TD15-01 Threader Dragger

Transcription

1 Thomson Engineering Design Ltd TD15-01 Threader Dragger Operators Instructions, Maintenance Instructions & Parts Book Original Document in English Language Issue 1 May 2016 Copyright: Thomson Engineering Design Ltd all rights reserved

2 Introduction The Thomson Engineering Design TD15-01 Threader Dragger is designed for the handling and installa on of running and conductor rails. The device can either be hydraulically clamped to a long rail sec on so that the rail can be dragged into posi on longitudinally or fixed to the rail by rollers which allows the unit to be used to thread rail into posi on laterally. Two independently controlled hydraulic services are required to operate the TD15-01 Threader Dragger: one to operate the rail clamp and the other to deploy and release the rail threading rollers. This manual describes the safe use and maintenance of the TD15-01 Threader Dragger and includes spare parts lists. Warning The Thomson Engineering Design TD15-01 Threader Dragger must not be used for any purpose or in any way not described within this document. Using this device for any purpose not described in this document may be dangerous and may invalidate the manufacturer s warranty. EXCEPT TO ASSIST WITH ATTACHING OR DETACHING THE DEVICE NEVER ALLOW PERSONNEL WITHIN THE WORKING AREA OF THE MACHINE AND LOAD. Warning The maximum hydraulic pressure which may be applied to the circuits of the Manipulator must not be exceeded. Exceeding the stated pressures may damage or reduce the life of the hydraulic components. It is extremely dangerous to over pressurise a hydraulic system and doing so can lead to severe injury. The hydraulic services on the host machine must be adjusted to ensure that the maximum pressure ra ng of the TD15-01 Threader Dragger is not exceeded. 2 Copyright: Thomson Engineering Design Ltd all rights reserved Thomson Engineering Design TD15-01 Threader Draggers are proudly designed and made in the United Kingdom.

3 Contents Introduc on 2 Specifica ons 3 Issue Record 3 Descrip on of the TD15-01 Threader Dragger 4 A aching & Connec ng the TD15-01 Threader Dragger 5 Using the TD15-01 Threader Dragger 6 Detaching & Transpor ng the TD15-01 Threader Dragger 10 Maintenance Plan 11 Warnings 37 Contac ng the Manufacturer 38 Cer ficate of Conformity 39 Spare Parts Lists 40 Specifications (typical) Overall Transport Dimensions 1214mm (L) x 984mm (W) x 1400mm (H) Overall Weight 725kg Transport Weight (inc s llage) 890kg Minimum Hydraulic Pressure 110 Bar Maximum Hydraulic Pressure (dragger circuit) 250 Bar Maximum Hydraulic Pressure (threader circuit) 210 Bar Maximum Working Load (li ) 2,500 kg Maximum Tow Load 10,000 kg Issue Record Issue 1 May 2016 Copyright: Thomson Engineering Design Ltd all rights reserved 3

4 Description of the TD15-01 Threader Dragger The main parts of a Thomson Engineering Design TD15-01 Threader Dragger are illustrated below. The TD15-01 Threader Dragger is suspended from the host machine by the shackle and connected to the host machine s hydraulic system via the supply hose connec ons. Two hydraulic services are required: one to open and close the Dragger jaws and one to deploy and retract the Threader rollers. The TD15-01 Threader Dragger is designed for handling both UIC60 and BS113A running rails and for conductor rail. Attachment Yoke Shackle Handle for Alignment Rail Head Roller Threader Roller 4 Copyright: Thomson Engineering Design Ltd all rights reserved

5 Attaching & Connecting the TD15-01 Threader Dragger A aching the TD15-01 Threader Dragger to the Host Machine Connect the TD15-01 Threader Dragger to the host machine by suspending the shackle in the centre of the a achment yoke from a hook or suitable li ing point on the host machine. The host machine must have sufficient li ing and pulling capacity for the work to be undertaken and its li ing capacity must include allowance for the weight of the TD15 Threader Dragger itself. Connect the TD15-01 Threader Dragger Hydraulic System to the Host Machine Stop the engine of the host machine and de-pressurise the hydraulic system. The TD15-01 Threader Dragger is equipped with four supply hoses: two of these supply the Dragger grab cylinder and the other two supply the cylinders which retract and deploy the Threader rollers. Connect the hoses of the TD15-01 Threader Dragger to the auxiliary hydraulic connec ons of the host machine. TD15-01 Threader Dragger suspended from host machine Note: changes of temperature can mean that the closed system of the TD15-01 Threader Dragger can become pressurised whilst it is being stored. Beware of the risk from release of hydraulic fluid under pressure which can cause very serious injury. Once the hydraulic connec ons are secure, re-start the host machine, li the TD15-01 Threader Dragger clear of the ground and operate the hydraulic control to check all the hydraulic func ons, this ensures that any trapped air is discharged from the cylinders and pipes of the TD15-01 Threader Dragger before use. Check that the hoses do not catch or rub on any part of the machinery. Dragger Connections Check the complete hydraulic system for signs of leakage. Stop the host machine and correct any leaks found before using the TD15-01 Threader Dragger. Note: hydraulic quick release couplings should be of a type which prevents fluid discharge to the environment on connec on and release. Respect the Environment Threader Connections Hydraulic fluids, even biodegradable fluids, can cause serious damage to the natural environment par cularly if discharged into a watercourse. Respect the environment and handle hydraulic fluids carefully. Contain and remove any fluid spills immediately. Copyright: Thomson Engineering Design Ltd all rights reserved 5

