trakrat® Link
Contents
1. Adjuster Nut 3 Remove 19mm axle retaining nut PEE u 9mm Spanner SECTION 14 DISC AND WHEEL REMOVAL 4 Remove the four 4mm allen headed shoulder bolts one at a time depressing the actuator and rotating the wheel to gain access as you progress If fitted with insulating washers these should be discarded and new ones fitted during the rebuild Insulating Washers Allen Bolt Allen Socket 5 Partially remove axle using a suitable drift 6 Press the actuator and slide disc aside then remove the large spacer tube Press the actuator again and remove disc Finally completely remove axle and remove the wheel and two nylon spacers Two Nylon Spacers Insulating Bearing an Housing Outer Pad Inner Pad Mounting Posts Spring SECTION 15 BRAKE PAD REMOVAL 8 Loosen both brake pad retaining hex bolts Note the brake pad retaining bolts are the outer of the four DO NOT loosen the inner two Carefully remove both pads springs Brake Pad Retaining Bolts Brakepad Mounting Inner Retaining Bolts Posts Pad DO NOT LOOSEN 9 Carefully remove both pads and springs Clean grease the mounting posts and springs To fit new brake pads simply reverse the above procedure 14 trakrat Maintenance Brake Test Report Trolley Number Owners Name NE All braked wheels must be torque tested Number of Braked2. Lift the unit onto the track with all wheels correctly positioned ready to use Lifting will require a minimum of 3 persons or 4 persons for the LT1500A Insert the push handle into receiving sockets ensuring it is fully and securely engaged Brake Handle BOGIE RECEPTICLE ANTI SKEW COMPONENTS Two pins and two recepticles per side Trolley Coupling Plate Brake Pilot Plate Insert the brake pivot handle onto the brake pivot plate and carry out a test to confirm that moving the handle in the direction of the ARROW label releases both the wheel brakes evenly Receiving Slot Brake Pivot Note both push handle and brake pivot handle can be fitted to either end of the deck and should be placed so that the operator is pushing the unit in the required direction NOT pulling WELDERS TROLLEY Bottle Braces The Welders Trolley comprises of LT 1500 A with the option of a frame that supports a pair of i gas cylinders Insert one frame into receiving sockets on one side of the deck and the remaining frame on the opposite side ensure both are fully and securely engaged Next connect the two bottle braces to their respective anchor points e Gas bottles must be stood vertically against the bottle brace bars and be strapped roped securely Receiving Socket via the tie down eyes provided LINKING TRAKRAT LINK TROLLEYS You may link a maximum of 2 trakrat Link Trolleys but you may not link to any other make
3. UV DEGRADATION All plastics are susceptible to UV degradation Check all polymer components for stress fractures hairline cracks and brittleness trakrat Spares listing S RAI 040 S RAI 050 SRAK055 Wheel Spacer Tube imm Brake Pivot End 20x20x247 LT1000 Spring S RAL320 Aluminium Deck Sheet 748x1618mm S RAI 440 SRALS20 Trolley Light Bracket SRALS50 ToleyPushBar S RAL810 S RALS15 S RAI 920 S RAI 940 S RAI 950 S RAI 990 S RAI 999 Trakrat Tool Tray Brace Trakrat Tool Tray Set 1 x Brace 1 x Tray Trakrat Gas Bottle Set 2 x Brace 1 x Push Trakrat P1 Profile Guage Trakrat Brake Test Tool SECTION 7 TECHNICAL DATA LT 1000P LT 1250A LT 1500A 50mm 750mm 800mm 800mm Platform Height From Rail Crown Overall Height Including Push Rail I000mm I000mm 1000mm Platform Area 1400mm3 1215mm3 1860 mm3 Maximum Graden The SWL is based upon a load evenly distributed over the deck and may be revoked by local codes of practice COMPLIANCE trakrat Link Trolley complies with GM RT 1310 BSEN 13977 2005 E EN 13977 European Machinery Directive CE SECTION 8 WARRANTY Your trakrat Link Trolley is covered by a 12 month warranty The Company undertakes to replace or repair free of charge any defect which the Company considers to be due to faulty workmanship or material within I2 months of the sale date except for e Defects arising from neglect misuse or unauthorised mo
4. www trakrat com trakrat Link Trolley Instruction Manual Thank you for purchasing a trakrat Link Trolley Before using this equipment and to avoid personal injury carefully read and understand these instructions If there is anything you do not understand DO NOT use this equipment contact your supplier for advice Regular inspection servicing and periodic maintenance will ensure many years of trouble free operation CONTENTS PAGE trakrat Link Trolley SECTION Introduction Disclaimers SECTION 2 General Safety Risk Assessment 2 3 SECTION 3 Know your trakrat Link Trolley SECTION 4 Assembly Instructions 5 SECTION 5 Operating instructions 6 SECTION 6 Cleaning and general care SECTION 7 Technical data I SECTION 8 Warranty I SECTION 9 Stopping Distance Table 2 Bogie Brake Inspection Test SECTION 10 General 9 SECTION II Inspection SECTION 12 Test Procedure SECTION 13 Brake Pad Wheel Disc Replacement Procedure 10 SECTION 14 Disc and Wheel Removal SECTION 15 Brake Pad Removal SECTION 16 Label Information SECTION 17 Certification 25 31 trakrat Link Trolley INTRODUCTION DESCRIPTION The trakrat Link Trolley is a portable link trolley for use on rail infrastructure Polymer Link Trolley TR 1000 P Constructed from Polypropylene and aluminium to give a combination of strength with minimum weight NB Please note that local practice may limit the SWL capacity to 1000Kg LT 1000 P Link
