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Heavy Duty Assisted Lift Trunnion Operation and Maintenance Manual

Form Reference

C64.65546

Issue

5.00

31 of 39

Issue Date

May 2021

Colour Light Signal

Cat Number

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

Obscuration

Junction Route Indicator Arms

The JRI Visor Kit is available in Mark 1 or 2 variants and this is determined as shown in the Module
replacement section above

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Содержание HD ALT

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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