6 Using the TD15-01 Threader Dragger The TD15-01 Threader Dragger is completely controlled from the cab of the host machine using the auxiliary hydraulic controls to handle long rail sec ons. When gripped using the Dragger jaws the rail is firmly anchored to the Threader Dragger and may be pulled longitudinally. When held by the Threader rollers the Threader Dragger is free to run along the length of the rail and can now be used as a Threader (thimble) to move the rail laterally. Warning This device requires skill and practice. Don t try to operate the Threader Dragger quickly until you are confident of all the controls. BE SURE THAT YOU ARE COMPLETELY FAMILIAR WITH THE CONTROLS AND THEIR FUNCTIONS BEFORE USING THE TD15-01 THREADER DRAGGER TO MOVE RAIL SECTIONS. The normal sequence of opera on is: 1) Open the Dragger jaws and the Threader rollers and lower the Threader Dragger onto the rail so that the rail head rollers lie on the head of the rail. 2) Close the Dragger jaws to grip the rail. 3) Li the rail clear of the ground. The rail can now be dragged using the host machine to pull on the yoke. 6 Copyright: Thomson Engineering Design Ltd all rights reserved

7 4) To thread the rail first deploy the Threader rollers: Once the Threader rollers are closed on the rail foot release the Dragger jaws and the rail can now be threaded into posi on. 5) To release the rail first close the Dragger jaws then open the Threader rollers. The rail can now be lowered to the ground and released. Copyright: Thomson Engineering Design Ltd all rights reserved 7

8 Threading rail with the TD15-01 Threader Dragger The TD15-01 Threader Dragger remains suspended by the shackle in the centre of the li ing yoke for all opera ons. When threading rail the Threader Dragger will hang from the host machine li ing point as shown in the illustra on above. When dragging rail over short distances the yoke automa cally lts over as shown in the illustra on at the top of page 9. When the rail must be moved a long way it is some mes be er to tow the rail from the machine s towing point using the tow chains supplied with the Threader Dragger. The illustra on at the bo om of page 9 shows how the auxiliary chains are fi ed for a long distance dragging opera on. Note that the Threader Dragger is s ll suspended from the host machine boom allowing the operator to li the end of the rail whilst dragging it. 8 Copyright: Thomson Engineering Design Ltd all rights reserved

9 Dragging rail using the machine boom. Dragging rail using the auxiliary chains Copyright: Thomson Engineering Design Ltd all rights reserved 9

10 Detaching and Transporting the TD15-01 Threader Dragger The TD15-01 Threader Dragger is supplied with a purpose-designed s llage for transport. Open both the Dragger jaws and the Threader rollers and lower the TD15-01 Threader Dragger into the s llage. When the Threader Dragger is firmly seated in the s llage fit the locking pins (4 total). The TD15-01 Threader Dragger may now be disconnected from the host machine. Stop the engine of the host machine and de-pressurise the hydraulic system. Disconnect the supply hoses from the host machine, coil them up and stow them in the s llage. Disconnect the shackle from the li ing point of the host machine. The TD15-01 Threader Dragger is now ready for transport. When securing to a vehicle lash the s llage down and take care that the lashings cannot damage the Threader Dragger. 10 Copyright: Thomson Engineering Design Ltd all rights reserved

11 Maintenance Plan The Thomson Engineering Design TD15-01 Threader Dragger is specifically designed for the dragging and threading of flat bo omed rail sec ons in railway applica ons. Use of the TD15-01 Threader Dragger is described in the Operators Instruc ons Sec on. This part of the document deals with the inspec on and maintenance opera ons necessary to keep the TD15-01 Threader Dragger in good condi on and to ensure that it is safe for use. This document does not cover repair and overhaul opera ons which are fully described in the TD15-01 Threader Dragger Repair Opera ons Manual available separately from the manufacturer. This sec on of the document is divided into three sub-sec ons: the first subsec on deals with the periodic inspec on and maintenance of the various parts of the Threader Dragger, the second sec on describes the maintenance opera ons mandated in the first sub-sec on and the last sub-sec on gives guidance on the thorough examina on (under LOLER) of all parts of the Threader Dragger which should be carried out at six monthly intervals. Thorough Examina on of Li ing Equipment The TD15-01 Threader Dragger is an item of li ing equipment as defined under the Li ing Opera on and Li ing Equipment Regula ons (LOLER). Under LOLER it is the responsibility of the owner and users of the TD15-01 Threader Dragger to: Appoint competent users and inspectors Ensure that the TD15-01 Threader Dragger is thoroughly examined at least once every six months Record thorough examina ons on a LOLER cer ficate Maintain the TD15-01 Threader Dragger in a safe condi on This document is intended to assist users, maintainers and examiners by detailing the rou ne maintenance program, describing the rou ne maintenance opera ons and highligh ng where defects may occur due to excep onal wear-and-tear, abuse, transit damage, etc. From me to me this document may be updated and new copies of the document may be obtained from the manufacturer. Copyright: Thomson Engineering Design Ltd all rights reserved 11