5. Designs Ltd operate a policy of constant improvement and reserve the right to change specifications without notice Wolfe Designs Ltd reserve the right to alter delete or make additions to this manual without notice at any time as is deemed necessary SECTION 2 SAFETY To ensure that the trakrat Link Trolley is used safely and responsibly we strongly recommend that this manual is read by all users prior to operating the trakrat Link Trolley and that the recommendations are followed at all times Make sure you are aware of all safety requirements and that this equipment is suitable for the task you wish to undertake This equipment must not be moved set up used or dismantled by persons who are under the influence of alcohol or drugs Do not use this equipment if you are tired or unwell Test brakes in accordance with brake test procedure as published Always read and follow the safety information found on the details fitted to the trakrat Link Trolley Be aware of trap hazard between 2 linked trolleys Use red indicator lights where required Do not overload the platform beyond the stated weight loading for the model you have and ensure that you secure any load adequately Wear the correct Personal Protective Equipment for the task you are performing Do not wear loose jewellery or clothing that may get in the way or become trapped in the mechanism Inform everyone in the work area of what you are doing Carefully inspect t
6. certificate EU Rula Book 18 section12 Track Trolleys MRSSL standard MR S TR QQ07 Manually Operated Track Trolleys Wolfe trakrat Instruction Manual Route Availability certificate Ref 0311 Plant Approval certificate Ref Toals Small Plant Braking Approval Slalement fram A G Morris dated 15 Jan 2008 ial under MRYCT C4199 and MRICTC 264 Approved fer SICH Certificato Ten Ma hein iin Register erry rin rd 800 M wane 26 Trans nort 257 epidor LUL Nominee BCV Limited Es LUL Nominee SSL Limited Templar House 81 87 High Holborn London Plant Approval Certificate Track plant or equipment rack maintenance plant and equipment submitted for Plant Approval must comply with the appropriate statuary regulations LU standards and the requirements of this certificate It is the responsibility of the Project Manager to ensure that the plant equipment submitted for approval is compliant with the regulations and standards of the above companies Plant and equipment approval requirements are defined in LU standard 1 172 Plant Tools and Equipment Performance and Design Note 1 If this plant is defined as a rail vehicle Approval must be granted by the Rolling Stock Engineer LU before it is allowed to run on the LU rail system Note 2 Approved plant must meet the inspection and maintenance requirements of LU standard 1 173 Plant Tools and Equipment Inspection and Maintenance Note Operators must be trained and
7. certificated TE QAS 0302 Note 4 Diesel engine powered plant must conform to the requirements of LU QUENSH conditions Ref 2 05104 432 Description trakrat 3 part trolley 2 bogies amp deck swl 1250kg amp 1500kg Make Wolfe Designs Limited Model LT1250A LUL amp LT1500A LUL Identification Number Generic Type of operation To carry miscellaneous materials on the track Area of operation On LU track managed by Nominees BCV amp SSL Limited Operational limitations or 1 The trakrat Link Trolley must carry the CE mark Conditions 2 Each bogie and the deck of the trakrat Link Trolley must be clearly marked with a unique identification number The unique number must be etched or stamped on the item or on a label riveted or welded to the item 3 Each bogie must be tagged with the date of its next routine maintenance and brake test 4 The deck must be tagged with the date of its next routine maintenance 5 The trakrat Link Trolley may only be used with the traction current OFF Normal protection procedures for trolleys must be followed 6 The trakrat Link Trolley operator must have trakrat Link Trolley training from a company approved by LUL Nominees BCV amp SSL Limited 7 Health and Safety signage must include the weight of each element of the Trakrat Link Trolley and Assembled 4 man lift 8 The trakrat Link Trolley must be marked Max 2 Trolleys linked 9 The trakrat Link Trolley must
