ROBEL 22.38/02 User manual

Vers. 2 / Status 16.07.2007 O:\BU_M&W 050 DOKU\Gruppe_2\2238\2238_02-EN-V3.docx
Operating Instructions
Hydraulic Rail Bender
22.38 / 02
Robel Bahnbaumaschinen GmbH
Industriestraße 31,
83395 Freilassing
e-mail:
Internet:
[e-mail]
www.robel.com
Telefon/Phone/Téléfone
Telefax/Fax
[phone]
[phone]
This operating manual was issued taking into consideration
the latest technology at the time of printing.
They are subject to change do to new developments.
Weights and measurements approximate.
Some photos show special designs.

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INDEX
1TECHNICAL DETAILS ........................................................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
4TRANSPORT AND STORAGE............................................8
5OPERATION........................................................................9
5.1 Pre-Operation Checks ....................................................................... 9
5.2 Changing Hooks.............................................................................. 11
5.3 Positioning the Rail Bender ............................................................ 12
5.4 Shaping............................................................................................ 14
6MAINTENANCE.................................................................15
6.1 General ............................................................................................ 15
6.2 Cleaning and maintaining................................................................ 16
6.3 Hydraulics........................................................................................ 16

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7APPENDIX A .....................................................................17
7.1 Intended Use ....................................................................................17
7.2 Liability Exclusions..........................................................................17
7.3 Copyright..........................................................................................17
7.4 General Specifications.....................................................................18
7.5Acceptance, Fittings and Operating Licence...................................18
7.6 Safety Regulations...........................................................................19
7.7 Protecting and Using the Appliance ................................................19
7.8 Intended Audience for Operating Instructions ................................20
7.9 Accident Prevention.........................................................................20
7.10 Safety Principles ..............................................................................21
7.11 Specific Dangers ..............................................................................21
7.12 Dangers from Hydraulic Power........................................................22
7.13 Dangers from Heat ...........................................................................22
7.14 Other Dangers –Safety Equipment .................................................22
7.15 Fire Hazards .....................................................................................23
7.16 Fire Prevention.................................................................................23
APPENDIX: EC-DECLARATION OF CONFORMITY

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1 TECHNICAL DETAILS
Maximum bending force
550 KN
Weight (aluminium version)
approx. 63 kg
Weight (steel version)
approx. 84 kg
Maximum piston stroke
110 mm
Appliance’s maximum pressure
580 bar
Hydraulic oil capacity (T 15 –900 151 0049)
approx. 1.5 l
Rail hooks for standard rails such as UIC 60, S49, S56...
Rail hooks for grooved rails with contoured inserts

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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 non-compliance with the
instructions may cause the death or heavy injuries of the
operator and considerable damage to the property of the
owner.
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 workplace’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 hydraulic rail press is for shaping rails.
3.2 Components
1
Hooks
2
Piston
3
Piston guard
4
Bending unit
5
Handles
6
Stop valve
7
Pump lever
8
Lever extension handle
Fit the appropriate hooks to the appliance for each type of rail.

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6
Stop valve
7
Pump lever
8
Lever extension handle
9
Oil filler
10
Connection for manometer

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Detail of Handle & Hook
1
Hook
4
Bending unit
5
Handle with bolt
11
Fastening bolt
12
Nuts for bolts (covered)

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Hooks for grooved rails (contoured inserts not shown!)
Please note: The photograph is for guidance only
4 TRANSPORT AND STORAGE
To avoid damaging the appliance during transport and in storage, the piston should
be pushed in until it is fully retracted.
Store the rail bender in dry conditions.

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5 OPERATION
5.1 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).
•Check that there is sufficient hydraulic oil in the tank before every use:
•Position the appliance horizontally.
•Unscrew the oil level fitting (hexagon
socket screw A/F 8 mm) (1) and open
the stop valve (2).
Danger of tilting!
Make sure the device is always in a
stable position!
•Place the rail bender vertically onto a
sufficiently high support so that the
piston can be pressed down fully to its
home position (piston is retracted)
without the claws of the rail bender
touching the ground.
•Unscrew the oil level fitting (1).
•If the oil level is more than 2 cm below
the oil filler opening, replenish with
sufficient hydraulic oil until the oil level
reaches the specified 2 cm below the
oil filler opening.
•After replenishing the hydraulic oil, close the oil level fitting by turning it
clockwise.