12 Competency Standards Competency Standards for Maintenance It is the responsibility of equipment owners to ensure that all staff carrying out maintenance opera ons are competent. Thomson Engineering Design Ltd can provide training in the necessary maintenance and examina on tasks relevant to the TD15-01 Threader Dragger. As a minimum, all maintenance staff working on the TD15-01 Threader Dragger should be assessed as competent in: Machinery Maintenance and Repair Skills Fault Finding on Hydraulic Systems Competency Standards for Thorough Examina ons (LOLER) LOLER does not define any specific competency standards or recommend any relevant qualifica ons for li ing examiners. It is the responsibility of employers to define who is competent to carry out LOLER examina ons and different companies may have different standards. The TD15-01 Threader Dragger is a specialised item of li ing equipment which is not generally covered by li ing industry training courses however its component parts are rela vely simple and of a design which anybody with experience of examining li ing equipment should be able to cope with. The guidance given in this document should enable operators and examiners to use and maintain the TD15-01 Threader Dragger in a safe and efficient manner but we will be pleased to answer any specific queries or assist in the development of any further training material or documenta on which owners may require. Discovery of Cracks, Distor on or Serious Failure In the event of the discovery of cracks or distor on within the load bearing parts of the TD15-01 Threader Dragger or any other failure which might cause the Threader Dragger to drop a rail or injure any person, the Threader Dragger should be removed from service, quaran ned and the manufacturer should be contacted at once. Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire. GL14 2NZ Tel: Fax: sales@thomsondesignuk.com 12 Copyright: Thomson Engineering Design Ltd all rights reserved

13 Glossary of Defined Maintenance Terms Throughout this document the following terms shall have the meanings given below: Adjust Blueing Change Check Clean Daily Defec ve Dismantle Examine Gauge Gauge Grease Inspect Lubricate Overhaul Paint Re-assemble Record Record Rec fy Refit Remove Renew Repair Test Correct to defined limits Discoloura on of metal components caused by overhea ng Remove the original and fit a new or overhauled part or assembly it its place Determine a par cular nominated condi on, for example completeness, security, posi on, etc.. Remove all dirt and deposits Per working shi (typically not exceeding 8 hours con nuous use) Containing a fault or faults which may impair the normal func oning of a part or assembly Take to pieces Carefully inspect in order to seek out defects for example wear, cracks, leaks, corrosion, etc. (n.) Tool specifically designed for measuring or checking a specific parameter (eg. profile) (vb.) Measure a specific parameter or compare with a calibrated instrument Apply grease via a grease nipple or by hand to a surface Determine general condi on and conformity to required standards Apply lubricant Carry out repair opera ons and inspec ons necessary to return equipment to fitness for use Apply a suitable coloured coa ng to a surface in accordance with the coa ng makers instruc ons Put together all the parts of an assembly to return it to the as-manufactured state. (n.) Wri en or electronically stored data (vb.) Take down data in wri ng or enter into an electronic data store To correct Put back and re-connect Disconnect and take off Replace the original with a new part or assembly Restore to fitness for use Prove correctness by trial (for example correct opera on or func on) Copyright: Thomson Engineering Design Ltd all rights reserved 13

14 Maintenance Facilities All of the maintenance ac vi es and opera ons described in this document may be carried out in a normal plant workshop environment. Where special service tools and gauges are required to complete a task these are noted and part numbers for the tools given. All service tools and gauges may be obtained from the manufacturer. Maintenance staff must ensure that they are familiar with all local safety rules and advice and that they are working under a safe system of work. Warning The TD15-01 Threader Dragger has a high pressure hydraulic system Hydraulic fluid under pressure can puncture skin and, if injected into so ssue, can cause massive injuries. Changes in temperature can cause a build up of pressure in closed hydraulic systems. Always treat hydraulic systems with great cau on especially when checking for leaks. Wear appropriate PPE especially goggles. Remember that moving machinery can kill! 14 Copyright: Thomson Engineering Design Ltd all rights reserved

