- Railtech UK
Contents
1. a h EN a Lt Y r Rd I E i s BE 24 71 S EE No 1 I RE Xx B A HI i LO I Suas y As F Pd LA PS a PP VI il N E d sf q 7 uy Lo 2 N F AN J ru a Ni 4 lt SS A L gt Sf E 4 Z aw 2 my z F F z LA E 4 A 7 F D GROUPE DELACHAUH EPM3 11334008 01 02 07 PAGE 16 PUMP SUPPORT CROSSPIECE SUIT Qt R f rence 47401002 35910355 40914004 41014001 41108004 41008052 41108004 35910054 gt rep 32 35910055 31910028 31210145 39920001 47702005 47340001 47701028 47701029 41020002 41008003 41010017 40910009 40910003 41110004 41008008 41120004 41004003 0 ND ON b2 NW LS N OO LN OO b2 ae 2 RRR Re a NDN gt Description Rubber handle Pump support Hm M14 nut HM 14 x 60 screw W8 washer Screw CHc M8 x 16 W8 washer Oil tank with cap rep 53 Tank cap Stud Pump lever2. Traditionally this deadhead was removed manually with a hammer and chisel hard work which exposed the workers to projections of metal The hydraulic shearing machine allows to cut the metal excess without any risk of damaging the rail After mould release 2 hydraulically operated blades guided by the rail itself move and cut off the deadhead This machine is lightweight and can easily be manipulated by two men A set of blades adapted to the various types of Vignole rails allows the cutting in a single operation with precision Blade Masselotte Deadhead Dessus du rail Running surface EPM3 11334008 01 02 07 PAGE 5 V ADJUSTMENTS BEFORE STARTING THE MACHINE 1 ADJUSTING THE BLADES a Longitudinal guide The cutting unit is guided longitudinally along the rail by 4 guide screws rep D and E 2 on the front crosspiece and 2 on the back one which create a space between the cutting edge of the blade and the profile of the rail head Instructions Unlock the lock nuts and unscrew the rep D and E screws On the left side adjust the screw rep D so as to obtain a space of 1 5 mm between the vertical cutting edge of the blade and the rail On the right side tighten the screw rep E so as to leave a space of 0 5 to 1 mm between this screw extremity and the rail Lock up the lock nuts b Vertical adjustment The front and back crosspieces are each fitted with a screw rep C These screws ar
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4. Aspect g n ral General aspect 7 Outillage Tools 8 Notice d utilisation Ref 42111002 User s manual 9 Garantie moteur Garantie moteur Engine guarantee mag o Etanch it des constituants hydrauliques sous mise en pression Inspection of hydraulic components under pressure Raccords Couplings Tuyauteries Pipings V rins Hydraulic jacks i Ss En Ss Date de fabrication Date of manufacturing Fait Raismes le Drawn up in ROSES IME a Nom D E E EE EEE A Signature Signature R f rences rappeler en cas de r clamation In case of complaint please quote these references N de machine Machine nbr Pompe Type N Pump Type S A V Assistance Technique RAILTECH Service Commercial After Sales Department INTERNATIONAL Commercial Department Tel 03 27 22 26 03 Tel 01 46 88 17 00 France Fax 03 27 22 26 00 33 01 46 88 17 60 Export Fax 01 46 88 17 01 EPM3 11334008 01 02 07 PAGE 20 IEAA LT E FS O GROUPE DELACHAUX DECLARATION DE CONFORMITE CONFORMITY CERTIFICATE Le constructeur soussign the undersigned manufacturer RAILTECH INTERNATIONAL DIVISION MATERIEL Z I DU BAS PRE 59590 RAISMES Certifie que le mat riel neuf d sign ci apres certify that the under described products EBA VUREUSE HYDRAULIQUE WIDE HYDRAILIC RAIL WELD T TE LARGE EPM3 TYPE UK SHEARING MACHINE EPM3 UK Type A pompe manuelle With hand
