ROBEL 22.38/02 Operating Instructions Manual Download Page 33 | Manualshive

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ROBEL 22.38/02 Operating Instructions Manual Download Page 33

22.38 / 02

液压弯轨机

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预期用途

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责任免除

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一般要求

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验收、配件及经营许可证

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安全规程

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设备防护与使用

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产品说明书的阅读对象

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事故预防

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安全原则

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具体危险

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液压动力危险

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其他危险

—安全设备

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火灾危险

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附录：欧盟声明

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Summary of Contents for 22.38/02

Page 1: ...estraße 31 83395 Freilassing e mail Internet info robel com www robel com Telefon Phone Téléfone Telefax Fax 49 0 8654 609 0 49 0 8654 609 445 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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Page 3: ...rnings 3 2 3 First Aid 3 3 APPLIANCE DESCRIPTION 5 3 1 Intended Use 5 3 2 Components 5 4 TRANSPORT AND STORAGE 8 5 OPERATION 9 5 1 Pre Operation Checks 9 5 2 Changing Hooks 11 5 3 Positioning the Rail Bender 12 5 4 Shaping 14 6 MAINTENANCE 15 6 1 General 15 6 2 Cleaning and maintaining 16 6 3 Hydraulics 16 ...

Page 4: ...e 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 ...

Page 5: ...ht 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 ...

Page 6: ...Page 2 22 38 02 HYDRAULIC RAIL BENDER This page remains empty ...

Page 7: ...e 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...

Page 8: ...Page 4 22 38 02 HYDRAULIC RAIL BENDER This page remains empty ...

Page 9: ...IPTION 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 ...

Page 10: ...Page 6 22 38 02 HYDRAULIC RAIL BENDER 6 Stop valve 7 Pump lever 8 Lever extension handle 9 Oil filler 10 Connection for manometer ...

Page 11: ...Page 7 22 38 02 HYDRAULIC RAIL BENDER Detail of Handle Hook 1 Hook 4 Bending unit 5 Handle with bolt 11 Fastening bolt 12 Nuts for bolts covered ...

Page 12: ... 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 ...

Page 13: ...crew 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 oi...

Page 14: ...enkrecht 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...

Page 15: ...or 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 ...

Page 16: ... 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 ...

Page 17: ...ed 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 ...

Page 18: ...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 reser...

Page 19: ...ore 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 ru...

Page 20: ...ly 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 ...

Page 21: ...and maintenance personnel have not read and understood these instructions and have used the appliance for other purposes Operating or maintenance personnel are not sufficiently qualified or the appliance has been used under conditions exceeding limiting values The appliance has not been serviced within the time specified These exclusions from liability for damage to people or material property do ...

Page 22: ...aining or other consultative services Further details and conditions can be obtained separately 7 5 Acceptance Fittings and Operating Licence It is the buyer s responsibility to check that the condition fittings performance and especially the safety features of the goods delivered match the relevant specifications agreed and to take account of the regulations specified in the contract The buyer mu...

Page 23: ...onally applicable regulations support and expand the manufacturer s safety and operating conditions for use of the appliance and its accessories If necessary whoever is responsible for the equipment s use must set out additional regulations and measures specific to particular use of the machine in order to ensure that all safety requirements are met In addition to these instructions we would ask y...

Page 24: ...followed for its use and safety This is especially relevant where regulations relate to safety and protection of the workplace and environment as well as the operating maintenance and safety regulations or other instructions supplied by the manufacturer or supplier 7 9 Accident Prevention The legal regulations and accident prevention measures that apply to the relevant area of operation must be ob...

Page 25: ...ediately to avoid larger ones Before leaving the appliance the following checks should be performed Appliance has been switched off correctly Tools and accessories are stored safely 7 10 Safety Principles The appliance should only be operated by trained personnel Possible sources of danger should also be indicated on the appliance by warning signs and or captions 7 11 Specific Dangers The applianc...

Page 26: ...0 minutes 7 14 Other Dangers Safety Equipment Fingers and hands may be burnt by hot parts Injuries especially to eyes may occur from hoses becoming disconnected or oil spraying from any of the hydraulic conduits Long term damage especially to hearing may occur if operators are not routinely protected from noise Scalding may occur from oils grease and other hot materials if the operator cannot unde...

Page 27: ... immediate proximity of the appliance Familiarize yourself promptly with the fire prevention regulations and the use of extinguishers To do so consult the authorized delegate for fire prevention in your workplace Only authorized fire extinguishers dry extinguishers of the appropriate fire prevention class should be used Fire extinguishers should be checked periodically and labelled with inspection...

Page 28: ...Page 24 22 38 02 HYDRAULIC RAIL BENDER This page remains empty ...

Page 29: ...Page 25 22 38 02 HYDRAULIC RAIL BENDER APPENDIX EC DECLARATION OF CONFORMITY ...