8. for any other purpose whatsoever it must not be copied nor transmitted to any other than the company to whom it was supplied It must not be held on any other internet web site than trakrat com it is not to be considered to be in the public domain
9. label may change to state SWL subject to client requirements NOTE BOGIE SERIAL NUMBERS ARE NOW ALSO ETCHED ONTO THE BOGIE 17 The labelling shown depicts that which we supply to the UK rail industry If your requirements differ then please state clearly at the time of order BOGIE LABEL LOCATIONS UK TRA 071 SWL 1000Kg ABOVE GROUND ON BOTH LT1250 amp LT1500 TRA 072 SWL1250Kg TRA 073 SWL1500Kg On Appropriate Bogies For Underground UK Used On Insulated Bogies UK TRA 121 INSULATED TRA 141 USE ON LUL ONLY Sern Monee Nan i i i i Bogie serial number and detail Etched Here TRA 111 Inside point towards the brake actuation side g TRA 101 Next brake test date has the next date written in before shipping 3months from date of manufacture 18 LT1000P LABEL SET 107mm x 39mm Placed under the deck in view See drawing EN13977 P amp TEHTPE EIHA BEST RIL TILES Lee LU CA LIVE SRD SHD ATH FALL For detail on bogie label set and location see LT1250A bogie 19 Labelling shown depicts that which we supply to the UK Rail industry In the case of decks whether that be the LT1250 or LT1500 we would include all the following plus if you wish to add SWL labelling to the deck rather than the bogies please ensure we are made aware T1230A DECK LABEL SET Dimensions atyPer Notes Placed on both sides to 89mm x 39mm indicate direction of brake release Note one left hand and one right hand la
10. the work being carried out SECTION 9 STOPPING DISTANCE TABLE Figures quoted are the maximum permitted under BS EN 13977 2005 section 5 4 l Stopping Distance at Stopping Distance at Gradient 3mph 5km h Dry Rail 3mph 5km h Wet Rail 6m lOm Level Single Trolley o 6m tm in 27 Single Trolley www trakrat com Ce Bogie Brake Inspection Test Bogie Brake Inspection Test SECTION 10 GENERAL Full inspections of the bogie braking system must be carried out at 3 monthly intervals in line with codes of practice documented in COP 0018 March 2006 The results of these inspections reported in the maintenance log and new validation labels indicating the next 3 monthly inspection date applied to each wheel set at the position indicated IMPORTANT As each wheel set Bogie is completely independent and interchangeable from deck to deck Each wheel set Bogie will require its own report form and Brake Test Label TOOLS REQUIRED 9mm ring spanner x 2 lOmm ring spanner 4mm allen key 5mm allen key trakrat brake test tool torque wrenches Vernier or rule SECTION II INSPECTION With the wheel set upside down on a suitable surface visually inspect the brake pads They require a minimum gap of 00mm to be operational If it is likely that this figure will be reached before the next quarterly inspection replace the pads now Minimum 3 5mm Minimum 1 0mm Check the con
11. Trolley 1000 Plastic En 800 x 1750 Link Trolley 1250 Aluminium Insulated Link Trolley 1250 Wood Insulated LT 1500 A I Link Trolley 1500 Aluminium Insulated o sow LT 1500 W I Link Trolley 1500 Wood Insulated The trakrat Link Trolley comprises of a deck and two bogies Both bogies are detachable to enable the users to transport the trakrat Link Trolley manually over reasonable distances where access by vehicular transport is not an option The trakrat Link Trolley is fitted with a unique disc brake system which increases braking efficiency and reduces wheel damage associated with traditional block brakes An additional version is available with wheels isolated from the main bogie for use on underground rail systems DISCLAIMERS Due care has been taken in the publication of this User Operator Manual but it is intended as a guide only The information and instructions included in this manual are provided to help you get the best possible service from your trakrat Link Trolley Users are reminded of their individual responsibility to ensure health and safety at work and their duty under current Health and Safety Legislation No warranties are implied or offered in relation to this manual its content or use and Wolfe Designs Ltd accept no liability whether actual or consequential arising from its use or that its use alone is sufficient to ensure the safety of those so engaged Your statutory rights remain unaffected Wolfe
