INSTRUCTION MANUAL Double acting rail gap adjuster KT-30

1
KONEPAJA
MANKINEN Oy
INSTRUCTION MANUAL
Double acting rail gap adjuster KT-30
manual_kt-30_en
16.3.2012
2
KONEPAJA
MANKINEN Oy
1. Table of contents
1.
Table of contents ....................................................................................................................................... 2
2.
Technical information................................................................................................................................ 2
3.
Intended use .............................................................................................................................................. 3
4.
Safety ......................................................................................................................................................... 3
5.
Operation................................................................................................................................................... 3
6.
Maintenance and service check list........................................................................................................... 4
Monthly or after 100 rail gaps ....................................................................................................................... 4
Yearly ............................................................................................................................................................. 4
After 5 years .................................................................................................................................................. 4
7.
Storage....................................................................................................................................................... 4
8.
Discarding the machine or used parts ....................................................................................................... 4
9.
Declaration of conformity ......................................................................................................................... 5
10.
Technical support & Spare parts ........................................................................................................... 5
11.
Appendices ............................................................................................................................................ 5
2. Technical information
Weight
Height
Length
Width
Pressure relief, rail pressing and pull
Pressure relief, rail pushing
Oil volume
manual_kt-30_en
130 kg
520 mm
1350 mm
800 mm
255 bar
195 bar
2L
16.3.2012
3
KONEPAJA
MANKINEN Oy
3. Intended use
Enerco KT-30 is a double acting rail gab adjuster which is designed amounting both normal- and
isolated joints. On normal conditions the devices design allows the fish bolts mechanical fastening/
unfastening.
The device has jaws for grabbing the rail sides. Standard jaws are suitable for rail types K43, UIC54,
UIC60, 54E1, 60E1, and BS95 ... BS113. Jaws for other rail types are available.
The device functions fully hydraulically by manual pump.
Machine shall not be used handling any other beams or objects.
It is forbidden to grab the rail with the device and move it by crane.
Applying this manuals instructions one can ensure machines endurance, safety and economic use.
4. Safety
All users have to be able to lose the device from the rail quickly before using it on site
The device weights 130 kg. Use crane or similar when lifting or moving it.
Watch the device while moving it on the rail. It can fall down easily.
Wear always proper gloves and safety shoes
Only personnel with proper training are allowed to use the device. Railway safety
standards must be followed.
When pistons of hydraulic cylinders are driven to end positions, full pressure may stay in
the cylinders. Always when machine is stopped, when serviced, when stored or
transported, jaws should be left away from end positions.
Use always original spare parts to avoid damages
Inspect and maintain machine regularly, then it is safe to personnel and environment.
Safety is everyone’s responsibility
5. Operation
Check cleanliness and condition of grabbing jaws under the device. Check that they are suitable for
the rail type.
Prepare crane for lifting the device. If no crane is available four men should be available for lifting.
The gab adjuster is equipped with rolling wheels allowing transport on rail.
manual_kt-30_en
16.3.2012
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KONEPAJA
MANKINEN Oy
If pistons of the work cylinders are inside position, then pump pistons half way out. Total stroke is
90 mm. See attached ”valve instruction”, chapter 2.
Turn select valve (A) to pressing position, close return valve (B) and turn directional valve (C) of the
pump to the right. Move the device above the rail gap and turn it upright position. Tighten the
device to the rail until pressure relief valve opens.
Turn select valve (A) to work cylinders and adjust rail gap with pump.
When finished with the device, adjust all pistons inside position, but do not leave pressure.
6. Maintenance and service check list
Monthly or after 100 rail gaps
Grease all joints, total 6 pcs of grease nipples. Use NLGI-2 grease.
Check hydraulic hoses and couplings in case of wear and oil leaks.
Check hydraulic cylinders in case of oil leaks.
Check hydraulic oil volume. Oil plug in the tank side indicates oil level when all pistons are
inside position.
Check cleanliness and condition of grabbing jaws.
Yearly
Check roller bearings.
Check joints against excessive backlash
Change hydraulic oil. Use ISO VG 32 oil. Oil volume 2 litres.
After 5 years
Change hydraulic hoses. Check that hoses are not pressurized before opening connections.
7. Storage
Machine can be stored outside. All pistons must be inside position, do not leave pressure. Sun may
burn the hydraulic hoses.