15 Section 1: Periodic Maintenance & Inspection The Thomson Engineering Design TD15-01 Threader Dragger is designed for heavy duty use in a challenging environment. The following maintenance programme has been designed to ensure that the TD15-01 Threader Dragger is kept in good condi on so that it is safe and reliable in service. Maintenance and Inspec on tasks are listed for Daily (pre-use), Monthly and Six-monthly intervals represen ng 8, 150 and 1,000 hours use respec vely. This programme should be considered as a guide and may be modified if experience demonstrates that modifica on is jus fied. All maintenance and repair ac vi es should be recorded and these records periodically reviewed to look for pa erns of defects. If repeated defects are observed then the manufacturer should be alerted. Sec on 1 Content 2.1: Pre-Use Maintenance & Inspec on : Monthly Maintenance (150 hours use) : 6-Monthly Maintenance (1,000 hours use) : Disposal at End of Life 20 Copyright: Thomson Engineering Design Ltd all rights reserved 15

16 1.1: Pre-Use Maintenance & Inspection Daily checks of the TD15-01 Threader Dragger are designed to ensure that it is fit for use. Daily maintenance is limited to greasing of the jaw hinges, the rollers and the hydraulic cylinder ends. The following is a list of the relevant daily checks. These should be carried out at the start of the shi before pu ng the TD15-01 Threader Dragger into service. If the device is used for an extended period then these checks and maintenance opera ons should be repeated every eight hours of use. Dragger jaws open and close freely Threader rollers spin freely Threader rollers open and close freely Rail head rollers turn freely Yoke hinge moves freely All nuts and bolts are ght One grease nipple is fitted in each Threader roller arm (4 total) Hydraulic hoses are free from damage All parts free of cracks, wear and distor on Hydraulic system is free from leaks Dragger jaw pads are in good condi on Grease should be applied to the following points Hinge bosses Hydraulic cylinder ends Roller sha s Threader cylinders have a grease nipple at each end (8 total) Lubricants Always use a good quality EP (extreme pressure) rated grease such as Castrol Contractor Special, Castrol Pyroplex, Shell Gadus S3 or similar. The Dragger jaw hinge pin has a grease nipple in one end 16 Copyright: Thomson Engineering Design Ltd all rights reserved

17 Grease the cylinder ends (4 total) and hinge pins (2 total) of the adapter head Grease the rail head roller shafts (2 points) and the hinge pins for the Threader roller arms (4 points) Copyright: Thomson Engineering Design Ltd all rights reserved 17

18 1.3: Monthly (150 Hours) Maintenance A er every month or 150 hours (whichever is soonest) perform the following maintenance checks and opera ons. In addi on to the daily maintenance inspec on opera ons detailed on pages 16 and 17: Thoroughly clean the TD15-01 Threader Dragger Carefully inspect for wear, cracks and distor on of frame Check ghtness of all bolts Check cylinder rods for damage, scoring and pi ng Check Manufacturers plate is secure and legible Check the cylinder ends & cylinder pins for wear Check the ghtness of the cylinder pin bolts Check the yoke bushes Check the Dragger grip bars If any significant defect is noted the TD15-01 Threader Dragger should be quaran ned and correc ve ac on must be taken before returning the TD15-01 Threader Dragger to service. 18 Copyright: Thomson Engineering Design Ltd all rights reserved

19 1.4: 6-Monthly (1,000 Hours) Maintenance A er every six months or 1,000 hours use (whichever is soonest) complete a daily and a monthly maintenance schedule and then also perform the following checks and opera ons. The following checks are designed to ensure the correct opera on of the hydraulic system: Check the cylinder check valves & piston seals Check the Threader roller sha s, bushes and thrust washers Check the frame for cracking, damage and distor on Check the Threader roller profile Check the rail head rollers and bushes Check the Dragger jaw hinge bushes Once the maintenance has been completed the TD15-01 Threader Dragger should also be given a thorough examina on as required under LOLER. Loler Inspec on A competent person must carry out a thorough (LOLER) examina on every six months. Ideally this should not be the person who carried out the maintenance opera ons. Guidance on inspec ng the TD15-01 Threader Dragger is given on pages 31 to 34. Copyright: Thomson Engineering Design Ltd all rights reserved 19

20 1.5: Disposal at End of Life At the end of its useful working life almost all of the parts of the TD15-01 Threader Dragger can be recycled. The TD15-01 Threader Dragger may be returned to the manufacturer for proper disposal, alterna vely please contact the manufacturer for advice on how each of the component parts may be disposed of in an environmentally sensi ve manner. 20 Copyright: Thomson Engineering Design Ltd all rights reserved