12. amed above has been designed to comply with the relevant sections of the above referenced specifications The unit complies with all applicable Essential Requirements of the Directive s T EE MU A ie Hnm Name A Pugh Position Director 0 Done at Leyland Document ref No On 10 October 2007 Wolfe Designs Limited 125 Clydesdale Place Moss Side Industrial Estate Leyland LANCS PR26 7QS UK Tel 44 0 1772 456191 Fax 44 0 1772 622464 www wolfedesigns co uk Directors Chris Suter Michael Ashley Anthony C L Pugh Neil C Watson Managing Director Registered in England No 4056801 31 EE ENTE RIS y Mi 2 ER HS ae RER EC Declaration of We Wolfe Designs Ltd of 125 Clydesdale Place Moss Side Industrial Estate Leyland Lancashire PR26 7QS UK in accordance with the following Directive s 98 37 EC The Machinery Directive hereby declare that Equipment Trakrat Link Trolley LT 1500 A Model number DK 1500 A BY 1500 Serial Number DK 4001 to DK 6000 BY 8001 to BY 14000 is in conformity with the applicable requirements of the following documents Ref No Title Edition date BS EN ISO Safety of machinery Basic concepts general principles for design Technical 2003 AMD 12100 2 principles 14975 BS EN 13977 Railway applications Track Safety requirements for portable machines and 2005 trolleys for construction and maintenance RE STD 039 Brake system requirements category VII
13. be in good working order and suitable for its intended tasks 10 Any Notifiable incidents involving the trakrat Link Trolley must be copied to Track Assessment LU Type of Approval Limited Operational Approval Type Approval Weight 91 kg Powered By Manual Documents to be read as 1 LU Rule Book 18 section 12 part of this certificate 2 Metronet Rail Standard MR S TR 007 Manually operated Track Trolleys 3 Wolfe Designs Ltd trakrat Instruction Manual Period of certification 30 06 2013 Certificate Number Plant 8780 Rev 02 T A Date 10 02 2010 WJ Meyers Track Assessment Engineer Certificate no Plant 8780_Rev 02 Rev 01 superceded Was for Test Trial Conditions revised 2 Link up empowered by Achilles AS tr Registered Supplier Link up Qualification Scheme Wolfe Designs Limited Supplier Number 20212 Link up empowered by Achilles nl Registered esr Date Printed 19 February 2010 Peter Brookes Expiry Date 12 January 2011 Rail Sector Manager Certificate Number 58116 20212 68381 Achilles Information Limited Achilles Information Limited 30 Park Gate Milton Park Abingdon Oxon OX14 4SH UK T 44 0 1235 820813 F 44 0 1235 821093 E enquiries achilles com www achilles com enllahnrativa 28 In Link up hill empowered by Achilles Ay S PRODUCT CODE SUMMARY LINK UP QUALIFICATION SCHEME Wolfe Designs Limited 1703 1003 SMP P Way Trolleys SMP Sche
14. bel 89mm x 39mm See drawing rakrat LINK SERIAL Mo DK XX MANUFACTURE y C 2092 107mm x 39mm Placed under the deck in view See drawing T RACK 2 PERSONS MC Fr A EN1 3977 MA PYPE MANUAL LINK TROLLE RESTRICTIONS OF USE HOT TO BE USED PATENT PENDING c ON LIVE 3RD AND 4TH RAIL 4 Man Lift When Assembled Placed on deck behind 337mm x 39mm each lifting point position See drawing 4 Man Lift Wher Placed under the deck 73mm x 39mm eg in view See drawing DECK WEIGHT BOGEY WEIGHT 2 TOTAL WEIGHT PATENT PENDING Placed on side of the deck See drawing model TAREAA 219mm x 39mm IZSUA 20 LT1250 DECK LABEL LOCATION LT1500A DECK LABEL SET cm fA LP NT k PE Y rar Ez MAXIM 2 PERSONS LA IE EN13977 ATENT FR RIDING Y MENS CF USE ROT E IRD ANE 3TI I RAIL takrat DECK WEIGHT VP a AY gum A Bi BOGEY WEIGH TOTAL WEIGHT PATENT PENDING 89mm x 39mm 89mm x 39mm 107mm x 39mm 337mm x 39mm 73mm x 39mm 219mm x 39mm 22 Placed on both sides to indicate direction of brake release Note one left hand and one right hand label See drawing Placed under the deck in view See drawing Placed on deck behind each lifting point position See drawing Placed under the deck in view See drawing Placed onthe deck See drawing 23 trakrat label part numbers TRA 001 trakrat serial number deck LT1000P TRA 011 trakrat serial
15. difications e Damage caused by abuse misuse dropping or other similar damage caused by or as a result of failure to follow transportation storage loading or operation instructions e Alterations additions or repairs carried out by persons other than the Manufacturer or their recognised distributors e Transportation or shipment costs to and from the Manufacturer or their recognised agents for repair or assessment against a warranty claim on any trakrat Link Trolley or component e Materials and or labour costs to renew repair or replace components due to fair wear and tear e Faults arising from the use of non standard or additional parts or any consequential damage or wear caused by the fitting or use of such parts IMPORTANT warranty may at the sole discretion of the manufacturer be voided if the scheduled maintenance inspections are not carried out by a competent person The Manufacturer and or their recognised agents directors employees or insurers will not be held liable for consequential or other damages losses or expenses in connection with or by reason of or the inability to use the trakrat Link Trolley for any purpose MODIFICATIONS If additional equipment or any third party work modifications or alterations are to be carried out on the trakrat Link Trolley which will involve any welding drilling or any form of cutting or distortion of materials full written approval must be obtained from the Manufacturer prior to