We recommend storing inside, dark and dry room.
8. Discarding the machine or used parts
Oil of the machine to be collected and all parts dismantled. Most of the materials can be recycled. Hoses
should be discarded to official dumping ground.
manual_kt-30_en
16.3.2012
KONEPAJA
MANKINEN Oy
9. Declaration of conformity
We Konepaja Mankinen Oy, Tehtaankatu 9, 1,17I0 Riihimäki, declare under our sole responsibility
that the dual acting rail gap adjuster KT-30 to which this declaration relates is in conformitv with
machine directive 2006/42/EY and other normative documents.
Administrator of the technical file:Juha Pulkki, Tehtaankatu 9, tl7tO Riihimäki
ln Riihimäki L6.3.20I2
i
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--4 ,:---r/r,^
-J
;(ari
Saari, Froduction Manager
Technical support & Spare parts
10.
Konepaja Mankinen Oy
Tehtaankatu 9
Ll7IO Riihimäki
Finland
Telephone: +358
108 358 900
Telefax:
+358 108 358 902
site:
www.mankinen.fi
Web
LL.
Appendices
KT-3011
Dimensional drawing
KT-3012
Hydraulic diagram
KT-3013
Valve instruction
KT-3014
Pressing cylinder
KT-3015
Work cylinder
KT-3016
Wheelassembly
Spare parts list
manual_kt-30_en
1.6.3.2012
KONEPAJA MANKINEN Oy
1/2
KT-30 SPARE PARTS LIST
13.3.2012
Main assembly
Drawings: KT-3011, KT-3012 (parts 1-6)
Pos
Desription
1
Hand pump with tank
1
Hand lever for pump
1
Pump unit
1
Gasket set
2
Double pressure relief valve
3
6-way manual valve
4
Throttle / check valve
5
Pressing cylinder, complete
6
Work cylinder, complete
Jaw set, standard, 2° B=70…73
7
7
Jaw set, Sweden SJ-34
7
Jaw set, Australia 71.5D / 60B
8
Allen screw
9
Wheel assembly
15
Hand lever
16
Hand lever, pump side
17
Axle nut M50x1,5
18
Securing plate D50
Hexagon nut M45x3
19
Pivot pin D25
21
Split pin
22
Grease nipple
23
Type
Casappa PMI-25-2
Walvoil VAIL 5-38
MTC DDF6V-02-A
Tognella FT 257/5 14
KT-3040
KT-3050
KT-3021
KT-3022
KT-3023
M8x30 10.8
KT-3060
KT-3065
KT-3066
KM 10
MB 10
KT-3071
KT-3073
5x40
M6x1 45°
Assembled
pcs / mach.
1
1
1
1
1
1
1
2
2
1 set
1 set
1 set
8
2
1
1
2
2
4
4
4
2
notes
drw. KT-3014
drw. KT-3015
incl. 4 pcs
incl. 4 pcs
incl. 4 pcs
drw. KT-3016
For hydraulic hoses, see Hydraulic diagram, KT-3012 pos. 11-17
Pressing cylinder
Drawing: KT-3014
Pos
Desription
4
Piston seal
5
O-ring
6
Piston rod seal
7
Grease nipple
Type
OE 0800 052 00210 D
OR 74,5X3
OD 0600 052 00170 D
M6x1S
Assembled
pcs / cyl. notes
80676080000
1
80641227000
1
80675060100
1
2
Type
OR 94,5 X 3,0 NBR70
GA 50 X 60 X 7/10 NBR
B/MD 50 X 60 X 10 -E
TPM 393295 100/75 X 22,4
Assembled
pcs / cyl. notes
1
80641337000
1
80677070000
1
80651058030
1
80654100300
Work cylinder
Drawing: KT-3015
Pos
Desription
4
O-ring
5
Piston rod wiper
6
Piston rod seal
7
Piston seal
KONEPAJA MANKINEN Oy
2/2
KT-30 SPARE PARTS LIST
13.3.2012
Wheel assembly
Drawings: KT-3016
Pos
Desription
1
Wheel D60x70
2
Axle D15
4
Deep groove ball bearing
5
Split pin
Type
KT-3061
KT-3062
6002-2RS
D4x25
Assembled
pcs / mach. notes
2
2
4
4