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OPERATION & MAINTENANCE MANUAL TRACK PRESS TP-400* * NEW MODEL NO. TP-350 CLIENT : 1
OPERATION & MAINTENANCE MANUAL TRACK PRESS TP-400* * NEW MODEL NO. TP-350 CLIENT : 1

OPERATION

&

MAINTENANCE MANUAL TRACK PRESS TP-400*

* NEW MODEL NO. TP-350

CLIENT :

1

M/s Bacian y Rocha Ltda. Av. Las Parcelas Manzana D, Sitio 7, Alto Hospicio, Tarapaca,
M/s Bacian y Rocha Ltda. Av. Las Parcelas Manzana D, Sitio 7, Alto Hospicio, Tarapaca,

M/s Bacian y Rocha Ltda. Av. Las Parcelas Manzana D, Sitio 7, Alto Hospicio, Tarapaca, Chile

Manufactured by :

SIMPLETEC AUTOMATICS PVT. LTD.

UNIT I -A-4, R. I. C. Block 1, Bonhooghly Industrial Estate, Kolkata 700 108, India. Tel : 91 33 25776438, Fax : 91 33 25789237, E-mail : info@simpletec.org UNIT II Navaron, P.O. : Surjapur, North 24 Pargnas, Kolkata 700 121, India. Tel : 91 33 65005594, E-mail : sales@simpletec.org Web : www.simpletecautomatics.com, www.simpletectrackpress.com, www.simpletec.co,

CONTENTS

2

SL. NO. DESCRIPTION PAGE NO.

SL. NO.

DESCRIPTION

SL. NO. DESCRIPTION PAGE NO.

PAGE NO.

-------------------------------------------------------------------------------------------------------------------------------

01 TP-400 Double Ram Track Press

4

02 Consumables

19

03 Machine Installation and Startup

20

04 List of Annexure

1

05 Annexure I to XII

1

3

TP-400 HYDRAULIC TRACK PRESS (NEW MODEL NO. TP-350) TECHNICAL SPECIFICATION Type : Double Ram Track
TP-400 HYDRAULIC TRACK PRESS (NEW MODEL NO. TP-350) TECHNICAL SPECIFICATION Type : Double Ram Track

TP-400 HYDRAULIC TRACK PRESS

(NEW MODEL NO. TP-350)

TECHNICAL SPECIFICATION

Type

:

Double Ram Track Press

Model

:

TP 400

Capacity

 

:

3,432 kN/350T (each ram)

System Pressure

:

28.5 MPa (285 bar)

Ram Diameter

:

300 mm

Ram

Speeds - Rapid

Forward

:

2,200/min.

- Press

:

390 mm/min.

- Return

:

3,770 mm/min.

Connected Load

 

:

15x2 kW/20x2 HP

Mains Supply

:

380 V, 50 Hz, 3 Phase AC

Machine Dimensions Length

:

2,850 mm

 

Height

:

1850 mm

Depth

:

900 mm

Depth with Indexing Unit:

2,435 mm

Depth with Conveyor

:

12,260 mm

Weight

:

7,500 kg (approx.)

4

LEFT RAM ANVIL RIGHT RAM BASE CONTROL PENDANT DIRECTIONAL VALVE -LEFT RAM PRESSURE REGULATING VALVE

LEFT RAM

ANVIL

LEFT RAM ANVIL RIGHT RAM BASE CONTROL PENDANT DIRECTIONAL VALVE -LEFT RAM PRESSURE REGULATING VALVE DIRECTIONAL
RIGHT RAM BASE CONTROL PENDANT DIRECTIONAL VALVE -LEFT RAM PRESSURE REGULATING VALVE DIRECTIONAL VALVE -RIGHT
RIGHT RAM
BASE
CONTROL PENDANT
DIRECTIONAL VALVE
-LEFT RAM
PRESSURE REGULATING
VALVE
DIRECTIONAL VALVE
-RIGHT RAM
FOUNDATION
POCKETS (4 NOS.)
FOOT SWITCH
LOADING VALVE

DOUBLE RAM TRACK PRESS TP-400

5

TP-400 : PRESSURE TO FORCE RELATION PRESSURE (BAR) PRESSING FORCE (T / KN) 50 62.8
TP-400 : PRESSURE TO FORCE RELATION PRESSURE (BAR) PRESSING FORCE (T / KN) 50 62.8

TP-400 : PRESSURE TO FORCE RELATION

PRESSURE (BAR)

PRESSING FORCE (T / KN)

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

6

HYDRAULIC POWER PACK The Hydraulic Power Pack is placed behind the Track Press on the

HYDRAULIC POWER PACK

HYDRAULIC POWER PACK The Hydraulic Power Pack is placed behind the Track Press on the right.

