Unipart Dorman HD ALT User manual

Heavy Duty Assisted Lift Trunnion
Operation and Maintenance Manual
C64.65546
Issue 5
May 2021

Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64.65546
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Table of Contents
Document Control ....................................................................................................................... 2
Introduction ................................................................................................................................ 4
Product Labelling ........................................................................................................................ 5
Safety .......................................................................................................................................... 6
Dimensions .................................................................................................................................. 8
Description ................................................................................................................................ 10
Signal Configuration and Lifting Data ...................................................................................... 10
Storage and Movement ............................................................................................................. 12
Tooling ....................................................................................................................................... 13
Torque Loadings ........................................................................................................................ 13
Foundation and Site Checks ..................................................................................................... 14
Pre Installation Checks ............................................................................................................. 15
Installation ................................................................................................................................ 16
Raising &Lowering the HD ALT ................................................................................................ 17
Inserting the Post and Erecting the Signal .............................................................................. 18
Electrical Connection ................................................................................................................ 21
Signal Alignment ....................................................................................................................... 22
Post Installation Checks ........................................................................................................... 27
Module Replacement (CLS Module) ......................................................................................... 27
Module Replacement (Other Signal Modules) ......................................................................... 29
Additional Visors ....................................................................................................................... 30
Wedge Inserts ........................................................................................................................... 33
Blanking Plates ......................................................................................................................... 33
Maintenance Activity ................................................................................................................ 34
Signal Husbandry ...................................................................................................................... 34
Service and Repair .................................................................................................................... 35
End of Life Disposal ................................................................................................................... 35
Product Support ........................................................................................................................ 35
Appendix A - HD ALT/Signal Lifting Force Data ...................................................................... 35

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Document Control
It is the reader’s responsibility to ensure they have the correct version of this document. If in
doubt, please contact Unipart Dorman to verify the current issue status.
Issue Number
Dated
Reason
1
Jul 19
 Initial Issue
2 Sep 19  References to RBK-221 padlock added
3 Nov 19  Images and layout updated following feedback
from Network Rail PA review.
4 Jan 20  Wording changes following Network Rail Product
Acceptance and Ergonomics Review
5 May 21
 Additional Safety Warnings
 Addition of extra information on signal alignment
methods
 New section on Module Replacement
Name
Role
Digital Signature
Author Graham Scott Technical Sales Manager
Checked by Mike Durham Design and Development
Engineer
Approved by John Lee Head of Design and
Development
Graham
Scott
Digitally signed by Graham Scott
DN: dc=local, dc=unipartrail,
ou=Southport, ou=Departments,
ou=Technical Sales, cn=Graham Scott,
[email protected]
Date: 2021.06.03 15:00:21 +01'00'
Digitally signed
by: Mike Durham
Date: 2021.06.03
15:18:33 Z
Mike
Durham
Digitally signed by: John Lee
DN: CN = John Lee email =
[email protected] OU
= Southport, Departments,
Technical
Date: 2021.06.03 15:27:21 Z
John Lee

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Safety Warning
THE UNIPART DORMAN HEAVY DUTY ASSISTED LIFT TRUNNION (HD
ALT) UTILISES TWO SPRING ASSEMBLIES TO PROVIDE ASISTANCE
WHEN RAISING AND LOWERING THE SIGNAL BY HAND
WHEN THE HD ALT IS IN THE HORIZONTAL POSITION KINETIC ENERGY
IS STORED IN THE SPRINGS AND TO PREVENT RAPID DEPLOYMENT OF
THIS, A SUITABLE HEAD AND POST SHALL BE FITTED TO PROVIDE A
BALANCING LOAD TO COUNTER THE SPRING FORCE BEFORE ANY
ATTEMPT TO RAISE THE UNIT INTO ITS VERTICAL STATE
DO NOT REMOVE THE PADLOCK/SAFETY PINS UNTIL
THE HEAD AND POST ARE FITTED AND SUFFICIENT
STAFF ARE AVAILABLE TO CONTROL THE SIGNAL AS IT
RISES TO THE VERTICAL POSITION
THERE ARE NO USER MAINTAINABLE PARTS ON THE HD ALT
ANY ATTEMPT TO DISASSEMBLE THE SPRING UNITS OR FULCRUM ARMS
COULD RESULT IN CATASTROPHIC RELEASE OF THE STORED SPRING
ENERGY WHICH WILL PRESENT CONSIDERABLE RISK OF INJURY OR
ENDANGER LIFE

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Introduction
The Unipart Dorman Heavy Duty Assisted Lift Trunnion (HD ALT) uses twin reactive springs
controlled by a fulcrum system that allows the force required to move the signal post from the
horizontal to vertical to be equalised across the full range of movement. This means that it can
be raised and lowered by hand without any additional mechanical handling equipment.
HD ALT is designed to interface with only Unipart Dorman Lightweight and CLS LITE Signals as
shown in the product configuration drawing C64.65378. Additionally, the HD ALT can be used
to mount a variety of Classic Signals & Indicators and level crossing Road Traffic Lights
(Wigwags) using the brackets detailed in the Network Rail Product Acceptance Certificate
PA05/06503.
A separate document will cover the Offset post when used in HD ALT
The complete signal can be quickly installed onto a standard foundation or screw pile system
set with 4 x M24 studs at 380mm centres as shown in Network Rail Drawing BRS-C-45. These
studs should have a MINIMUM of 200mm threaded section available above the top face of the
foundation.
Although the HD ALT was developed from and shares many similarities with the Standard ALT,
they are entirely separate products with distinctive operation and safety properties. Any
acquired knowledge of the Standard ALT shall not be used as a cross reference to the HD ALT.
Separate O&M Manuals and Product Awareness Sessions are available for both Trunnions and
these are available from Unipart Dorman.