16. dition of the brake disc It should be free of ruts and have a minimum thickness of 3 5mm Replace as necessary Inspect and check the wheel bearings for wear or damage Replace as necessary SECTION 12 TEST PROCEDURE Testing should be done with dry wheels brake pads trakrat BRAKE TEST TOOL Insert the brake test tool into the receiving holes in the disc Locating the tool over the axle to stabilise it whilst the torque wrench is attached Set the torque wrench to 65lbs ft 90Nm and apply The wheel should not rotate This test is applied to each quarter turn of the wheel Test as above Release brake rotate wheel one quarter turn and repeat torque test Test Receiving Holes Torque Wrench If the minimum torque figures are not obtained tighten the adjusting nut on the Brake Pad Tensioning Spring and re test as above To adjust release the lock nut turn the adjuster nut clockwise as viewed then retighten the lock nut Once successfully completed Fill out the form entitled Maintenance Brake Test Record and apply the New Test Date Label SECTION 13 BRAKE PAD WHEEL DISC REPLACEMENT PROCEDUR 1 Release external 19mm locknut on the tension adjuster bolt WE gt 9mm Spanner OT Ea TIGHTEN Y LOOSEN Lock Nut Spring ension uud N E D D
17. failsafe braking devices she Personal inium lapa a Proper pace for the prevailing Ensure all components are properly stacked and secured Brake failure Runaway Transport Storage Personal injury to self or others SECTION 3 KNOW YOUR trakrat LINK TROLLEY la b Ic 2a 2b Deck Polymer Deck Aluminium 750mm Deck Alluminium 150mm Bogie 750mm Bogie 1150mm Locking Hand Wheel Push Handle Brake Handle Brake Pivot Plate Trolley Coupling Cap Lifting Handle Wheel Axle Spacer Large M12 Nylok Nut Standard Disc Bogie Body Warning Light Holder Bogie Anti Skew Receptacles M12 Washer 9 19MM Nylon Washers x 2 On inside of box section LT 1500 A y gt s A e 2a US e A LT 1250 A SECTION 4 ASSEMBLING THE trakrat LINK TROLLEY Position the deck upside down on a firm level surface LT 1000 P Check that the brake test date label is valid on each bogie Position either aluminium bogie onto the deck with the brake push rod facing inward Retain the bogie in place by turning the locking hand wheel clockwise until secure Ensuring that the anti skew pins on the deck match up to the receptacles on the bogie and the bogie sits flush with the deck Check that all brakes function The braked wheel must resist attempts to rotate it with one hand Repeat for other side Roll the deck over until it is standing on its wheels
18. fies buit oa composilvehicle complies sth Me Wo Enae a sedie penile Tat operalinei Deas is areas of the London Underground system shown Kt is Ihe responsibility of the Project Manager to ensure that all subsequent production vehicles conform to the same engineering standards Title Wolfe trakrat Link Trolley Composition Tha trakrat ls a modular three part Link Troliay consisting of two bogles skate type and a trollay deck manufactured by Wolfe Designs Lid Two sizes are currently considered suitable for use on London Underground TheLT 12504 1 which has a 750mm x tB00mm deck and carles a load of 1256 kg The LT 15004 1 which has an 1105mm x 1800mm deck and carries a laad of 1500 kg The bogies for Ihe LT 15004 1 are longer to accommodate the Increased deck size The trolley is manually operated Type of operation The trakrat ls intended for use as a general purpose trolley lo carry miscellaneous materials Up to two trakrat trolleys may be coupled together Area of operation Tha trakrat may be used on LU track managed by MRSSL and or MRECV It may only travel and werk with the traction current OFF in Engineering Hours or within a Possession The following conditions apply The iraction current must be discharged before tha trolley is taken onto the track The trakrat must not be coupled lo other Link type trolleys Period of certification 30 June 2013 Attached documents to be read as part of