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 HEAT EXCHANGER ELECTRIC MOTOR-1 ELECTRIC MOTOR-2
ELECTRIC JUNCTION BOX
HEAT EXCHANGER
ELECTRIC MOTOR-1
ELECTRIC MOTOR-2

OIL LEVEL INDICATOR

MANHOLE COVER

OIL TANK

7

VALVE BANK FOR CHAIN INDEXING UNIT LOW PRESSURE RELIEF VALVE CHECK VALVE PRESSURE GAUGE (LOW
VALVE BANK FOR CHAIN INDEXING UNIT LOW PRESSURE RELIEF VALVE CHECK VALVE PRESSURE GAUGE (LOW

VALVE BANK FOR CHAIN INDEXING UNIT

LOW PRESSURE

RELIEF VALVE
RELIEF VALVE

CHECK VALVE

PRESSURE GAUGE

(LOW PRESSURE)

ELECTRIC PANEL

ELECTRIC MOTOR-2

ELECTRIC MOTOR-1

PRESSURE) ELECTRIC PANEL ELECTRIC MOTOR-2 ELECTRIC MOTOR-1 BREATHER/OIL FILLING CAP HIGH PRESSURE LOW PRESSURE

BREATHER/OIL FILLING CAP

HIGH PRESSURE

LOW PRESSURE

RELIEF VALVE

RELIEF VALVE

8

LOW PRESSURE HIGH PRESSURE ELECTRIC MOTOR-1 RELIEF VALVE RELIEF VALVE The Hydraulic Power Pack is

LOW PRESSURE

HIGH PRESSURE

LOW PRESSURE HIGH PRESSURE ELECTRIC MOTOR-1 RELIEF VALVE RELIEF VALVE The Hydraulic Power Pack is provided

ELECTRIC MOTOR-1

RELIEF VALVE RELIEF VALVE
RELIEF VALVE
RELIEF VALVE

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.
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.

9

CONSUMABLES The main consumables are : (i) Hydraulic Oil ‘Servo - system 68’ (or equivalent)

CONSUMABLES

The main consumables are :

CONSUMABLES The main consumables are : (i) Hydraulic Oil ‘Servo - system 68’ (or equivalent) for

(i)

Hydraulic Oil ‘Servo-system 68’ (or equivalent) for the hydraulic systems.

(ii)

SAE 40 (or equivalent) for the gear boxes.

10

OPTIONAL EQUIPMENT The following optional equipments make the manufacturing process easier. # Roller Conveyor #
OPTIONAL EQUIPMENT The following optional equipments make the manufacturing process easier. # Roller Conveyor #

OPTIONAL EQUIPMENT

The following optional equipments make the manufacturing process easier.

# Roller Conveyor

# Chain Indexing Device

# Hydraulic Wrench

# Track Chain Winder

RC-400 ROLLER CONVEYOR

For the convenience of transportation/shipment, the Roller Conveyor is made in four parts,

which are connected to the track press during installation/commissioning. Several rollers are

provided, driven by chain and sprocket dive. The rollers are rotated in both the directions to

move the chain forward (away from the track press during assembly) and towards the track

press for disassembly. The Hydraulic Torque Wrench moves on the Roller Conveyor Stand.

The chain under assembly or disassembly is moved forward or backward in sequence with

the Chain Positioning/Referencing Device.

TRACK FOR HYD. TORQUE WRENCH

TRACK LINK

Device. TRACK FOR HYD. TORQUE WRENCH TRACK LINK CHAIN & SPROCKET DRIVE TECHNICAL SPECIFICATION Drive

CHAIN & SPROCKET DRIVE

TECHNICAL SPECIFICATION

Drive

ROLLERS

:

PLUMBER BLOCKS

Intermittent Chain-Sprocket Drive

11

Speed : 4,250 mm/min. Power : 2.25 kW Weight : 2,275 kg RD-400 CHAIN INDEXING
Speed : 4,250 mm/min. Power : 2.25 kW Weight : 2,275 kg RD-400 CHAIN INDEXING

Speed

:

4,250 mm/min.

