Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
&
MAINTENANCE
MANUAL
TRACK PRESS TP-400*
CLIENT :
1
Manufactured by :
CONTENTS
SL. NO.
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------
01
02
Consumables
19
03
20
04
List of Annexure
05
Annexure I to XII
Type
Model
TP 400
Capacity
System Pressure
Ram Diameter
300 mm
2,200/min.
- Press
390 mm/min.
- Return
3,770 mm/min.
Connected Load
15x2 kW/20x2 HP
Mains Supply
2,850 mm
Height
1850 mm
Depth
900 mm
Weight
2,435 mm
12,260 mm
7,500 kg (approx.)
LEFT RAM
ANVIL
RIGHT RAM
BASE
CONTROL PENDANT
DIRECTIONAL VALVE
-LEFT RAM
FOUNDATION
POCKETS (4 NOS.)
FOOT SWITCH
PRESSURE REGULATING
VALVE
DIRECTIONAL VALVE
-RIGHT RAM
LOADING VALVE
PRESSURE (BAR)
50
62.8 / 616.8
75
93.8 / 919.8
100
125.6 / 1231.6
125
157.0 / 1539.5
150
188.4 / 1847.5
175
219.8 / 2155.4
200
251.2 / 2463.3
225
282.6 / 2771.2
250
314.0 / 3079.1
275
345.4 / 3387.0
280
351.7 / 3448.8
The Hydraulic Power Pack is placed behind the Track Press on the right. It is can be placed
on a concrete floor or can be placed on four rubberized pads provided with the machine. The
power pack is connected to the machine with hydraulic hoses. The hydraulic system is as per
Drg. No.SA-260-11-000. The tank capacity is about 750 lit. Hydraulic oil Servo-System 68 or
equivalent grade oil can be used.
ELECTRIC JUNCTION BOX
ELECTRIC MOTOR-1
ELECTRIC MOTOR-2
HEAT EXCHANGER
MANHOLE COVER
OIL TANK
LOW PRESSURE
RELIEF VALVE
CHECK VALVE
ELECTRIC PANEL
PRESSURE GAUGE
(LOW PRESSURE)
ELECTRIC MOTOR-2
HIGH PRESSURE
RELIEF VALVE
ELECTRIC MOTOR-1
LOW PRESSURE
RELIEF VALVE
LOW PRESSURE
RELIEF VALVE
HIGH PRESSURE
RELIEF VALVE
ELECTRIC MOTOR-1
The Hydraulic Power Pack is provided with a heat-exchanger to cool the hydraulic oil. The
heat-exchanger has to be connected to a water supply of about 200 lpm for cooling.
Two pumps, one a high pressure radial piston pump and the other a low pressure gear pump
are co-axially mounted and are driven by an electric motor. There are two such sets in the
hydraulic system. The low pressure is set to 30 bar. This pressure need not be changed. The
high pressure can be set from 75 bar to 280 bar (max), depending upon the requirement.
Two motors along with set of pumps are provided. For normal operation only one motor can
be used. This will save power, but the ram speeds will be slower.
ELECTRIC PANEL
The electric Panel is placed in front of the Track Press on the right side. The supply voltage
required is 380 V, 50 Hz, 3 Phase AC. The control voltage is 24 V DC. An Electric Control
Pendant is provided on the right of the machine for operating the Track Press.
CONSUMABLES
(ii)
10
OPTIONAL EQUIPMENT
The following optional equipments make the manufacturing process easier.
#
Roller Conveyor
#
Hydraulic Wrench
TRACK LINK
ROLLERS
PLUMBER BLOCKS
TECHNICAL SPECIFICATION
Drive
11
Speed
4,250 mm/min.
Power
2.25 kW
Weight
2,275 kg
TABLE
TRACK LINK
TRACK PRESS
KNIFE
ROLLER CONVEYOR
ROLLERS
PLUMBER BLOCKS
TECHNICAL SPECIFICATION
Lifting/Pushing/Pulling Force
29 kN
Referencing Speed
4,250 mm/min.
Weight
735 kg
12
OPERATION SEQUENCE
The chain indexing works with utmost ease. The indexing operation is obtained with the help
of a FOOT SWITCH and a JOYSTICK and the following actuators.