19. he trakrat Link Trolley during and after assembly and before each work session if there is any doubt about its condition DO NOT USE IT A competent person should remain close by whenever the equipment is being used in case of an emergency It is the responsibility of all user s to carry out a full risk assessment and ensure that a safe working environment is created and secured with safe working practices before using the trakrat Link Trolley EMERGENCY OFF TRACKING To off track in an emergency requires two people Each person should grasp the lifting handle from one side of the unit and raise so that the bogie on the other side is used to pivot the trakrat on the track Your risk assessments must include but are not limited to e Manual Handling e Safe Working Conditions e Safe Operation e Safe and Secure Transportation The trakrat Link Trolleys must only be used by authorised personnel suitably trained in their use and deployment Where needed it is the operator s responsibility to ensure all necessary Permits permissions or authorisations are in place prior to using this equipment on the infrastructure trakrat LINK TROLLEY RISK ASSESMENT PURPOSE This document is intended to provide an assessment of the hazards and risks involved to the user s of the trakrat Link Trolley This document does not replace trakrat Link Trolley user manual which is required reading for any user s whom will additionally
20. ications The unit complies with all applicable Essential Requirements of the Directive s Name A Pugh Position Director 0 Done at Leyland Document ref No On 10 October 2007 Wolfe Designs Limited 125 Clydesdale Place Moss Side Industrial Estate Leyland LANCS PR26 7QS UK Tel 44 0 1772 456191 Fax 44 0 1772 622464 www wolfedesigns co uk Directors Chris Suter Michael Ashley Anthony C L Pugh Neil C Watson Managing Director Registered in England No 4056801 30 RUD VC AT ED EIRE e DING E AR E Su EC Declaration of Content We Wolfe Designs Ltd of 125 Clydesdale Place Moss Side Industrial Estate Leyland Lancashire PR26 7QS UK AAA A VA IT ed een IN AN in accordance with the following Directive s 98 37 EC The Machinery Directive hereby declare that Equipment Trakrat Link Trolley LT 1250 A Model number DK 1250 A BY 1250 Serial Number DK 1001 to DK 3000 BY 2001 to BY 8000 is in conformity with the applicable requirements of the following documents Ref No Title Edition date BS EN ISO Safety of machinery Basic concepts general principles for design Technical 2003 AMD 12100 2 principles 14975 BS EN 13977 Railway applications Track Safety requirements for portable machines and 2005 trolleys for construction and maintenance RE STD O39 Brake system requirements category VII vehicles minimum requirements Issue B Part7 I hereby declare that the equipment n
21. ired in 150 to I in 70 4 3 Always work with sufficient personnel to perform the task at hand in 70 to I in 50 NONE 4 2 working within the guidelines for manual handling and operation of this equipment f x Lan SU to ee 6 2 You must observe 2000kg maximum load pushable by three operatives Number of persons required to push a loaded trolley as indicated in CoP0018 Code of Practice Where authorised by local instructions Theoretical figures not recommended It is recommended that no more than 3 men push a trolley DO NOT Tie off mechanically or otherwise the braking handle Use the trolley if the brake test labels are either missing or out of date Link trakrat Link Trolley with other manufacturer s link trolleys THEY ARE NOT COMPATIBLE Tow ride on motorise or exceed walking pace with trolleys Stand on trolley Overload Example where the maximum load 1000 kg per trolley eg 2000 kg over 2 trolleys 1000 kg each NOT 1500 kg on no l and 500 kg on no 2 Place hot items above 65 C crucibles welding torches etc onto Polypropylene deck PERMANENT DAMAGE WILL OCCUR Allow the load to under hang the deck it may impact the brake mechanism or the infrastructure Drag items over the edge of the deck You must only lift all items and place on to the deck Use the Trolley near live DC third rail or fourth rail Use the Trolley with insulated wheels where live overhead AC power li
22. lity of all labels QUARTERLY BRAKES Perform a complete maintenance brake test Refer to brake test inspection and replacement section of the workshop manual Inspect all linkages ensure they are free from damage and operate easily Remove all brake pads inspect for wear and contamination clean and replace as required Pads must be replaced if the brake material gap is less than mm thick Clean and lightly grease all moving components including all springs whilst re assembling the brake callipers Re fasten all fastenings and test to the appropriate torque settings Re adjust brake levers to remove any play from the system Re test using torque brake test complete the Maintenance Brake Test Record Sheet Conduct practical brake test Minimum acceptable torque figure of 90Nm 65lbs ft must be achieved If the brakes do not achieve the minimum figure replace or adjust components as required BEARINGS AXLES Examine all wheel bearings for play noise and replace if worn Check the end float on each axle does not exceed 3mm re shim with new spacer sets if required WHEELS Conduct a detailed examination of the Aluminium wheels Check for signs of excessive wear or distortion and compare dimensions against the P1 profile guage refer also to diagram on page 16 If the wheel is worn to the limits indicated on the guage or is likely to reach the max wear limit before the next scheduled inspection the wheel must be replaced