5. Long pump lever Pump ATOS modified Distributor with pressure relief valve Shock absorber Oil filling piece Exhaust Plug CHC M20 x 50 screw CHC MS x 30 screw CHc M10 x 50 screw Nylstop M10 nut Hm M10 nut L10 N washer HM 8 x 16 screw M20 N washer Sheet Iron screw gt parts belonging to the referenced system they cannnot be sdold separately HYDRAULICAL FITTING EPM3 11334008 01 02 07 PAGE 17 Rep A B P R A B P R Reference 21332018 21332019 21332012 EPM3 11334008 01 02 07 PAGE 18 FO A F LT E FS ARR SS AE 1 AE I R NN A 7 7 O NA Z E FICHE DE CONTROLE CONTROL CARD CLIENT CUSTOMER S COPY EBAVUREUSE HYDRAULIQUE TETE LARGE EPM3 WIDE HYDRAULIC RAIL SHEARING MACHINE EPM3 A POMPE MANUELLE REF 11334008 WITH HAND PUMP REF 11334008 D signation des contr les Contr le Description of controls Checked by R glage des vis de positionnement en hauteur Hight positionning screws adjustment R glage des vis de guidage Guide screws adjustment Syst me de verrouillage Locking system Ecrou de r glage en hauteur Hight adjustment nut D battement des verrous Clearance of locks N 2 3 4 5 Essai de fonctionnement pression maximum de 250 bars Operating test at maximum pressure of 250 bars 6 Aspect g n ral General aspect Outillage Tools Etanch t des constituants hydrauliques sous mise en pression Inspection of hydraulic components under pressur
6. EPM3 11334008 01 02 07 PAGE 1 KAILTELH INTERNATIONAL D GROUPE DELACHAUX WIDE HYDRAULIC RAIL WELD SHEARING MACHINE EPM3 INTEGRAL TYPE WITH HAND PUMP REF 11334008 OPERATING AND MAINTENANCE MANUAL REVISION 00 EDITION 02 2007 RAILTECH INTERNATIONAL Si ge Social et Usine Z I du Bas Pr B P 9 59590 RAISMES FRANCE T l 33 0 3 27 22 26 26 Fax 33 0 3 27 22 26 00 Direction G n rale et Commerciale 119 Avenue Louis Roche BP 152 92213 GENNEVILLIERS Cedex France Tel 33 1 46 88 17 00 management railtech fr Fax 33 1 46 88 17 01 et 17 66 EPM3 11334008 01 02 07 PAGE 2 AAA EA ES RE SENEESE se RES E AS 7 E OR 14 A 7 7 ON AE Il HI IV VI VII VIII IX XI D GROUPE DELACHAUX CONTENTS SAFETY LABELS EXPLANATION GENERAL SAFETY INSTRUCTIONS SAFETY MEASURES TO BE TAKEN PRIOR TO INITIAL USE PRINCIPLE ADJUSTMENTS BEFORE STARTING THE MACHINE 1 Blades 2 Stops adjustments 3 Locks HOW TO OPERATE THE MACHINE 1 Mold release 2 Cutting BLADES 1 Sharpening 2 Differents profiles blades HYDRAULICAL DIAGRAM TECHNICAL SPECIFICATIONS SPARE PARTS 1 Shearing unit 2 Pump support crosspiece suit 3 Hydraulical fitting CONTROL CARD CONFORMITY CERTIFICATE Pages N Un NJ 10 11 13 amp 14 15 amp 16 17 18 amp 19 20 EPM3 11334008 01 02 07 PAGE 3 I SAFETY LABELS EXPLANATION WARNING The machin
7. LANP OLA PPT ESSPERE TT N S DONNE HTVET 00860090 04 8105221 piepue s ad ze sepeig poua yus S1VY FIONDIA dO SAdAL SNOISVA JHL HO4 1811 SI0QV19 31110Hd EPM3 11334008 01 02 07 PAGE 10 1 AA A ET ef FS ARRETE AE SIN E SO N AE E SAS D GROUPE DELACHAUX VIH HYDRAULIC DIAGRAM EPM3 11334008 01 02 07 PAGE 11 IX TECHNICAL SPECIFICATIONS D signation Single unit with manual pump Weight 56 kg without blades LxWxH 1020 x 500 x 480 Force 216 KN 22 T Hydraulic pressure 250 bar 3626 psi Hydraulic oil ISO 22 VG Viscosity 2 3 Engler at 50 C Viscosity index 100 Flash point 2G DO NOT MIX DIFFERENT TYPES OF OIL FEAA LT E E FA 22 ES EI RR NA 7 7 O NA Z E O GROUPE DELACHAUX XI SPARE PARTS LIST Shearing unit Pump support crosspiece suit Hydraulical fitting EPM3 11334008 01 02 07 PAGE 12 EPM3 11334008 01 02 07 PAGE 13 a 7007 7 lg LINN ONIAVAHS o SiS o as E E e eE CINdH e pss s m A pe 7 qH A p o U im Nu A St Ww a ONTIAN3SSY SONIA NV Sddddv os 1 3S ana LNIOF 13 SLANISSNOD 530 IIVINOW ONMaN3SsSv 331108 LAWS IOVINOM EPM3 11334008 01 02 07 PAGE 14 IEAA LT E FS D GROUPE DELACHAUH SHEARING UNIT 47401002 1 Rubber handle 33210001 1 Holding handle 35910146 1 Handle support 41014002 2 HM14 x 60 screw 40914004 4 Hm M14 nut 41014001 6 H M14 x 90 screw 31230014 4 Ad