21 Section 2: Maintenance Operations The following sec on describes the maintenance opera ons required under the maintenance programme set out in Sec on 1. Thomson Engineering Design Ltd can provide training in maintenance and hydraulic system repair skills if required. Sec on 2 Content 2.1: Checking the Threader Rollers & Bushes : Checking Roller Sha and Thrust Washers : Replacing the Roller Bushes : Checking the Rail Head Rollers and Bushes : Tes ng Cylinder Check Valves and Piston Seals : Checking Cylinder Ends, Pins and Pin Bolts : Checking Cylinder Rods : Checking the Yoke Bushes : Checking the Frame 30 Copyright: Thomson Engineering Design Ltd all rights reserved 21

22 2.1: Checking the Threader Rollers & Bushes Rollers Rotate Freely Rotate each roller by hand in both direc ons (red arrow on illustra on) every roller should move freely without any ght spots. If a roller is ght or if ght spots in the rota on are felt then this may indicate either contamina on of the bearing with foreign ma er or that the surface of the bearing bush or the roller sha is breaking down. Roller Bushes free from Excessive Play Rock each roller in turn in the direc on of the blue arrows and feel for excessive wear in the bearings. A small amount of play in this direc on is normal however if the roller can be rocked so that the edge on one side can be made to rise and fall by more than 1.5mm (as illustrated right) then the bearing or the sha is worn to excess. Note that the roller should be free to slide up and down on the sha by up to 2mm. Take care not to mistake this sliding movement for rocking movement. Rollers not Excessively Worn The rollers are case hardened. This means that the outer 2mm layer of the roller metal has been heat treated for wear resistance. Once this hard layer is worn away the so er metal beneath is exposed and this will wear much more quickly. Inspect the rollers for signs of wear and change rollers when the wear exceeds 1.5mm. To assist in this assessment a drawing of the roller is included on page 35. A profile gauge for checking the rollers is available from the manufacturer part number Checking a roller with profile gauge There should not be more than 1.5mm gap between the gauge and the roller at any point 22 Copyright: Thomson Engineering Design Ltd all rights reserved

23 2.2: Checking Roller Shaft and Thrust Washers To check the roller sha and thrust washers the rollers and sha s must be removed from the TD15-01 Threader Dragger. This opera on requires the retaining bolts and Nord-Loc washers to be removed. It is inadvisable to re-use Nord-Loc washers as the ramp surfaces and grip surfaces can become damaged when they are undone. New Nord-Loc washers are available as spare parts from the manufacturer. Removing and Replacing the Rollers and Sha s Undo and remove the two M16 bolts and Nord-Loc washers. Withdraw the roller sha and slide off the upper thrust washer, roller assembly and lower thrust washer. Re-assembly is the reverse of removal but fit new Nord-Loc washers and ghten the bolts to 120 Nm. Note the following points: The coated face of the thrust washers should be against the roller. The grease groove in the sha must be aligned with the grease nipple in the frame Rollers may be fi ed either way up. Checking the Roller Sha Using a calibrated measuring instrument such as a digital caliper check the diameter of the roller sha. This should be 49.95mm to 50mm for a new sha. Replace any sha worn to less than 49.85mm diameter. Measure the thickness of the sha end flange. This should be 14.5mm to 15.5mm for a new sha. Replace any sha worn to less than 13mm flange thickness. Tip In use the bottom thrust washer carries most of the load and will wear out the most quickly. To get the greatest life from the components it is advisable to swap the top and bottom thrust washers each time the assembly is dismantled Examine the sha for signs of blueing, scoring, pi ng, cracking or any other defects. Replace any defec ve sha. Checking the Thrust Washers Using a calibrated measuring instrument such as a digital caliper, check the thickness of the thrust washers. This should be 2.58mm to 2.62mm for a new washer. Replace any thrust washer worn to less than 2.25mm thick. Copyright: Thomson Engineering Design Ltd all rights reserved 23

24 2.3: Replacing the Roller Bushes Replacement bushes are available from the manufacturer and are simple to replace using workshop tools and a suitable press mandrel. Two bushes are press fi ed into each roller. A special press mandrel (part number ) is available which should be used to support the bush and prevent damage to the bush end faces when driving the bushes in and out of the roller. Replacing Roller Bushes Ideally the bushes should be removed and installed using a press but a bench vice may be used if a press is not available. Do not use a hammer to drive bushes in or out of the rollers as this can distort the bushes and damage the roller. To remove the old bushes place the roller on a piece of thick walled steel tube at least 56mm bore and 82mm long with square cut ends. Fit the press mandrel into the upper bush and press both bushes so that they fall into the steel tube. To press a bush using the press mandrel first fit the bush to the spigot of the mandrel then offer the bush up to the centre of the roller and check that it is correctly aligned before pressing into place. Press the bush into the roller un l the face of the bush is flush with the face of the roller. Reaming the Bushes A er the bushes are pressed into the roller they must be reamed out to between 50.00mm and 50.05mm bore using a sharp expanding hand reamer. Press Bushes into the Roller using press mandrel part number Copyright: Thomson Engineering Design Ltd all rights reserved