Page 30: ...8_02 EN V3 docx 产品说明书液压弯轨机 22 38 02 德国罗湃尔轨道机械有限公司 Industriestraße 31 83395 Freilassing 电子邮箱网址 info robel com www robel com Telefon 电话 Téléfone Telefax 传真 49 0 8654 609 0 49 0 8654 609 445 本使用说明书是在考虑印刷时的最新技术的基础上发布的本说明书会在工艺技术改进的基础上进行修改重量和测量值均为近似值部分照片显示的是特殊设计 ...

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Page 32: ...22 38 02 液压弯轨机目录 1 技术参数 1 2 安全 3 2 1 一般危险 3 2 2 危险警告 3 2 3 急救 3 3 设备简介 4 3 1 预期用途 5 3 2 组件 5 4 运输和储存 8 5 操作 9 5 1 调试前检查 9 5 2 更换轨钩 11 5 3 弯轨机定置 12 5 4 定型 13 6 保养维护 15 6 1 综述 15 6 2 清洗与维护 16 6 3 液压装置 16 ...

Page 33: ... 7 1 预期用途 17 7 2 责任免除 17 7 3 版权 17 7 4 一般要求 18 7 5 验收配件及经营许可证 18 7 6 安全规程 19 7 7 设备防护与使用 19 7 8 产品说明书的阅读对象 20 7 9 事故预防 20 7 10 安全原则 21 7 11 具体危险 21 7 12 液压动力危险 22 7 13 热危险 22 7 14 其他危险安全设备 22 7 15 火灾危险 23 7 16 防火 23 附录欧盟声明 ...

Page 34: ...第1页 22 38 02 液压弯轨机 1 技术参数最大弯曲力 550 KN 重量铝版大约63 kg 重量钢版大约84公斤最大活塞行程 110 mm 设备最大压力 580 bar 液压油容量 T 15 900 151 0049 大约1 5 升标准轨道用轨钩如UIC 60 S49 S56 带异形嵌件的槽形轨道用轨钩 ...

Page 35: ...第2页 22 38 02 液压弯轨机此页留空 ...

Page 36: ...A 2 2 危险警告下列所有备注和说明旨在保护操作人员的人身安全和身体健康使之免受危害并保护使用方的资产免受损害本说明书始终使用特定的命名惯例来区分不同类型的危险以及如果不遵循本说明书可能产生的后果的程度特别是危险表示不遵守本说明书可能导致操作人员死亡或重伤并对业主的财产造成相当大的损害警告表示不遵守本说明书可能导致操作人员受伤以及业主财产受到损害注意包含关于机器及其操作或关于现有部分说明的重要信息 2 3 急救任何时候都要保持急救箱的良好状态向贵方作业场所所在地的医疗服务机构或医生咨询急救措施和相应设备 ...

Page 37: ...第4页 22 38 02 液压弯轨机此页留空 ...

Page 38: ...第5页 22 38 02 液压弯轨机 3 设备简介 3 1 预期用途本液压弯轨机用于轨道整形 3 2 组件 1 轨钩 2 活塞 3 活塞护罩 4 弯曲装置 5 手柄 6 截止阀 7 泵杆 8 杠杆式加长手柄 ...

Page 39: ...第6页 22 38 02 液压弯轨机根据轨道类型安装相应的轨钩到设备上 6 截止阀 7 泵杆 8 杠杆式加长手柄 9 注油器 10 压力表接头 ...

Page 40: ...第7页 22 38 02 液压弯轨机手柄及轨钩的详图 1 轨钩 4 弯曲装置 5 带螺栓的把手 11 紧固螺栓 12 螺栓螺母隐蔽处 ...

Page 41: ...第8页 22 38 02 液压弯轨机槽形轨用钩异形嵌件未显示请注意此照片仅供参考 4 运输和储存为避免运输和储存过程中设备损坏应将活塞推入直至完全收回为止将弯轨机存放在干燥的环境中 ...

Page 42: ... 操作 5 1 调试前检查本设备交付时已注油随时可以使用使用设备之前检查是否有明显的损坏迹象裂纹轨钩有缺陷轨钩上的螺母和螺栓松动每次使用前检查油箱内是否有足够的液压油将设备水平放置拧下油位接头内六角螺钉A F8 mm 1 并打开截止阀 2 倾斜的危险确保设备始终处于一个稳定的位置将弯轨机垂直放置在一个足够高的支架上这样活塞就可以完全下压到其原位置活塞缩回而弯轨机的爪钩无需接触地面拧下油位接头 1 ...