8. e Raccords Couplings Tuyauteries Pipings V rins Hydraulic jacks I o ES Notice d utilisation Ref 42111002 User s manual 9 Garantie moteur Engine guarantee Date d fabrication Date ol manufacturing soii Fait Raismes le Drawn up in Raismes the Nom V dd tia Signature Signature R f rences rappeler en cas de r clamation In case of complaint please quote these references N de machine Machine nbr Pompe Type N Pump Type S A V Assistance Technique RAILTECH Service Commercial After Sales Department INTERNATIONAL Commercial Department Tel 03 27 22 26 03 Tel 01 46 88 17 00 France Fax 03 27 22 26 00 33 01 46 88 17 60 Export Fax 01 46 88 17 01 EPM3 11334008 01 02 07 PAGE 19 FICHE DE CONTROLE CONTROL CARD ATELIER WORK S COPY EBAVUREUSE HYDRAULIQUE TETE LARGE EPM3 WIDE HYDRAULIC RAIL SHEARING MACHINE EPM3 A POMPE MANUELLE REF 11334008 WITH HAND PUMP REF 11334008 D signation des contr les Contr le Description of controls Checked by Reglage des vis de positionnement en hauteur Hight positionning screws adjustment Reglage des vis de guidage Guide screws adjustment Systeme de verrouillage Locking system Ecrou de r glage en hauteur Hight adjustment nut D battement des verrous Clearance of locks Essai de fonctionnement pression maximum de 250 bars Operating test at maximum pressure of 250 bars
9. e adjusted in the workshop so that there is a space of 1 5 to 2 mm between the cutting edge of the blades and the rail running surface Instructions Loosen the lock nuts and unscrew the 2 screws rep Place a 1 5mm wedge on the rail running surface Place the cutting unit on the wedge Tighten the screws rep C until they make contact with the rail Block the lock nuts To optimise the cutting this adjustment should be made systematically every time the blades have been sharpened or replaced EPM3 11334008 01 02 07 PAGE 6 FO A F LT E FS ARR SS AE 1 AE I R NN A 7 7 O NA Z ES O GROUPE DELACHAUH 2 STOPS ADJUSTMENTS To provide the blades cutting edges from damaging it s absolutely necessary to leave a space of 1 mm when adjusting the 2 screws rep F witch act like stop pieces on the travelling crosspiece 3 ADJUSTING THE LOCKING SYSTEM The locking system improves the cutting action making 1t safe and of good quality EPM3 11334008 01 02 07 PAGE 7 Instructions The shearing unit placed on the rail the blades adjusted rotate the bolt lever through 90 so as to engage the bolt under the rail head Turn the knurled nut rep G until the bolt make contact under the rail head Loosen 1 8 of a turn the nut rep G to create un little space Do the same with the three other bolts VI HOW TO OPERATE THE MACHINE Before welding operation put the shearing unit on the rail so as to
10. e can be dangerous Careless and incorrect use can result in injury to the operator Read carefully the instructions of the operating manual and make sure you understand them before using the machine WARNING Be carefull to the mobile pieces of the shearing machine so as to avoid any risk of squashing II GENERAL SAFETY INSTRUCTIONS Do not use the shearing machine until you have read and understood the entire contents of the operator s manual The shearing machine is specially designed to cut off the metal excess or deadhead generated by rail aluminthermic welding never use this machine for any other work Never use the shearing machine when you are tired under the influence of medicines alcohol or any substance that can affect your perception dexterity or your appreciation capacity Do not mix different types of oil HI SAFETY MEASURES TO BE TAKEN PRIOR TO INITIAL USE Chek that all hydraulic pipes are correctly positioned so as to avoid their shearing or a contact with the weld To obtain high performances and get most satisfaction with the shearing machine realise the different adjustments recommended with a particular attention before starting the machine EPM3 11334008 01 02 07 PAGE 4 IEAA LT HK FS 1 EI E RR NA 7 kf O NA Z E D GROUPE DELACHAUH IV PRINCIPLE During aluminothermic welding a deadhead which serves of metal reserve during solidification remains above the rail head