1 Table Lifting/Lowering Cylinder (Foot Switch)
2 Knife Lifting/Lowering Cylinder (Joystick)
3 Knife Forward/Reversing Cylinder (Joystick)
The Knife is kept in the forward (towards the Anvil) and lowered position for assembly of the
track chain. For disassembly, the knife is kept in the backward (away from the Anvil) and
lowered position. For taking the track chain forward or reverse, the Table is lifted up by the
Foot Switch. Keeping the Foot Switch pressed, the Knife is taken up by operating the
Joystick. With the knife in the ,up, position the track chain is brought forward or backward
with the same Joystick.
7000 Nm
Wrench RPM
10-150
Power
5.6 kW
1020 mm
325 mm
Machine Weight
850 kg
950 mm
Height
Depth
1060 mm
13
PRESSURE (BAR)
TORQUE (NM)
50
2258
75
3386
100
4516
125
5645
150
6774
155
7000
HYDRAULIC SYSTEM
ELECTRIC PANEL
PRESSURE CONTROL
VALVE
TORQUE WRENCH
TROLLEY
OPERATING HANDLE
SPINDLE
WITH PUSH BUTTON
HOUSING
HYDRO-MOTOR
TRACK CHAIN
SUPPORT/GUIDE
TORQUE WRENCH
SPINDLE
TRACK ROLLERS
14
9000 Nm
Wrench RPM
8-125
Power
7.5 kW
1200 mm
375 mm
Machine Weight
1,250 kg
950 mm
Height
Depth
1000 mm
PRESSURE (BAR)
TORQUE (NM)
50
2711
75
4466
100
5422
125
6777
150
8133
166
9000
15
HYDRAULIC SYSTEM
ELECTRIC PANEL
OPERATING HANDLE
WITH PUSH BUTTON
PRESSURE CONTROL
VALVE
TORQUE WRENCH
TROLLEY
TRACK CHAIN
SUPPORT/GUIDE
SPINDLE
HOUSING
HYDRO-MOTOR
TORQUE WRENCH
SPINDLE
TRACK ROLLERS
16
The CW-850 Track Chain Winder is used for winding and un-winding of tracks. It is generally
placed in line with the Roller Conveyor for winding the track after assembly or for spreading
the track on the Roller Conveyor for disassembly of the track.
MAIN SPINDLE
ELECTRIC
PANEL
DUPLEX
GEAR BOX
ELECTRIC
MOTOR
TECHNICAL SPECIFICATION
Torque
8500 Nm
Spindle RPM
1600 mm
6000 kg
1460 mm
17
Machine Weight
1550 kg
2600 mm
Height
1900 mm
Depth
1250 mm
3.75 kW
Power
TOOLING
The TP-400 Track Press is equipped with very heavy duty tooling, designed to last for
several years of continuous work. The tooling comprises of the following.
1 Base
2 Anvil
3 Disassembly Tool
4 Assembly Tooling
The machine is fitted with a common Base, which is common for all models of track chains,
irrespective of the size and model of the track chain. It is securely tightened to the track press
table.
A TYPICAL ANVIL
12 OR 14 MOUNTING HOLES
TAPPED HOLE FOR EYE BOLT
18
DISASSEMBLY TOOLING
ASSEMBLY TOOLING
19
20
TRACK PRESS
(REAR SIDE)
CONVEYOR - 1
For the convenience of shipment, one Roller Conveyor (with chain and sprocket drive) is
placed over another Roller Conveyor (non-driven conveyor). These have to be placed in line
with the Conveyor - 1, matching the markings on the conveyors (like B-B, C-C and D-D). All
the conveyors are locked to one another with locking plates. The conveyors are to be
mounted on leveling pads supplied with the machine.
21
LEVELING SCREW
MATCH MARKINGS
RUBBER FOOT
LOCK NUT
SPACER
The Hydraulic Torque Wrench can be rolled on the Roller Conveyor. For shipment the torque
wrench is welded to one of the conveyor. This welding has to be removed.
HYDRAULIC TORQUE
WRENCH
CONVEYOR
Connect the Electric Panel, Control Pendant and the Hydraulic Power Pack motor with the
respective connectors provided. Connection to the geared motor of the Roller Conveyor is
also provided through cable connectors. All the cable connectors are to be connected as per
their sizes. These are not interchangeable and it is not possible to make mistake during
connecting.
The Hydraulic Torque Wrench however has to be given independent power supply.
22
Give mains supply to the Electric Panel and ground the Electric Panel, the Track Press,
the four Conveyors and the Hydraulic Power Pack.