Page 43: ... 直至油位达到注油口以下2厘米为止补充液压油后顺时针旋转油位接头以将其关闭液压系统中的空气防止活塞保持回缩将弯轨机水平放置尽可能小心地使用泵抽活塞最大110毫米倾斜的危险确保设备始终处于一个稳定的位置将弯轨机垂直放置在一个足够高的表面上这样活塞就可以完全推入到其基础位置活塞缩回而弯轨机的爪钩无需接触地面转约一圈以打开油位接头 1 和截止阀 2 活塞被完全压回原位置时见右图空气将逸出将油位接头 1 往回旋入并关闭截止阀 2 如有必要重复这个过程数次 ...

Page 44: ...第11页 22 38 02 液压弯轨机 5 2 更换轨钩请注意这张照片仅供参考 1 钩 4 弯曲装置 5 带螺栓的把手 11 紧固螺栓 12 螺栓螺母隐蔽处损坏轨钩更换时必须相同类型匹配成对将弯轨机水平放置拧下螺母 12 SW 30 mm 拉出紧固螺栓 11 和带螺栓的把手 5 轨钩现在可以从弯曲装置 4 中移除并替换为与轨道外形相对应的钩拧紧螺栓用同样的方法替换另一个钩子 ...

Page 45: ...弯轨机 5 3 弯轨机定置有受伤的危险本设备须两人操作手指会卡在泵杆的上方和下方在定置过程中弯轨机倾斜可能会损坏设备并可能影响整形或校正的顺利进行弯轨机只能手动定置不会使坚硬的表面倾斜将弯轨机水平放置使活塞与轨头侧面保持水平并将两个轨钩放置在轨道面上有损坏槽形轨的危险根据爪钩 2 x 或柱塞 1 x 的弯曲方向在槽形轨道上各放置一个压垫详见下图槽形轨道爪钩压垫 2 x 槽形轨柱塞压垫 1 x ...

Page 46: ...2 液压弯轨机标准轨道上的位置槽形轨道上的位置 A与B平行 C 活塞 D 异形嵌件定置弯轨机时见上图一旦将钩子放置在轨道上尽可能地泵抽活塞直到轨道卡在钩子和活塞之间的正确位置在泵抽过程中活塞 2 向轨道快速运动 5 4 定型泵杆区域有压伤危险小心泵抽活塞底座损坏切勿在没有目标物体比如轨道的情况下对活塞施加全部压力来定型这将迫使弯曲装置内的活塞以全部力量抵住油缸底座并可能使活塞底座断裂 ...

Page 47: ...阶段为实现持久成型应以比要求稍大的程度小心弯曲轨道这是因为一旦弯轨机离开铁路在一定程度上会恢复到其原来的形状重复这个过程直至达到想要的形状如果超过110 mm的最大活塞行程或550 kN的最大弯曲力或泵抽超过泵内设置的最大压力580 bar 则内部安全阀自动开启液压油将回流到储液器中直到超过的油位返回到允许的许公差范围内与此同时缩回活塞这样可以保护设备免受损坏手指有被卡住的危险弯轨机迅速向后倒在泵杆一侧一旦整形工作完成通逆时针旋转打开截止阀使油从活塞周围回流到油箱中活塞向后滑动直至几乎完全收回为止活塞还必须手动推回其正常静止位置 ...

Page 48: ...时始终使用原厂替换零件除遵守保证条款外这对于增加你的机器的操作安全性也很重要正确订购备件可以极大地加快交货速度使机器更加经济地恢复运行订购备件时请提供以下资料机器类型机器号组件备件说明和编号数量交货方法交货地址 6 1 综述液压弯轨机损坏每次加油时必须使用液压油如Panolin HLP Synth 46 始终保持活塞洁净经常润滑以避免积锈泵活塞在泵杆上必须时刻保持清洁有油以防损坏理想情况下两个活塞在使用后都应缩回以避免积锈和弄脏 ...

Page 49: ...第16页 22 38 02 液压弯轨机 6 2 清洗与维护定期清洗液压弯轨机以免因污物过多造成生产损失只使用湿布清洁液压弯轨机只使用水必要时使用不添加化学添加剂的温和清洁剂切勿使用溶剂和腐蚀性或可燃性的清洗剂 6 3 液压装置每年换油 ...

Page 50: ...其他用途均未获授权并可能危及操作和维修人员的生命和健康以及操作方的物质财产如果发生下列情况本设备制造商在此声明对属于使用方或第三方的人员或财产的损害不承担任何责任未按规定使用本设备操作和维护人员没有阅读和理解本说明书并已将本设备用于其他用途操作或维护人员资质不足或设备在超过限值的条件下使用设备没有在指定的时间内进行保养这些对人身伤害或物质财产损害的责任豁免并不影响其他除外责任 7 3 版权机器的特殊特性和特质均属德国罗湃尔轨道机械有限公司的知识产权罗湃尔公司拥有本说明书的版权无论是否付费本说明书不得全部或部分复制出版或以其他方式用于竞争性用途公司员工不得将其内容传递给企业以外的任何人 ...