11. justing nut 41301012 4 Elastic pin Mecanindus 35910052 4 Roller hook handle 41020001 2 CHC M20 x 80 screw 41120002 2 W20 washer 41120003 2 L20 U washer 32930045 1 set Fixe crosspiece equiped with 2 cylindrical pins 10x30 rep 31 41116004 2 M16 N flat washer 40916001 2 H M16 screw 41016007 2 HM16 x 160 screw 41006049 8 CHc M6 x 100 24 screw 41106001 8 W6 washer 44201004 2 Scraper seals 45301005 4 Rings PCM 30x34x40 31110184 4 Operating rod 47501011 2 Light hydraulic jack 47501003 2 Jack column 41108004 6 W8 washer 32930046 1 set Mobile crosspiece quiped with 2 scraper seals rep 19 4 rings PCM 30x34x40 rep 20 2 cylindrical pins 10x30 rep 31 41304001 4 Cylindrical pin 10x30 42221010 1 Label 41008002 4 HM8 x 20 screw 41802001 4 Circlips for 16 shaft 31210142 4 Roller 45302002 4 Bearing 31210143 4 Positionning ring 41301013 4 Elastic pin diameter 8 31910027 4 Roller axle 1p Blades refer to the list page 9 47501016 1 Gasket kit for light hydraulic jack EPM3 11334008 01 02 07 PAGE 15 PUMP SUPPORT CROSSPIECE SUIT
12. pump R f rence 11334008Reference 11334008 N de machine machine number Est conforme comply with AUX DISPOSITIONS REGLEMENTAIRES DEFINIES PAR L ANNEXE 1 DE LA DIRECTIVE 98 37 CE THE INFORMATIONS STATED IN THE LEGAL DOCUMENTATION ANNEXE l OF DIRECTIVES 98 37 CE Aux prescriptions de l article R233 53 proc dure d auto certification The regulations of R233 53 article self certification procedure Fait a Raismes F vrier February 2007 Le Directeur Industriel D BOURDON
13. till links the deadhead to the rail VII BLADES 1 SHARPENING The shape of the cutting edge along all the profile of the blade 1s very important in order to obtain optimum cutting quality The blades must be systematically inspected and sharpened about every 50 cuts EPM3 11334008 01 02 07 PAGE 9 t00Z r0 L0 8b Sb 0y 9 Z X 30 PEN ANIHOVW ONIYVIHS YOW S3GV18 BUUSq q1 SSL Sd q1 GGL LZ Sin bL V avs DIN 442 aileasny By r 34 q1 OF ayeysny q1 01 no 9b INN JH 97 9 L ailensny By cs ari 1449 HH 97 9 L I 9 49 97 001 1449 I 9 49 97 MEL 38 971 001 Spuelez ll N q7 16 eyessny By 89 Ve 41 001 I 9 49 9106 JY 97 l ave v 41 00 4S 9106 ss n qu 97 cel JOSY q1 001 gy q1 06 ees no ge n HH 81 Z L VJIYV q1 001 va 91 06 essiedo uuv n 9a1 e1sny By 99 3H 91 O L os n N9 97 06 LS By OF e yz 34 971 0 1 css By Z9 OS rs gvuv 0 06 SPAS S Sp PIS 0rS By 9 JY 97 LEL q16LL aesjsny By 0S IS219 YYYY 0206 1sa By Sr ELS By 9 Sd 97 0 1 aileajsnv By 09 aulyo By OS YSN BA Sp PION By Sr je6nyod By 9 OAN 91 431 HH euensny By 09 6r S Sd 91 58 VVYV S8 u lssniq By y ee q1 201 12 49971 611 aileasny By Zy 69 n 39SV 0198 I 9 49 98 By 9 Le ga By 9 JY 97 GEL ysg q1 06 N By09 aileajsny By Lp wy adh By OF essing By 0 qI Zz SHATELL janbiquezoy vo 09N Say 9108 PION BA OF PION By 0 O 9 99 zz VELL AOSV 91 06 oon
14. verify that all the adjustments have been made see section III Adjustments 1 MOULD RELEASE The welding finished proceed as follows respecting the time required between casting and mould release according to the welding process Break the upper part of the mould f Remove the sand from each side of the deadhead Using a wire brush remove sand and debris resulting from the mould from both sides of the deadhead These operations must be done quickly otherwise the deadhead may cool down too much and become impossible to cut EPM3 11334008 01 02 07 PAGE 8 IEAA LT HK FS 1 EI E RR NA 7 kf O NA Z E D GROUPE DELACHAUH 2 CUTTING The welder and his assistant place the shearing machine on the rail with the deadhead centered in relation to the blades Pivot the 4 bolts of the locking system under the rail head The operator on the hydraulic distributor side pushes the lever towards the welding to cut towards himself for the return Quickly manipulates the small lever from right to left to activate the pump As soon as the tensile becomes important sets up the big lever and carries on acting the pump until the stop screws make contact Then reverses imm diately the distributor lever in order to prevent a prolonged heating of blades and pump for their return Release the bolts of the locking system Remove the shearing machine from the rail Using a hammer break the layer that s
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