ELECTRIC PANEL/JUNCTION BOX
CONNECTOR TOP
CONNECTOR BASE
ELECTRIC
MOTORS
HYDRAULIC
POWER PACK
CONNECTOR TOP
CONNECTOR BASE
TRACK PRESS
CONVEYOR
ELECTRIC PANEL
23
The Hydraulic Torque Wrench in placed on the Conveyor No. 3. To accommodate in the
container, the hydro-motor is removed from the gearbox during dispatch. The hydro-motor
has to be assembled on the top of the gearbox and the three seamless tube connections
have to be made. The open end of the 12 mm tube connection has to go to the hydraulic tank
of the power-pack. This is the drain line for the hydro-motor. The other connections are for
the forward/ reverse rotation of the hydro-motor.
PLANETARY
GEAR BOX
HYDRAULIC TORQUE
WRENCH
HYDRO-MOTOR REMOVED
FOR SHIPMENT TO BE MOUNTED BACK
DURING INSTALLATION
ELECTRIC PANEL
For shipment, rotating head of the hydro-motor is locked with wooden packing, which has to
be removed during installation. Connect the power cable to a 380 V, 50 Hz, 3 Phase supply.
24
NOTE : After all the machines are positioned, it is desirable that the cable connecters
are properly locked so that the tops of the connectors do not by chance come out of
sockets/vibrations. This is very important for safety.
It is desirable that Track Press, Hydraulic Power Pack, Roller Conveyor, etc are are
properly earthed for safety. Similarly, all electric motors have also to be earthed.
.
25
CONVEYOR FRAME
The RC-400 Roller Conveyor is designed to operate with the TP-400 Double Ram Track
Press. It comprises of a set of drive rollers mounted on heavy duty plumber blocks. The drive
26
rollers are driven by a motorized gear box. Chain and sprocket drive is used to drive the
rollers. The rollers are made of low alloy steel. They are hardened to give long life.
CONVEYOR
USE A SCALE TO
LEVEL THE RAIL/TRACK
The Chain Indexing Device is mounted on the first conveyor, nearest to the Track Press. All
the four conveyors are mounted on rubberized leveling pads, on to the concrete floor. They
have to be leveled so that all the rails/track on which the Hydraulic Torque Wrench move are
in the same level and parallel to the Track Press Anvil/Base.
27
CONVEYOR
(NO. 1)
SWIVEL
JOINT
INCLINABLE
DRIVE ROLLERS
INDEXING DEVICE
VALVE BANK
KNIFE
28
KNIFE
TRACK PRESS
HYDRAULIC PIPE
LINES FOR LEFT RAM
The unit comprises of (i) Table, (ii) Table Lift Cylinder, (iii) Knife Traverse Cylinder and (iv)
Knife Lift Cylinder.
TABLE
CHAIN GUIDE
TRACK PRESS
(RIGHT RAM)
DISASSEMBLY
TOOLING
29
CHAIN SUPPORTS
CHAIN GUIDES
CONVEYOR (NO. 1)
TABLE
For disassembly, the track chain is placed on the Roller Conveyor. It is brought forward
towards the Indexing Table by driving the Rollers with the Push Button on the Control
Pendant placed in front of the Track Press. With the chain on the Indexing Table, it is placed
on the Anvil by operating the Joystick located in the Control Pendant.
For assembly, the two links are placed on the assembly tooling. The pin and bush to be
assembled are placed on the Anvil. After assembly, the assembled chain is retracted back by
the Indexing Device, for the next set of links, pin and bush to be assembled.
Refer to Machine Operation and Setting for complete details.
30
The TW-700/TW-900 Hydraulic Torque Wrench is designed for the removal and tightening of
grouser bolts that fasten the shoes to the track. The torque can be selected as requires. The
Hydraulic Torque Wrench travels on the Roller Conveyor. Eight rollers are provided for
smooth and easy movement of the wrench. It is important to level the conveyor for easy
travel of the Torque Wrench.
The wrench comprises of (i) an independent Hydraulic Power Pack having two pumps, one
high volume low pressure gear pump and one high pressure radial piston pump. (ii) hightorque hydraulic motor, (iii) in-line planetary gear box, (iv) main spindle with replaceable
sockets and (v) electric panel. A hand lever is provided for lowering and lifting the socket.
The hand lever is provided with a push button for rotating the main spindle.
Fill hydraulic oil up to the top most level of the oil level indicator.
Power supply to the Torque Wrench has to be given separately. Check the direction of
rotation of the electric motor after connecting power. The direction of rotation is marked on
the motor.