Page 51: ...付的产品并培训员工此外还必须提供足够安全且明确的轨道和作业区段使员工可以学习如何使用交付的产品并进行实操训练德国罗湃尔轨道机械有限公司及其客户服务部门乐于提供进一步的建议培训或其他咨询服务更多细节和条件可另行获取 7 5 验收配件及经营许可证买方有责任检查所交付货物的条件配件性能特别是安全性能是否与所商定的有关规格以及合同中的规定相符买方必须为交付的货物配备一切必要的配件以满足现有操作和安全规程规范法规或其他规定及其任何变更比如安全告示等除非另有约定货物交付时不提供此等性质的配件此外买方有责任证明所交付的货物已通过鉴定供有关当局使用制造商或供应商为此需提供的任何文件说明证明认证等应在供应合同中加以规定为取得操作认证所需的任何额外措施和费用都须由买方承担 ...

Page 52: ... 请提供证明表明所有相关人员均已知悉所有有关事项法定安全措施建筑及营运规例专业和贸易组织条例工作场所及环境保护条例许可条件操作要求及任何其他适用规定支持并扩大制造商对使用本设备及其附件的安全及操作条件要求必要时负责设备使用的任何人必须针对机器的特殊用途制定额外的规定和措施以确保满足所有的安全要求除了这些说明之外我们还请您特别注意以下针对设备的安全规程并确保满足这些规程 7 7 设备防护与使用保护设备以免未经授权人员配置本设备及使用其器材和附件只有在符合安全使用所需的所有条件的情况下才能设置并使用本设备 ...

Page 53: ...书只有在考虑到相应轨道或具体操作机构的有效安全和操作规程并严格遵守其使用和安全要求的情况下尤其是与工作场所和环境的安全和保护有关的法规以及制造商或供应商提供的操作维护和安全规程或其他说明才可安装维护和操作本设备 7 9 事故预防适用于相关业务领域的法律规定和事故预防措施都必须遵守如未遵守由此引起的任何法律后果均由设备操作人员负责任何时候都要遵守一般的和特定于操作的事故预防规定熟悉与设备的特定活动区域相关的潜在危险并获得相应说明书的副本安装机器之前请检查它是否处于工作状态配件临时装置工具附件安全装置等的完整性和可靠性在适当的时间进行适当的检查和维护操作所需的作用剂燃料润滑剂等保持充满满足您和他人以及财产和环境的所有无事故使用要求关注在您的作业区内使用本设备的具体危险特别是关于人与障碍遵守安全准则在邻近的轨道上作业 ...

Page 54: ...状态的工具和设备溢出的物质油油脂等应立即清除以防止滑倒或起火危险将用于油封和清洁的材料放在手边立即修复较小缺陷以避免较大缺陷离开设备之前应进行下列检查设备已正确关闭工具和附件安全存放 7 10 安全原则受过培训的人员操作才可操作本设备可能的危险源也应在设备上标明警告标志和或说明 7 11 具体危险进行调整或维护工作之前必须关闭设备如果使用发动机驱动的液压动力机组则关闭发动机并且应固定设备以防意外或无意中再次启动还必须关闭所有能源机械或液压并加以保护以防再次启动 ...

Page 55: ...仍然处于锁定状态则应检查管道中的压力可通过以下方法避免来自液压动力的危险关闭发动机开启回流阀以此中和手动泵使用时的液压压力 7 13 热危险处理热部件之前设备必须冷却至少30分钟 7 14 其他危险安全设备手指和手可能被发热部件灼伤软管断开或液压管喷油可能会造成人身伤害特别是对眼睛如果操作人员不经常佩戴噪音防护装置就可能造成长期损害特别是对听力如果操作人员不能理解和遵守包装上的说明和规定油油脂和其他发热材料可能会引起烫伤事故发生操作人员有义务确保所提供的安全装置在其指定的作业地点得到切实使用或固定在规定的地方操作人员必须穿着合身的衣服没有宽大的袖子以及其他易被设备夹住的其他零件负责维护工作的人员在进行维护工作后应重新配装安全装置基本培训包括参加制造商的培训课程此为基本要求使用该设备的操作人员必须已经阅读并理解了上述说明 ...

Page 56: ...够随时查阅本说明书特别是操作人员必须按照本说明书对设备进行维护以保证设备的安全 7 15 火灾危险液压油燃烧时可能产生有毒物质或致癌物质一般来说所有火都必须用干粉灭火器扑灭 7 16 防火设备及其附近区域不得有明火或易燃材料及时熟悉防火法规和灭火器的用法为此请咨询授权代表以防您的工作场所发生火灾只使用达到适当防火级别的经认可的灭火器干粉灭火器灭火器应定期检查并贴上检查告示标签检查到期日灭火器一旦使用后即应立即更换 ...

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