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Unipart Dorman HD ALT, Operation And Maintenance Manual

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Unipart Dorman HD ALT Operation And Maintenance Manual Download Page 33

 

Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual

 

Form Reference   

C64.65546

 

 

Issue 

5.00 

32 of 39 

Issue Date 

May 2021 

 

 

Cat Number 

Part Number 

Description 

086/009514            

D04.03540     

iLS JRI Visor Fitting Kit Position 1  

(Mk1 Indicators only) 

086/009515            

D04.03541     

iLS JRI Visor Fitting Kit Position 4  

(Mk1 Indicators only) 

086/009516            

D04.03542     

iLS JRI Visor Array Fitting Kit Position 1 

086/009517            

D04.03543     

iLS JRI Visor Fitting Kit Position 2 

086/009518            

D04.03544     

ILS JRI Visor Fitting Kit Position 4 

086/009519            

D04.03545     

iLS JRI Visor Fitting Kit Position 5 

 

 

Position Light Signal 

 

 

 

     

 

 

 

 

Cat Number 

Part Number 

Description 

086/009531           

D04.03546     

iLS PLS Visor Fitting Kit  

 

 

 

 

 

Summary of Contents for HD ALT

Page 1: ...Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual C64 65546 Issue 5 May 2021...

Page 2: ...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 Alignm...

Page 3: ...nce 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 Scot...

Page 4: ...REVENT 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 REM...

Page 5: ...assic 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 Off...

Page 6: ...on Operation and Maintenance Manual Form Reference C64 65546 Issue 5 00 5 of 39 Issue Date May 2021 Product Labelling The following labels are applied to each HD ALT The RBK 211 padlock is not shown i...

Page 7: ...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 m...

Page 8: ...ciated 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 i...

Page 9: ...Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64 65546 Issue 5 00 8 of 39 Issue Date May 2021 Dimensions...

Page 10: ...Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64 65546 Issue 5 00 9 of 39 Issue Date May 2021...

Page 11: ...se of transport and installation Once the signal head and post are inserted and the HD ALT is in its vertical position the two sub assemblies are secured together using 8 x M24 bolts and this action f...

Page 12: ...final sign off by the customer Manufacturing begins when the signed drawing is received by Unipart Dorman The HD ALT spring system is designed to provide mechanical advantage to personnel engaged in m...

Page 13: ...LEASED The HD ALT is supplied on a large pallet as shown below and may be stored in the open air The fasteners used to secure the unit to the pallet shall not be used as mounting hardware during insta...

Page 14: ...scope the only tools required to install a HD ALT onto a pre prepared foundation are simple hand tools such as Torque Wrenches 30mm and 36mm Sockets Spanners A RBK 221 key to remove the locking pin p...

Page 15: ...to the swept area of the signal being raised lowered plus a reasonable margin either side to allow adequate footing for personnel engaged in the lift should be established This zone should be firm and...

Page 16: ...nstalled immediately it is recommended the connection box is re secured with a cable tie or padlock Mounting nuts and the cup and cone washers shall then be fitted strictly in the sequence shown below...

Page 17: ...s locked in place by the R pin and an RBK 221 padlock Unlike the standard ALT and Winch Trunnion Enclosure Base it is not possible to carry out the alignment of the signal without the head and post in...

Page 18: ...eplate parallel with the direction of the running rail Then fit the remaining washers and nuts to secure it onto the studs Raising Lowering the HD ALT The HD ALT is normally delivered to site in the h...

Page 19: ...nto a vertical HD ALT or to lift a pre assembled post and HD ALT onto a foundation using strops etc around the signal head may result in undetectable damage to the GRP post head assembly The bore of t...

Page 20: ...hat the post cannot rotate in the HD ALT bore and that the painted witness mark indicated below on the post is level with the top of the HD ALT Do not fully tighten the locking collar until the signal...

Page 21: ...e upright position using correct manual lifting technique augmented by the spring system IT IS VITAL THAT CONTROL OF THE MOVABLE SECTION AND HEAD POST IS RETAINED AT ALL TIMES BY THE PERSONNEL CARRYIN...

Page 22: ...e keyway and lug inside the connector shells then turn the locking collar by hand until an audible click is detected and the two indicator spots are aligned The spots may be of different colours this...

Page 23: ...lock The HD ALT should be bonded to earth if required by the use of bonding straps No specific earth bonding arrangements to the signalling elements are required by virtue of the double insulated desi...

Page 24: ...a lint free cloth moistened with the water detergent solution carefully wipe the lens clean before using a dry second cloth to remove any water spotting etc and give a final buffing When the scope is...

Page 25: ...lways be consulted prior to commencement of work The signal should not be aligned to a target board when the sighting scope is fitted onto the Trunnion The illustration below shows a representation of...

Page 26: ...5 00 25 of 39 Issue Date May 2021 Using the alignment scope to provide visual cues the signal is adjusted horizontally by rotating the base within the kidney slots and vertically by adjusting the angl...

Page 27: ...nt scope is removed and stored in its protective case The arbitrary method of sighting to the AWS magnet shall not be used unless specifically authorised by the Signal Sighting Chair and correctly rec...

Page 28: ...it will be secured onto the cable clamp bar Prior to lowering the signal ensure that you have the correct replacement module especially with Medium Range signals a check to confirm whether it is a wi...

Page 29: ...46 Issue 5 00 28 of 39 Issue Date May 2021 Withdraw the module sufficiently to access the inside of the signal head If the signal is a four aspect variant disconnect the plug coupler which connects th...

Page 30: ...ble if the signal has a second module or fit the blanking cover if not and refit the cable clamp s Carefully stow any excess cable inside the post head and secure the new module in place using the soc...

Page 31: ...in the head or in the connection box depending on the module type and remove As the signal alignment has not been disturbed there is no need to carry out a signal sighting exercise Additional Visors U...

Page 32: ...er Part Number Description 086 007488 B20 19436 CLS 600mm Extended Visor 086 007485 B20 19433 CLS 600mm Extended Visor 135 LH Obscuration 086 007486 B20 19434 CLS 600mm Extended Visor 135 RH Obscurati...

Page 33: ...icators only 086 009515 D04 03541 iLS JRI Visor Fitting Kit Position 4 Mk1 Indicators only 086 009516 D04 03542 iLS JRI Visor Array Fitting Kit Position 1 086 009517 D04 03543 iLS JRI Visor Fitting Ki...

Page 34: ...at particular signal Cat Number Part Number Description 086 009532 D04 03554 iLS JI Pos 1 or 4 Tapered Insert 1 5 Mk1 086 009533 D04 03555 iLS JI Pos 1 or 4 Tapered Insert 1 5 Mk 2 086 009534 D04 0355...

Page 35: ...and iLS CLS LITE signals are designed to be maintenance free However Network Rail may mandate some maintenance activity and this will be promulgated through the normal channels There is no provision t...

Page 36: ...mblies are recyclable and end users should consult local and national regulations prior to disposal Please contact Unipart Dorman for full details of the procedure to be undertaken when a signal is pe...

Page 37: ...has been used The dataset uses the lowest height 1 82m of the standard height range of a person 5th percentile women to 95th percentile men The distance from the ground to the lower part of the tube w...

Page 38: ...Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual Form Reference C64 65546 Issue 5 00 37 of 39 Issue Date May 2021...

Page 39: ...Maintenance Manual Form Reference C64 65546 Issue 5 00 38 of 39 Issue Date May 2021 Contact Us Unipart Dorman Wennington Road Southport Merseyside United kingdom PR9 7TN T 44 0 1704 518000 E dorman e...

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