Power

:

2.25 kW

Weight

:

2,275 kg

RD-400 CHAIN INDEXING DEVICE

The chain is automatically moved away from the anvil or towards the anvil by the Chain Indexing Device. The forward or retracting stroke is obtained with the help of a joystick, as per the pitch of the track chain. During assembly or disassembly, the chain is lifted from the anvil by hydraulic actuators moved forward or backward by another hydraulic actuator. The device works with clock-work precision in synchronization with the ram travel.

LEFT RAM TRACK PRESS RIGHT RAM ROLLER CONVEYOR TABLE TRACK LINK KNIFE ROLLERS
LEFT RAM
TRACK PRESS
RIGHT RAM
ROLLER CONVEYOR
TABLE
TRACK LINK
KNIFE
ROLLERS

PLUMBER BLOCKS

TECHNICAL SPECIFICATION

TRACK FOR HYD. TORQUE WRENCH

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

OPERATION SEQUENCE

OPERATION SEQUENCE The chain indexing works with utmost ease. The indexing operation is obtained with the

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.

TW-700 HYDRAULIC TORQUE WRENCH

The TW-700 Hydraulic Torque Wrench is designed for the removal and screwing of grouser

bolts that fasten the shoes to the track. The torque can be selected as required. The

Hydraulic Torque Wrench travels on the Roller Conveyor.

TECHNICAL SPECIFICATION

Torque

:

7000 Nm

Wrench RPM

:

10-150

Power

:

5.6 kW

Max. Chain Width with Shoes

:

1020 mm

Max. Chain Height with Shoes

:

325 mm

Machine Weight

:

850 kg

Machine Dimensions Length

:

950 mm

Height

:

1660 mm (above Roller Conveyor)

Depth

:

1060 mm

13

TW-700 : PRESSURE TO TORQUE RELATION PRESSURE (BAR) TORQUE (NM) 50 2258 75 3386 100
TW-700 : PRESSURE TO TORQUE RELATION PRESSURE (BAR) TORQUE (NM) 50 2258 75 3386 100

TW-700 : PRESSURE TO TORQUE RELATION

PRESSURE (BAR)

TORQUE (NM)

50

2258

75

3386

100

4516

125

5645

150

6774

155

7000

SPINDLE HYDRAULIC SYSTEM ELECTRIC PANEL OPERATING HANDLE WITH PUSH BUTTON HYDRO-MOTOR HOUSING TORQUE WRENCH
SPINDLE
HYDRAULIC SYSTEM
ELECTRIC PANEL
OPERATING HANDLE
WITH PUSH BUTTON
HYDRO-MOTOR
HOUSING
TORQUE WRENCH
SPINDLE
PRESSURE CONTROL
VALVE

TORQUE WRENCH TROLLEY

TRACK CHAIN

SUPPORT/GUIDE

TRACK

ROLLERS

14

TW-900 HYDRAULIC TORQUE WRENCH SIMPLETEC Hydraulic Torque Wrench TW-700 having maximum torque of 7000 Nm,

TW-900 HYDRAULIC TORQUE WRENCH

TW-900 HYDRAULIC TORQUE WRENCH SIMPLETEC Hydraulic Torque Wrench TW-700 having maximum torque of 7000 Nm, is

SIMPLETEC Hydraulic Torque Wrench TW-700 having maximum torque of 7000 Nm, is

more than adequate for the removal and tightening of shoe bolts of most of the small,

medium, medium and large sizes of Track Chains. However, for very large size track chains,

especially where the bolts are very badly damaged or even welder during the field

operations, Hydraulic Torque TW-900 is recommended. The wrench has two speeds, one for

low speed and high torque for the initial removal or final tightening of the bolts and high

speed and low torque for quick removal of the bolt or initial screwing of the bolt during

tightening.

