fault has been corrected, operations can be terminated by re-locking the
points.
•If the resulting reshaping is insufficient, repeat the whole process.
•If the reshaping has gone too far and the switch blade has too great a radius at
the deformation point, follow instructions for Case 2.

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4.3.2 Case 2: Decreasing the Radius
Where the switch blade deformation increases the radius.
•Switch blades should only be shaped when points are not
locked
X
Wedges
▪Completely retract the hydraulic cylinder.
▪Turn the pump valve (10) on the hydraulic pump to shut.
•Insert 2 wedges at a distance of between 1 and 1.5 m from the site of the fault.
•Bend the switch blade (as described in more detail in Case 1).
Smaller gaps: The aligning device does not have sufficient force.
Larger gaps: The switch blade deformation is springy and the tip of the blade
is already touching the stock rail.
•Introduce wedges to both left and right of the damaged spot. This should
completely fill the gap between switch blade and stock rail or the aligning
device’s stroke cannot be used fully.
•Using the hydraulic pump, extend the cylinder and bend the switch blade
against the fault. Having identified the best spot, place the switch blade under
bending tension for at least 60 seconds.
•Opening the pump valve (10) on the hydraulic pump releases the switch blade.

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