23. me Status With Link up High Street Only o E Audit National Rail ScoredEvaluation No NA Underground Scored Evaluation N A N A 83183 20212 68382 20212 19 February 2010 1703 1007 SMP Trackside Lighting Temporary amp Permanent SMP With Link up High Street Only u Audit E National Rail Registered No N A nd Registered mtd N A N A e 83183 20212 68382 20212 19 February 2010 Undergrou nd 29 HESS IN SDR IR ERS il N ON eun E We Wolfe Designs Ltd of 125 Clydesdale Place Moss Side Industrial Estate Leyland Lancashire PR26 7QS UK in accordance with the following Directive s 98 37 EC The Machinery Directive hereby declare that Equipment Trakrat Link Trolley LT 1000 P Model number DK 1000 P BY 1000 Serial Number DK 8001 to DK 9000 BY 2001 to BY 8000 is in conformity with the applicable requirements of the following documents Ref No Title Edition date BSENISO Safety of machinery Basic concepts general principles for design Technical 2003 AMD 12100 2 principles 14975 BS EN 13977 Railway applications Track Safety requirements for portable machines and 2005 trolleys for construction and maintenance RE STD 039 Brake system requirements category VII vehicles minimum requirements Issue B Part7 I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specif
24. nes are present Link more than 2 trolleys together SECTION 6 f CLEANING AND GENERAL CARE Observe local regulations Operate within Manual Handling Regulations Adherence to guidelines All maintenance inspection procedures must be carried out within the guidelines set out in Rail Industry Standards for Portable and Transportable Plant Used for Infrastructure Work as well as those criteria mandated by CoP0018 Code of Practice for Rail mounted Manually propelled Equipment Axles wheels and brakes are defined under CoP0018 as Railway Safety Critical and must be maintained in accordance with the guidelines laid out in CoP0018 Maintenance Elements of Small Plant and Equipment GENERAL GUIDELINES Always adhere to the maintenance schedule as detailed below Use only original trakrat Link Trolley replacement components Only trained competent staff should complete all work Re cycle used components where possible DAILY Inspect all components for damage or abnormal wear Check integrity of deck sub frame fastenings Check integrity of all bogie fastenings Check security of axle retaining pins Check Maintenance Brake Test Label is in date for each bogie Test the operation of all brakes by turning each braked wheel with one hand the wheel must resist attempts to rotate it WEEKLY Carry out the daily inspections as above plus Inspect all wheels for wear damage Operate and inspect brake linkage tubes Check legibi
25. number deck LT1250A TRA 021 trakrat serial number deck LT1500A TRA 031 trakrat serial number bogie LT1000P LT1250A TRA 032 trakrat serial number bogie LT1000P LT1250A INSULATED TRA 041 trakrat serial number bogie LT1500A TRA 042 trakrat serial number bogie LT1500A INSULATED TRA 052 trakrat model label LT1250A TRA 055 trakrat model label LT1500A TRA 062 trakrat weight label LT1250A TRA 065 trakrat weight label LT1500A TRA 071 trakrat SWL1000Kg TRA 073 trakrat SWL1500Kg TRA 081 trakrat brake release arrow left Max 2 trolleys linked TRA 082 trakrat brake release arrow right Max 2 trolleys linked TRA 091 trakrat lifting point 4 Man lift when assembled TRA 101 trakrat next brake test TRA 111 trakrat bogie inside arrow TRA 121 trakrat insulated TRA 141 trakrat Underground Only Note that labels TRA 121 TRA 140 TRA 141 relate to UK Network Rail or London Underground LUL In all cases Insulated refers to the bogie having insulated wheels serial Numbers are etched onto bogies and decks subject to customer requirements 24 Network Certificate of Acceptance Certificate No PA05 03291 Issue 1 Date 01 07 2008 Effective date 01 07 2008 Trakrat Modular Rail Link Trolleys Manufacturer Wolfe Designs Ltd 125 Clydesdale Place Moss Side Industrial Estate Leyland Lancs PR26 7QS 25 METRONET RAIL LIMITED CERTIFICATE OF TECHNICAL pageioft CONFORMANCE FOR ROLLING STOCK 2 COnstii i Kt certi