TECHNICAL SPECIFICATION

Torque

:

9000 Nm

Wrench RPM

:

8-125

Power

:

7.5 kW

Max. Chain Width with Shoes

:

1200 mm

Max. Chain Height with Shoes

:

375 mm

Machine Weight

:

1,250 kg

Machine Dimensions Length

:

950 mm

Height

:

1760 mm (above Roller Conveyor)

Depth

:

1000 mm

TW-900 : PRESSURE TO TORQUE RELATION

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 SPINDLE HOUSING HYDRO-MOTOR TORQUE WRENCH
HYDRAULIC SYSTEM ELECTRIC PANEL OPERATING HANDLE WITH PUSH BUTTON SPINDLE HOUSING HYDRO-MOTOR TORQUE WRENCH
HYDRAULIC SYSTEM ELECTRIC PANEL OPERATING HANDLE WITH PUSH BUTTON SPINDLE HOUSING HYDRO-MOTOR TORQUE WRENCH
HYDRAULIC SYSTEM
ELECTRIC PANEL
OPERATING HANDLE
WITH PUSH BUTTON
SPINDLE
HOUSING
HYDRO-MOTOR
TORQUE WRENCH
SPINDLE
PRESSURE CONTROL
VALVE

TORQUE WRENCH TROLLEY

TRACK CHAIN

SUPPORT/GUIDE

TRACK

ROLLERS

16

CW-850 TRACK CHAIN WINDER The CW-850 Track Chain Winder is used for winding and un-winding

CW-850 TRACK CHAIN WINDER

CW-850 TRACK CHAIN WINDER The CW-850 Track Chain Winder is used for winding and un-winding of

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 DUPLEX ELECTRIC PANEL GEAR BOX MOTOR
MAIN SPINDLE
ELECTRIC
DUPLEX
ELECTRIC
PANEL
GEAR BOX
MOTOR

TECHNICAL SPECIFICATION

Torque

:

8500 Nm

Spindle RPM

:

2

Floor to Spindle Height

:

1600 mm

Max. Weight Allowed on Spindle

:

6000 kg

Max. Track Shoe Width

:

1460 mm

17

Machine Weight : 1550 kg Machine Dimensions – Length : 2600 mm Height : 1900
Machine Weight : 1550 kg Machine Dimensions – Length : 2600 mm Height : 1900

Machine Weight

:

1550 kg

Machine Dimensions Length

:

2600 mm

Height

:

1900 mm

Depth

:

1250 mm

Power

:

3.75 kW

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.

12 OR 14 MOUNTING HOLES TAPPED HOLE FOR EYE BOLT

It is securely tightened to the track press table. 12 OR 14 MOUNTING HOLES TAPPED HOLE
It is securely tightened to the track press table. 12 OR 14 MOUNTING HOLES TAPPED HOLE

A TYPICAL ANVIL

18

PUSHER FOR PIN DISASSEMBLY TOOLING COMMON TOP PLATE PUSHER FOR BUSH ASSEMBLY TOOLING SPRING LOADED
PUSHER FOR PIN DISASSEMBLY TOOLING COMMON TOP PLATE PUSHER FOR BUSH ASSEMBLY TOOLING SPRING LOADED
PUSHER FOR PIN DISASSEMBLY TOOLING COMMON TOP PLATE PUSHER FOR BUSH ASSEMBLY TOOLING SPRING LOADED
PUSHER FOR PIN
PUSHER FOR PIN

DISASSEMBLY TOOLING

COMMON TOP PLATE

PUSHER FOR BUSH

FOR PIN DISASSEMBLY TOOLING COMMON TOP PLATE PUSHER FOR BUSH ASSEMBLY TOOLING SPRING LOADED LOCATOR FOR

ASSEMBLY TOOLING

SPRING LOADED LOCATOR FOR LINK (PIN SIDE)

SPRING LOADED LOCATOR FOR LINK (BUSH SIDE)

19

MACHINE INSTALLATION AND STARTUP 20
MACHINE INSTALLATION AND STARTUP 20

MACHINE INSTALLATION AND STARTUP

20

TRACK PRESS TP-400 The Track Press has to be grouted on concrete floor with four
TRACK PRESS TP-400 The Track Press has to be grouted on concrete floor with four

TRACK PRESS TP-400

The Track Press has to be grouted on concrete floor with four grouting bolts (M 20 x 300).