25 2.4: Checking the Rail Head Rollers & Bushes To check the rail head rollers and bushes the roller assemblies must be removed from the frame. Undo the bolts securing the axle washer and remove the washer. Undo and remove the axle pin retaining bolt and withdraw the axle pin to release the rail head roller. Checking the Axle Pin Using a calibrated measuring instrument such as a digital caliper measure the diameter of the axle pin in the areas where the roller bushes run on its surface. Rotate the pin 90 degrees and check the measurement again to see if the axle pin is round or if it has worn oval. The minimum acceptable measurement is 34.8mm at any point on the axle pin. If any part of the pin is smaller than this it must be replaced. Checking the Roller Bushes Having ascertained the axle pin is not worn to excess (or having obtained a new axle pin if it is), clean all grease and dirt from the bushes and insert the pin through the roller. Holding the roller firmly check for clearance between the pin and the bushes by rocking the pin. If clearance is detected measure the clearance either using feeler gauges between the pin and the bush or using a dial micrometer to measure the movement of the pin. Bushes should be replaced if there is more than 0.4mm clearance. NOTE When re-assembling the bushes must be packed with fresh grease. Copyright: Thomson Engineering Design Ltd all rights reserved 25

26 2.5: Testing Cylinder Check Valves & Piston Seals If a piston seal or check valve leakage is suspected the cylinder assembly can be checked by following this procedure. This test will only determine if there is a fault. The fault could be either a leaking check valve or leaking piston seals or both. If a fault is detected in a cylinder the TD15-01 Threader Dragger should be quaran ned un l the fault can be fully diagnosed and rec fied. Fault diagnosis, repair of cylinder check valves and replacement of cylinder and piston seals are detailed in the TD15-01 Threader Dragger Repair Opera ons Manual available from the manufacturer. Cylinder for test with hoses connected to a hydraulic supply To Test Check Valves and Piston Seals Remove the 3/8 BSP banjo from the rod end cylinder port and install a gauge adapter. Connect a calibrated pressure gauge to the gauge adapter. Connect the cylinder to a hydraulic supply with a maximum pressure of 210Bar. Extend and contract the cylinder three mes to expel any trapped air then retract the cylinder to full pressure. Remove the banjo from the rod end cylinder port Switch off the hydraulic supply and de-pressurise the supply hoses so that the pressure is held in the cylinder by the check valve. Note the reading on the pressure gauge. Leave the cylinder for 2 minutes then re-check the pressure reading. This should not have dropped by more than 10%. More than 10% pressure loss indicates a fault with either the cylinder seals or the check valve. Once the test is complete, release the pressure in the system, remove the gauge and re-fit the 3/8 BSP banjo. Check for leakage. Pressure should be released by opera ng the hydraulic service to par ally open the TD15-01 Threader Dragger NOT by undoing hydraulic fi ngs. Fit a gauge adapter such as part TD Hydraulic fluid under pressure can cause very serious injuries. Connect a calibrated pressure gauge. The cylinder is now ready for testing. 26 Copyright: Thomson Engineering Design Ltd all rights reserved

27 2.6: Checking Cylinder Ends, Pins & Pin Bolts Each end of the hydraulic cylinders has a pin joint. These tests are designed to check for excessive wear in these joints and to check the pins to which the cylinders are a ached. Normally the a achment pins do not wear unless the retaining bolts work loose. Checking the Pin Bolts Check that both bolts holding the cylinder retaining pins are ght. If any bolt is found to be loose then the bolt should be removed and the Nord- Loc washer discarded. Remove and, using a calibrated measuring instrument such as a digital caliper, check the diameter of the pin. Replace any cylinder pin which has worn by more than 0.2mm on diameter. When re-fi ng a cylinder retaining pin use a new Nord-Loc washer. Checking the Cylinder End Joints Grasp each cylinder end joint in turn and, using moderate hand force, a empt to move the joint in a horizontal direc on. Feel for any clunking from the joint which would indicate wear in the joint. All joints should appear ght under hand force. Copyright: Thomson Engineering Design Ltd all rights reserved 27

28 2.7: Checking Cylinder Rods Damage to the chrome surface of the cylinder rods will quickly lead to failure of the cylinder headbush seals and hydraulic fluid leakage. Bending of the cylinder rods may lead to jammed cylinders and failure of the TD15-01 Threader Dragger. To Check the Cylinder Rods Connect the TD15-01 Threader Dragger to a host machine and operate the hydraulic system so that the cylinders are fully extended. Visually inspect the chromed surfaces of the cylinder rods for signs of dents, pi ng, burrs and peeling of the chrome plate. Using a short straight edge check that the rods are straight. Check in both the horizontal and the ver cal direc on. 28 Copyright: Thomson Engineering Design Ltd all rights reserved