Different sockets are used as per the size of the bolts. The socket is locked to the spindle
with a M16 bolt.
31
The Track Chain Winder IS placed behind the Roller Conveyor. The spindle has to be
centrally placed in line with the Roller Conveyor. It is recommended to grout the machine with
M 20 foundation bolts.
Separate power supply has to be given to the machine. Check the direction of rotation of the
electric motor by pressing the FORWARD and REVERSE push buttons.
The spindle is provided with spacers. The gap has to be set as per the size/width of the track
chain, keeping sufficient clearance.
32
ANNEXURE I
ELECTRIC CIRCUIT
TRACK PRESS TP-400
33
34
35
36
ELECTRIC CIRCUIT
HYDRAULIC TORQUE WRENCH
TW-700/TW-900,
37
38
ELECTRIC CIRCUIT
TRACK CHAIN WINDER
CW-850
39
ANNEXURE II
HYDRAULIC CIRCUIT
TRACK PRESS TP-400
40
&
CHAIN INDEXING DEVICE RD-400
41
HYDRAULIC CIRCUITS
TW-700/TW-900
42
43
SETTING
The Double Ram Track Press TP-400 is operated in semi-automatic cycles. Two electric
motors are provided. The track press can be run using the two motors or only one motor can
be used. With two motors the ram speeds become two times A selector switch is provided to
run one motor or both the motors. For normal operation, only one motor need to be run.
Machine operation is simple. Some practice will make the operation easy and safe.
The hydraulic system low pressure is set to 30 to 35 bar at SIMPLETEC works. This
pressure should not be reduced or increased.
The chart given in page-6 shows the pressing force obtained for the corresponding oil
pressure (high) pressure. The maximum high pressure allowed is 280 bar. This
pressure must never be crossed. The high pressure can be seen during pressing on
the pressure gauge provided on the top of the machine on the right side. One pressure
ANVIL
TOOLING
CONTROL
PENDANT
44
HIGH PRESSURE
REGULATING VALVE
LOADING
VALVE
FOOT
SWITCH
LEFT RAM
DIRECTIONAL
VALVE
RIGHT RAM
DIRECTIONAL
VALVE
gauge is provided to indicate the pressure. The high pressure relief cum unloading
valve is placed on the top of the Power Pack. This is set once for all and need not be
disturbed. As per the requirement, the high pressure can be set by the pressure
regulating valve placed in front of the machine on the right side.
DISASSEMBLY
To disassemble the track chain, place the track chain on the Roller Conveyor. Bring
the chain forward towards the Anvil by the pressing the push button to operate the the
Roller Conveyor. After the the chain has reached the Indexing Table, lift the Indexing
Table by pressing the Foot Switch. Keeping the Foot Switch pressed, lift the Knife by
the Joystick and bring the chain over the anvil by bringing the Knife forward by
operating the (same) Joystick. Lower the Table by releasing the Foot Switch, so that
the chain is placed in the Anvil.
FORWARD/REVERSE
PUSH BUTTONS FOR
45
ROLLER CONVEYOR
JOYSTICK FOR
INDEXING
DEVICE
EMM OFF
PUSH BUTTON
Use the correct tooling for the track chain being dismantled.
Select the correct position of the manual directional valve for the left and the right
rams. For disassembly, while left ram moves forward, the right ram is stationary and
while the right moves forward, the left ram is stationary.
Bring the left forward by pressing the lever of the Loading Valve. Normally both the low
pressure and the high pressure pumps are in unloaded condition. By pressing the
Loading Valve, the limit switch attached to this valve is actuated. Oil flow of two the
pumps are now directed to the left cylinder. The ram moves forward and the tool touch
the chain. The oil pressure builds up and actuates a pressure switch, which unloads
the low pressure pump. The ram speed drops and the tool push the pin and the bush
out from the left side link and this link can be removed. Similarly the right link is also
removed.
The Indexing Table is again lifted up along with the chain and the cycle is repeated till
the entire chain is dismantled.
46
ASSEMBLY
For assembly of the chain, the links are mounted on the assembly tooling. Select the
correct tooling and Anvil for the particular chain size/model.
ANVIL
PIN/BUSH PLACED ON
ANVIL FOR ASSEMBLY
Assembly operation is just the opposite the disassembly operation. The links have to
be placed on the respective assembly tooling. The pin and the bush are placed on the
anvil. Select the correct positions of the left and right directional valves, so that when
the Loading Valve is pressed both the rams move forward.
47