Place the hydraulic power pack in rear of the right of the machine on the right side. Open the

manhole cover of the hydraulic power-pack and thoroughly clean the inside of the tank with

cloth. Place back the cover, ensuring that the ‘O’ ring is properly placed. Fill the reservoir with

hydraulic oil (Servo System 68 or equivalent, about 750 lit.). Connect the hydraulic hoses as

per the markings provided on the manifold and on the distribution block (on Conveyor No. 1).

The Electric Panel is mounted on the back of the hydraulic power pack.

The Chain Indexing Unit is mounted on the Conveyor No. 1. Place it at a distance of 25 mm

from the Track Press. The marking ‘A’ on the Track Press and also on the Conveyor No. 1

have to be matched.

MATCH MARKS ‘A’ ON CONVEYOR AND TRACK PRESS

matched. MATCH MARKS ‘A’ ON CONVEYOR AND TRACK PRESS TRACK PRESS (REAR SIDE) CONVEYOR - 1
matched. MATCH MARKS ‘A’ ON CONVEYOR AND TRACK PRESS TRACK PRESS (REAR SIDE) CONVEYOR - 1
matched. MATCH MARKS ‘A’ ON CONVEYOR AND TRACK PRESS TRACK PRESS (REAR SIDE) CONVEYOR - 1

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

TIE PLATE FOR LOCKING MATCH MARKINGS LEVELING SCREW RUBBER FOOT LOCK NUT SPACER The Hydraulic
TIE PLATE FOR LOCKING MATCH MARKINGS LEVELING SCREW RUBBER FOOT LOCK NUT SPACER The Hydraulic
TIE PLATE FOR LOCKING MATCH MARKINGS LEVELING SCREW RUBBER FOOT LOCK NUT SPACER The Hydraulic

TIE PLATE FOR LOCKING

MATCH MARKINGS

TIE PLATE FOR LOCKING MATCH MARKINGS LEVELING SCREW RUBBER FOOT LOCK NUT SPACER The Hydraulic Torque
LEVELING SCREW RUBBER FOOT LOCK NUT
LEVELING SCREW
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.

to one of the conveyor. This welding has to be removed. CONVEYOR HYDRAULIC TORQUE WRENCH STRIP

CONVEYOR

of the conveyor. This welding has to be removed. CONVEYOR HYDRAULIC TORQUE WRENCH STRIP WELDED FOR

HYDRAULIC TORQUE WRENCH

STRIP WELDED FOR SHIPMENT TO BE REMOVED

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,
Give mains supply to the Electric Panel and ‘ground’ the Electric Panel, the Track Press,

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

and the Hydraulic Power Pack. ELECTRIC PANEL/JUNCTION BOX CONNECTOR TOP ELECTRIC CONNECTOR BASE CONNECTOR TOP TRACK

CONNECTOR TOP

ELECTRIC

CONNECTOR BASE

CONNECTOR TOP

TRACK PRESS

CONNECTOR BASE

CONVEYOR

MOTORS HYDRAULIC
MOTORS
HYDRAULIC

POWER PACK

ELECTRIC PANEL

23

The Hydraulic Torque Wrench in placed on the Conveyor No. 3. To accommodate in the
The Hydraulic Torque Wrench in placed on the Conveyor No. 3. To accommodate in the

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

HYDRO-MOTOR REMOVED

GEAR BOX

FOR SHIPMENT TO BE MOUNTED BACK DURING INSTALLATION

BOX FOR SHIPMENT TO BE MOUNTED BACK DURING INSTALLATION HYDRAULIC TORQUE WRENCH ELECTRIC PANEL For shipment,

HYDRAULIC TORQUE WRENCH

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
NOTE : After all the machines are positioned, it is desirable that the cable connecters

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

RC-400 ROLLER CONVEYOR For the convenience of transportation/shipment, the Roller Conveyor is made in four
RC-400 ROLLER CONVEYOR For the convenience of transportation/shipment, the Roller Conveyor is made in four

RC-400 ROLLER CONVEYOR

For the convenience of transportation/shipment, the Roller Conveyor is made in four parts, which are connected and tied to the track press during installation/commissioning. The four parts have to be tied with the locking plates provided with the conveyor. The conveyor is provided with several rollers. The rollers are driven by chain and sprocket drive. For shipment some of the drive chains are disconnected (and kept on the roller/sprocket). These have to be mounted on the sprockets for driving the rollers. The rollers are rotated in both the directions to move the chain away from the track press during assembly and towards the track press for disassembly. The Hydraulic Torque Wrench moves on the Roller Conveyor Stand. The chain under assembly or disassembly is moved forward or backward with the Chain Indexing Device.