26. or model Place 2 trakrat Link Trolleys in tandem on the track ensuring that the brake release direction arrows point in the same direction on each unit Gently bring them together until the brake pivot plates make contact Slide the pivot connecting cap over the two brake pivot plates and double check that they are locked together Note that you can link an LT 1250 A with an LT 1500 A Activate the brake pivot handle and ensure that all brakes are releasing properly SECTION 5 E OPERATING THE TRAKRAT LINK TROLLEY The trakrat Link Trolley is fitted with two disc brakes one either side which remain engaged under normal operation When moving the trakrat Link Trolley the brake mechanism must be manually released To release the brakes move the brake lever in the direction of the ARROW Label and hold in position As soon as you release the lever the brakes will re engage Should the brakes fail to re engage the trakrat Link Trolley must be removed from service immediately Note the brake lever only moves in the direction of the arrow Align direction arrows when linking trolleys IN USE CAUTIONS AND LIMITATIONS Be aware at all times of conditions underfoot never walk on the railhead or sleepers Conditions underfoot will change immediately if wet or icy Up to in 250 Gradients load ice and wet conditions will all affect the braking distances in 250 to I in 150 3 2 ot and braking effort requ
27. require training to perform the safe deployment and use of this machine in accordance with BSEN 13977 2005 E TASK Deployment Use of the trakrat Link Trolley GENERAL SAFETY Operatives must be fully trained in all aspects of the trakrat Link Trolley including Assembly lifting use maintenance personal protection equipment Prior to use Consult the manual Confirm brake test labels are within date each bogie has an independant brake test label Ensure correct assembly Note that bogie trolleys labelled for use on LUL London Underground must NOT be used on Network Rail Bogie trolleys labelled Network Rail must NOT be used on LUL London Underground Incorrect assembly Personal injury Check correct assembly Minimum 3 man lift or 4 man lift for the Lifting assembled trolley Personal injury LT1500A Where possible remove bogies and lift components seperately Personal injury to self or others Ensure safe and proper access p ini If h Ensure conditions underfoot are viable Dropping ersonal injury to self or others and min 3 man lifts 4 man lift for LT1500A Personal injury and damage to the trolley Overloading Uneven Loading Observe load limits Exercise caution and never allow overhanging loads to under hang the deck Injury to self and others plus damage to Overhanging loads sms the infrastructure Injury to self and others plus damage to Check and maintain the brakes infrastructure Never tie off
28. vehicles minimum requirements Issue B Part7 I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications The unit complies with all applicable Essential Requirements of the Directive s Name A Pugh Position Director 0 Done at Leyland Document ref No On 10 October 2007 Wolfe Designs Limited 125 Clydesdale Place Moss Side Industrial Estate Leyland LANCS PR26 7QS UK Tel 44 0 1772 456191 Fax 44 0 1772 622464 www wolfedesigns co uk Directors Chris Suter Michael Ashley Anthony C L Pugh Neil C Watson Managing Director Registered in England No 4056801 32 25 Clydesdale Place Mass Side Industrial Estate Leyland Lancashire England PR26 705 44 0 1772 456191 44 0 1772 622464 fax www trakrat com Emails General sales trakrat com sales Director chris trakrat com Managing Director neil trakrat com Feedback david trakrat com Instruction Manual EN 1238 IM en Revision Version 1 March 2010 2009 Proofed by M Ashley and D deSouza Kirby Wolfe Designs Ltd Text artwork and layout by Textwrite Publications Ltd http textwritepuhlications co uk Ammended by D deSouza Kirby Wolfe Designs Lid Please be advised that the contents of this document remain the property of the company and are only released on the basis of assisting clients of the company maintain their fleets The contents must not be used
29. wheels Torque figures for braked wheel Recommended Minimum Brake Test Setting 65Ibs ft 90Nm Before Adjustment After Adjustment Quadrant 1 forward Quadrant 4 forward Quadrant 1 reverse RN pi AAA I maw EEE AA BOGIE ID No NEXT BRAKE TEST DATE P1 PROFILE RAIL WHEEL 26387 238 67 225 81 252 56 SECTION A A SEALEI 253 l6 Labelling We are able to label bogies and or trolley decks with a variety of labels In general however we are indicating what are accepted within the UK Rail networks Whether that be overground which genrerally comes under the duresdiction of Network Rail or underground which generally applies to London underground or LUL When ordering outside the UK please specify the labelling you require if they differ from those shown on these pages BOGIE LABEL SET Dimensions Quantity Per Bogie 120mm x 35mm trakrat LINK TROLLEY LT xxxxx BOGIE SERIAL No BY XXX MANUFACTURER WOL FE DESIGNS L COUNTRY OF ORIGIN UK PR26 70S COMP ONENT WEIGHT 20K SUNSET RACK 2 P SONS M NUAL LINK TROLLE NOT TO BE USED 60mm X 38mm Model type and details depend upon whether LT1000P LT1250A or LT1500 60mm x 25mm Only used on live 61mm x 21mm rail bogies Use on London 109mm x 21mm Underground Only Use on Network Rail 174mm x 21mm Only SWL Figure Dependent 213 x 30 mm on bogie deck Note SWL
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