29 2.8: Checking the Yoke Bushes Check for excess play in the yoke bushes by using a lever to manipulate the joint on each end of the yoke as shown. If more than 0.75mm of play is found in either bush then the bush should be replaced. Copyright: Thomson Engineering Design Ltd all rights reserved 29

30 2.9: Checking the Frame The frame of the TD15-01 Threader Dragger must be checked periodically for cracking and distor on. This check should be carried out at least every six months as part of the thorough examina on required under LOLER. Begin by thoroughly cleaning the TD15-01 Threader Dragger. Visually inspect the paint for cracks which might be caused by cracking of the metal below. If a number of cracks are seen close together remove the paint in that area and inspect the metal for cracks. Pay par cular a en on to the areas shown in red in the illustra on below. 30 Copyright: Thomson Engineering Design Ltd all rights reserved

31 Section 3: Guidance on Thorough Examination (LOLER) Every six months the TD15-01 Threader Dragger must be given a thorough examina on and a new cer ficate of thorough examina on issued before it may be returned to work. The TD15-01 Threader Dragger has been designed to withstand heavy duty use over a long period and is unlikely to develop cracks or other defects in normal opera on. Careless handling and abuse can cause damage which may ul mately lead to premature and sudden failure and the examiner should be on the look out for evidence of this. This sec on of the Maintenance Plan is designed to guide the examiner by illustra ng areas where damage through abuse may occur and describing ways of checking. It is designed to be a stand alone sec on and therefore repeats many of the normal maintenance checks in Sec on 1. Sec on 3 Content 3.1: General Examina on : Func onal Examina on : Structural Examina on 34 Copyright: Thomson Engineering Design Ltd all rights reserved 31

32 3.1: General Examination Almost all faults may be spo ed by a thorough visual examina on. Begin by ensuring that the TD15-01 Threader Dragger has been wiped clean of excess grease and thoroughly cleaned. The following checks will give a good indica on of the general condi on of the TD15-01 Threader Dragger. Hydraulic System The hydraulic system should show no evidence of leakage All hoses should be free from chafing and exposed wires All joints should appear ght When operated, the cylinders should move smoothly Cylinder rods should be free from damage Hydraulic Cylinder Mounts Hydraulic cylinder end joints should be free from play Cylinder moun ng pin bolts should be ght Shackle Moun ng shackle should be free from burrs and bruising Moun ng shackle should be free from distor on Moun ng shackle pin should be securely fi ed Shackle boss in top of Threader Dragger should be free from distor on Handles Handles should not be bent or distorted Handle welds should be free from cracking Handles should be painted white* Fasteners All nuts, bolts, pins, co ers, etc. must be fi ed and secure * This is a United Kingdom Rail Standard, all parts of machines such as steps and handles are traditionally painted white to indicate that they are safe to hold. In other areas different standards may apply and the examiner should verify the local requirements before examining the Threader Dragger. 32 Copyright: Thomson Engineering Design Ltd all rights reserved

33 3.2: Functional Examination Rollers and Roller Sha s Rollers must turn freely in both direc ons Roller bushes must not have excessive play Roller sha flanges must not be worn by more than 2mm Roller sha s must be ght in the frame Yoke Flange bolts must be ght Yoke must move freely on its hinge bushes Yoke hinge bushes must be free from excessive play Copyright: Thomson Engineering Design Ltd all rights reserved 33

34 3.3: Structural Examination Rollers Yoke Rollers must be free of chips, cracks and distor on Roller profile must not be worn by more than 1.5mm Yoke must be free from cracks, distor on & bending Frame Frame must be free from cracks, twist and distor on Any repairs carried out to the frame should be properly documented and assessed Note that cracking of the paint work may indicate cracking of the metal below. If in doubt, remove the paint and check with a dye penetrant tester. If any weld repairs have been carried out on the TD15-01 Threader Dragger check that these are of good quality and carried out under a wri en Weld Process Specifica on by a welder qualified under a controlled Welder Approval Scheme. 34 Copyright: Thomson Engineering Design Ltd all rights reserved

35 A A R5 NOTE 1: ROLLER ONLY COMPATIBLE WITH TD15-01 THREADER DRAGGER 2: ROLLER IS NOT INTERCHANGEABLE WITH RAIL FOOT THIMBLE ROLLER Stock Size Stock Length Vendor Vendor No. Cost Configuration Q'TY REQ'D Client 25 PROJECT TD15-01 THREADER DRAGGER 150mm BRIGHT ROUND 80 Default 4 PER PRODUCT THOMSON ENGINEERING DESIGN LTD H SECTION A-A UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: +0.5 / -0.5mm ANGULAR: +/- 0.5deg FINISH: SOURCE: CASE HARDENED ROUND BAR STOCK DEBUR AND BREAK SHARP EDGES NAME ORGANISATION DATE DRAWN D. Thomson Thomson ED Ltd 31/05/2015 CHK'D APPV'D MFG Q.A MATERIAL: 080M40 (EN8) Third angle Projection WEIGHT: 80 DO NOT SCALE DRAWING REVISION 01 The information contained in this drawing is the sole property of THOMSON ENGINEERING DESIGN Ltd. Reproduction in part or as a whole is prohibited TITLE: RAIL FOOT ROLLER DWG NO. TD SCALE:1:2 SHEET 1 OF 1 A3 Copyright: Thomson Engineering Design Ltd all rights reserved 35