LOCKING PLATES LEVELING PAD MOUNTED ONLY ON ONE OF THE LEGS
LOCKING PLATES
LEVELING PAD MOUNTED
ONLY ON ONE OF THE LEGS

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
rollers are driven by a motorized gear box. Chain and sprocket drive is used to

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

give long life. CONVEYOR USE A SCALE TO LEVEL THE RAIL/TRACK The Chain Indexing Device is
give long life. CONVEYOR USE A SCALE TO LEVEL THE RAIL/TRACK The Chain Indexing Device is

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

RD-400 CHAIN INDEXING DEVICE The chain is automatically moved away from the anvil or towards
RD-400 CHAIN INDEXING DEVICE The chain is automatically moved away from the anvil or towards

RD-400 CHAIN INDEXING DEVICE

The chain is automatically moved away from the anvil or towards the anvil by the Chain Indexing Device (also called Positioning/Referencing Device). The forward or retracting stroke is set as per the pitch of the track chain. During assembly or disassembly, the chain is lifted from the anvil by hydraulic actuators moved forward or backward by another hydraulic actuator. The device works with clock-work precision.

CONVEYOR

(NO. 1)

SWIVEL INCLINABLE INDEXING DEVICE
SWIVEL
INCLINABLE
INDEXING DEVICE

JOINT

DRIVE ROLLERS

VALVE BANK

SWIVEL INCLINABLE INDEXING DEVICE JOINT DRIVE ROLLERS VALVE BANK KNIFE LIFTING CYLINDER KNIFE TRAVERSE CYLINDER KNIFE

KNIFE LIFTING CYLINDER

KNIFE TRAVERSE CYLINDER

KNIFE

28

KNIFE TABLE LIFT CYLINDER TRACK PRESS HYDRAULIC PIPE LINES FOR LEFT RAM The unit comprises

KNIFE

TABLE LIFT CYLINDER

TRACK PRESS

KNIFE TABLE LIFT CYLINDER TRACK PRESS HYDRAULIC PIPE LINES FOR LEFT RAM The unit comprises of
KNIFE TABLE LIFT CYLINDER TRACK PRESS HYDRAULIC PIPE LINES FOR LEFT RAM The unit comprises of

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.

(iii) Knife Traverse Cylinder and (iv) Knife Lift Cylinder. TABLE CHAIN GUIDE TRACK PRESS DISASSEMBLY

TABLE

CHAIN GUIDE

TRACK PRESS

DISASSEMBLY

 

(RIGHT RAM)

TOOLING

29

CHAIN SUPPORTS CHAIN GUIDES CONVEYOR (NO. 1) TABLE For disassembly, the track chain is placed

CHAIN SUPPORTS

CHAIN GUIDES

CONVEYOR (NO. 1)

TABLE

CHAIN SUPPORTS CHAIN GUIDES CONVEYOR (NO. 1) TABLE For disassembly, the track chain is placed on
CHAIN SUPPORTS CHAIN GUIDES CONVEYOR (NO. 1) TABLE For disassembly, the track chain is placed on

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.

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HYDRAULIC TORQUE WRENCH TW-700 & TW 900 TW-700 is adequate for the removal and fixing/tightening
HYDRAULIC TORQUE WRENCH TW-700 & TW 900 TW-700 is adequate for the removal and fixing/tightening

HYDRAULIC TORQUE WRENCH TW-700 & TW 900

TW-700 is adequate for the removal and fixing/tightening of shoe bolts of all the track chains. Its maximum torque is 7000 Nm. However, for the very large size track chains, especially chains which are badly damaged by use or by welding during operations in the field, TW -900 is recommended.

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) high- torque 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.

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CW-850 TRACK CHAIN WINDER The CW-850 Track Chain Winder is used for winding and un-winding
CW-850 TRACK CHAIN WINDER The CW-850 Track Chain Winder is used for winding and un-winding

CW-850 TRACK CHAIN WINDER

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.