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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!
•Schienen-Biegepresse senkrecht auf
eine ausreichend hohe Unterlage
stellen, so dass der Presskolben zur
Gänze in die Grundstellung (Kolben
ist eingefahren) gedrückt werden
kann, ohne dass die Schienen-
Biegepresse mit den Krallen den
Boden berührt.
•Open the oil level fitting (1) and the
stop valve (2) by approx. one turn.
While the piston is pressed back fully
to its home position (see Fig. on the
right), air will escape.
•Screw the oil level fitting (1) back in and shut the stop valve (2).
•If necessary, repeat this process several times.

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5.2 Changing Hooks
Please note: The photograph is for guidance only
1
Hook
4
Bending unit
5
Handle with bolt
11
Fastening bolt
12
Nuts for bolts (covered)
Damage!
•Hooks should only be replaced in matching pairs of the
same type!
•Position he rail bender horizontally.
•Unscrew nuts (12) (SW 30mm) and pull out the fastening bolt (11) and handle
with bolt (5).
The hook can now be removed from the bending unit (4) and replaced with the
hook that corresponds to the rail profile.
•Tighten bolts.
•Replace the other hook in the same way.

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5.3 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 and may prevent successful shaping or
correcting!
•The rail bender must only be positioned by hand! No rigid
surfaces which may cause tilting.
•Position the rail bender horizontally so that the piston will
push level with the side of the rail head with both hooks
placed on the surface of the rail!
Danger of damage to grooved rails!
•On grooved rails, place one pressure pad each into the
groove, depending on the bending direction either at the
claws (2x) or at the plunger (1x); see figure below!
For grooved rails: Pressure pad at claws (2x)

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For grooved rails: Pressure pad at plunger (1x)
Position on standard rails
Position on grooved rails
A is parallel with B
C
piston
D
contoured insert
When positioning the rail bender (see illustration above)
•Once the hooks have been placed on the rails, pump the piston as far as
possible until the rail is clamped in the correct position between hooks and
piston.
During pumping the piston (2) travels rapidly towards the rail.

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5.4 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.
•Close the stop valve (pos. 6, page 5) by turning clockwise.
Once the piston starts to shape the rail, the pump automatically switches pressure
level.
•This is the latest stage at which the extension handle (pos. 8, page 5) can be
used for pumping.
•To achieve permanent re-shaping the rail should be bent (carefully) slightly
further than is required.
This is because the rail returns to its original shape to some extent once
released from the rail bender.
•Repeat this process until the desired shape is achieved.
The internal safety valve opens automatically if the maximum piston stroke of 110
mm or the maximum bending force of 550 kN are exceeded or if pumping exceeds
the maximum force of 580 bar set within the pump. The hydraulic oil will flow back
into the reservoir until the level exceeded returns within permitted tolerances and in
so doing retracts the piston. This protects the appliance from damage.
Danger of trapping fingers!
•The rail bender rapidly falls back on the side of the pump
lever.
•Once shaping work is complete, open the stop valve by turning anti-clockwise
so that the oil flows back into the oil tank from around the piston.
The piston also slides back until it is almost fully retracted.
•The piston must also be pushed manually back to its normal resting position.

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6 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.
Ordering spare parts correctly can substantially speed up delivery thus making the
machine more economical.
•When ordering spare parts please supply the following:
−Machine type
−Machine number
−Component
−Spare part description and number
−Quantity
−Delivery method
−Delivery address
6.1 General
Damage of hydraulic rail bender!
•Hydraulic oil (such as Panolin HLP Synth 46) must be used
without fail whenever oil is added.
•Always keep the piston clean. Lubricate from time to time to avoid a build-up of
rust.
•To prevent damage, the pump piston (on the pump lever) must be kept clean at
all times and oiled.
•Both pistons should ideally be retracted after use to avoid a build-up of rust and
soiling.

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6.2 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.
•Never use solvents and aggressive or combustible cleaning agents!
6.3 Hydraulics
•Change oil annually.