36 36 Copyright: Thomson Engineering Design Ltd all rights reserved

37 Warnings WARNING ALWAYS STOP THE ENGINE OF THE HOST MACHINE AND RELEASE THE PRESSURE FROM THE HYDRAULIC SERVICES BEFORE ATTEMPTING TO CONNECT OR DISCONNECT HYDRAULIC ATTACHMENTS. MAXIMUM RATED PRESSURE OF HYDRAULIC CIRCUITS MUST NOT BE EXCEEDED. EXCEEDING RATED PRESSURE MAY LEAD TO BURST HOSES OR LEAKAGE FROM COMPONENTS. HYDRAULIC FLUID UNDER PRESSURE MAY CAUSE SEVERE INJURY. WARNING NEVER MOVE ANY LOAD UNTIL YOU ARE SURE THAT THE WORK AREA IS CLEAR OF ALL PERSONNEL. ALWAYS ENSURE THAT LIFTING OPERATIONS ARE PROPERLY PLANNED. REMEMBER THAT INADVERTENT OPERATION OF THE CONTROLS MAY CAUSE INJURY TO PERSONNEL IN THE WORK AREA. WORN OR DAMAGED PADS WILL REDUCE THE GRIP ON THE LOAD. WARNING SMOOTH AND STEADY OPERATION OF THE TD15-01 THREADER DRAGGER WILL PROLONG ITS WORKING LIFE. ALWAYS ENSURE THAT THE RAIL IS PROPERLY FIXED BEFORE RELEASING THE GRIP OF THE TD15-01 THREADER DRAGGER WARNING THREADING RAIL IS A LIFTING OPERATION. ALL LIFTING OPERATIONS MUST BE CAREFULLY PLANNED TAKING INTO ACCOUNT THE DUTY CHART OF THE HOST MACHINE TO ENSURE THAT NEITHER THE TD15-01 THREADER DRAGGER NOR THE HOST MACHINE CAN BECOME OVERLOADED. OVERLOADING OF THE TD15-01 THREADER DRAGGER OR THE HOST MACHINE MAY LEAD TO SERIOUS INJURY OR DEATH. WARNING THE TD15-01 THREADER DRAGGER IS DESIGNED FOR THE HANDLING OF RUNNING RAILS AND CONDUCTOR RAILS ONLY. IT MUST NOT BE USED FOR ANY OTHER PURPOSE. THE USE OF THE TD15-01 THREADER DRAGGER FOR ANY OTHER PURPOSE WILL INVALIDATE THE MANUFACTURER S WARRANTY AND MAY LEAD TO SEVERE INJURY TO PERSONS AND DAMAGE TO THE DEVICE. WARNING ONLY TRAINED AND COMPETENT OPERATORS SHOULD USE THE TD15-01 THREADER DRAGGER. DO NOT ATTEMPT TO USE THE TD15-01 THREADER DRAGGER UNTIL YOU HAVE READ AND UNDERSTOOD THIS OPERATORS MANUAL. ALWAYS COMPLETE THE DAILY CHECKS AND MAINTENANCE BEFORE USING THE TD15-01 THREADER DRAGGER If any part of this Operators Instruc on document is unclear or for any technical advice please contact the manufacturer. Manufacturer s contact details can be found on Page 38. Copyright: Thomson Engineering Design Ltd all rights reserved 37

38 Contacting the Manufacturer Thomson Engineering Design TD15-01 Threader Dragger is manufactured in the United Kingdom by: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire England GL14 2NZ Tel: +44 (0) Fax: +44 (0) All spare parts, technical, training and sales enquiries should be directed to the manufacturer. Please note that outside normal business hours all calls are monitored. Queries will be dealt with as soon as an on-call manager becomes free. 38 Copyright: Thomson Engineering Design Ltd all rights reserved

39 Certificate of Conformity We: Thomson Engineering Design Ltd Valley Road Cinderford Gloucestershire GL14 2NZ Declare under our sole responsibility that the product known as: TD15-01 Threader Dragger To which this declaration relates is in conformity with the following standards: 2006/42/EC Authorised signatory: David Thomson BSc David Thomson BSc CEng MIMechE Oct 2015 Copyright: Thomson Engineering Design Ltd all rights reserved 39

40 Thomson Engineering Design Ltd. Valley Road, Cinderford, Gloucestershire. GL14 2NZ Tel: +44 (0) Fax: +44 (0)