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.

Fill the gear box with lubrication oil (SAE 40).

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.

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ANNEXURE I ELECTRIC CIRCUIT TRACK PRESS TP-400 33

ANNEXURE I

ANNEXURE I ELECTRIC CIRCUIT TRACK PRESS TP-400 33

ELECTRIC CIRCUIT TRACK PRESS TP-400

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ELECTRIC CIRCUIT HYDRAULIC TORQUE WRENCH TW-700/TW-900, 37
ELECTRIC CIRCUIT HYDRAULIC TORQUE WRENCH TW-700/TW-900, 37

ELECTRIC CIRCUIT HYDRAULIC TORQUE WRENCH

TW-700/TW-900,

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ELECTRIC CIRCUIT TRACK CHAIN WINDER CW-850 39
ELECTRIC CIRCUIT TRACK CHAIN WINDER CW-850 39

ELECTRIC CIRCUIT TRACK CHAIN WINDER

CW-850

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ANNEXURE II HYDRAULIC CIRCUIT TRACK PRESS TP-400 40
ANNEXURE II HYDRAULIC CIRCUIT TRACK PRESS TP-400 40

ANNEXURE II HYDRAULIC CIRCUIT TRACK PRESS TP-400

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& CHAIN INDEXING DEVICE RD-400 41
& CHAIN INDEXING DEVICE RD-400 41

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CHAIN INDEXING DEVICE RD-400

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HYDRAULIC CIRCUITS TW-700/TW-900 42
HYDRAULIC CIRCUITS TW-700/TW-900 42

HYDRAULIC CIRCUITS

TW-700/TW-900

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DOUBLE RAM TRACK PRESS TP-400 ANNEXURE III MACHINE OPERATION & 43
DOUBLE RAM TRACK PRESS TP-400 ANNEXURE III MACHINE OPERATION & 43

DOUBLE RAM TRACK PRESS TP-400 ANNEXURE III MACHINE OPERATION

&

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SETTING The Double Ram Track Press TP-400 is operated in semi-automatic cycles. Two electric motors

SETTING

SETTING The Double Ram Track Press TP-400 is operated in semi-automatic cycles. Two electric motors are

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

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HIGH PRESSURE LOADING FOOT LEFT RAM RIGHT RAM REGULATING VALVE VALVE SWITCH DIRECTIONAL
HIGH PRESSURE LOADING FOOT LEFT RAM RIGHT RAM REGULATING VALVE VALVE SWITCH DIRECTIONAL
HIGH PRESSURE LOADING FOOT LEFT RAM RIGHT RAM REGULATING VALVE VALVE SWITCH DIRECTIONAL

HIGH PRESSURE

LOADING

FOOT

LEFT RAM

RIGHT RAM

REGULATING VALVE

VALVE

SWITCH

DIRECTIONAL

DIRECTIONAL

VALVE

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

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ROLLER CONVEYOR JOYSTICK FOR INDEXING DEVICE EMM OFF PUSH BUTTON # Use the correct tooling

ROLLER CONVEYOR

ROLLER CONVEYOR JOYSTICK FOR INDEXING DEVICE EMM OFF PUSH BUTTON # Use the correct tooling for

JOYSTICK FOR

INDEXING

DEVICE

EMM OFF

PUSH BUTTON

CONVEYOR JOYSTICK FOR INDEXING DEVICE EMM OFF PUSH BUTTON # Use the correct tooling for the

# 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.

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ASSEMBLY # For assembly of the chain, the links are mounted on the assembly tooling.

ASSEMBLY

ASSEMBLY # For assembly of the chain, the links are mounted on the assembly tooling. Select

# 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.

tooling and Anvil for the particular chain size/model. ANVIL LINKS MOUNTED ON THE ASSEMBLY TOOLING PIN/BUSH
tooling and Anvil for the particular chain size/model. ANVIL LINKS MOUNTED ON THE ASSEMBLY TOOLING PIN/BUSH

ANVIL

tooling and Anvil for the particular chain size/model. ANVIL LINKS MOUNTED ON THE ASSEMBLY TOOLING PIN/BUSH

LINKS MOUNTED ON THE ASSEMBLY TOOLING

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.

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