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Product Labelling
The following labels are applied to each HD ALT
The RBK-211 padlock is not shown in this illustration for clarity

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Safety
Activities, which may pose a hazard, will have the following highlighters:
Activities identified as needing extra care are highlighted using the Caution Symbol
ACTIVITIES WHICH ARE OR HAVE THE POTENTIAL TO BE HAZARDOUS TO
PERSONNEL AND/OR EQUIPMENT ARE HIGHLIGHTED WITH THE WARNING SYMBOL
BEFORE THE COMMENCEMENT OF ANY ACTIVITY, ARRANGEMENTS SHALL BE
APPLIED TO PROTECT THE WORKING RAILWAY.
It is the user’s responsibility to ensure all necessary risk assessments, permissions to work and
preparatory safety activities are correctly completed and adhered to throughout the installation
and subsequent life of the signal.
The Unipart Dorman HD ALT has been designed in accordance with the principles and methods
detailed in the Network Rail Design for Reliability Process and has been subjected to extensive
testing throughout its development to meet these requirements and subsequently obtain Network
Rail Product Acceptance.
This Operation and Maintenance document is designed to illustrate safe methods of work and
highlight potential dangers to workers. It is a generic guide only and the content is not to be used
to substitute or justify the omission of good engineering practices.
FAILURE TO ADHERE TO THE INSTRUCTIONS AND WARNINGS CONTAINED IN
THIS PUBLICATION COULD CAUSE SERIOUS INJURY, ENDANGER LIFE AND/OR
CAUSE CATASTROPHIC DAMAGE TO THE EQUIPMENT AND SURROUNDING
INFRASTRUCTURE.
The weight of the HD ALT (165Kg) is clearly marked and installers should ensure that they have
sufficient measures in place to ensure a safe lift. The marked weight is for the HD ALT only and
does not include any pallet or packaging weight.

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To enable simple transport and installation the HD ALT is delivered from the factory locked in the
horizontal position using the lockdown safety pin secured with a standard RBK-221 Padlock.
DO NOT ATTEMPT TO REMOVE THE PADLOCK AND SAFETY PIN UNLESS A
SUITABLE HEAD/POST IS FITTED CORRECTLY INTO THE HD ALT
REMOVING THESE HOLD DOWN DEVICES WITHOUT THIS LOAD MAY CAUSE SERIOUS
INJURY AND ENDANGER LIFE DUE TO THE STORED ENERGY IN THE SPRING SYSTEM
BEING RAPIDLY RELEASED
The HD ALT shall not be used for any purpose other than that described in the introduction above.
If it is used for any other purpose, Unipart Dorman will not accept any responsibility for damage,
injury or death caused by the activity.
THERE ARE NO USER SERVICEABLE PARTS IN THE HD ALT AND ANY ATTEMPT
TO DISASSEMBLE THE SPRING UNITS MAY ENDANGER LIFE AND WILL VOID ANY
WARRANTY
All activity on the HD ALT and any associated head/post, both mechanical and electrical, must
only be carried out by staff deemed competent in these fields by their employer. It is the user’s
sole responsibility to ensure that the apparatus is installed and/or maintained by competent staff
in accordance with the latest policies published by Network Rail such as Noticeboards etc. Where
a specific competency is subject to periodic retest and certification, it should be valid throughout
the time of the works.
A copy of these instructions shall be readily available. Anyone required to operate the HD ALT is
to be fully conversant with them and deemed sufficiently competent (and where necessary,
properly certified) to undertake the task by their supervisory chain.
The latest version of this document is available from Unipart Dorman using the contact details
on the back page or by visiting the Unipart Dorman website.
Operating Safely
IF ANY DOUBT EXISTS ON THE SERVICEABILITY OF THE HD ALT, YOU ARE NOT SURE
ABOUT ANY OF THE INSTRUCTIONS IN THIS DOCUMENT OR YOU ARE UNSURE OF
THE CORRECT WAY TO USE THE HD ALT, YOU SHOULD STOP WORK AND CONTACT
YOUR SUPERVISOR IMMEDIATELY AND IF NECESSARY, UNIPART DORMAN FOR
SPECIALIST ADVICE USING THE DETAILS ON THE BACK PAGE

Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64.65546
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Dimensions

Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64.65546
Issue 5.00
9 of 39 Issue Date May 2021