Cembre HTEPE.DET10 User manual

1
HYDRAULIC TOOL
HTEPE.DET10
ENGLISH OPERATION AND MAINTENANCE MANUAL
19 M 068 E

2
WARNINGS
– Before using the tool, carefully read the instructions in this manual.
– When operating the tool, keep hands away from the danger zone.
– Always wear safety gloves when operating.
2
1
123
3
TG0350

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HTEPE.DET10 system consists of:
– Pump unit
– Hydraulic head type RHTEPE-S16
– Plunger type OG10.5C (qty 2)
– GO / NO GO gauge type CAL135.145
– Adaptor M9M8
– Plastic case VAL-P14
–Application range: suitable for installing rail web electrical connection system into rail web
thickness 19-20 mm (e.j. BS113A, BS95RBH) and hole diameter 13,5mm.
–Installation force:.........................................................................................................................55 kN
–Rated operating pressure:.......................................................................................................700 bar (10000 psi)
–Flexible hose: length..................................................................................................................900mm
–Dimensions (pump body):
length..........................................................................................................................................285mm
width ...........................................................................................................................................130 mm
–Dimensions (head):
length..........................................................................................................................................133 mm
width ...........................................................................................................................................67,5mm
diameter.....................................................................................................................................48 mm
–Weight:.............................................................................................................................................3,8 kg
–Recommended oil:.............................................................. ENI ARNICA ISO32 or equivalent
–Safety: the tool is provided with a maximum pressure valve.
2.1) Setting
Connect the male coupler of the head to the female coupler on the tool hose; ensure that the couplers
are securely fitted.
Before connecting or disconnecting the head and the hose, ensure that the ram of the head is
fully retracted.
1. GENERAL CHARACTERISTICS
2. INSTRUCTIONS FOR USE

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2.2) Installation procedure for rail web electrical connection
–Drill rail web to Ø13,5mm or, if already drilled, use a suitable reamer to clean the hole (Fig. 1).
–Check the size of the hole with the CAL135.145 “GO/NO GO” gauge (Fig. 2):
- The hole size is correct if only the green part enters the hole.
-If the red part enters, the hole is too large, in this case it is necessary to drill a new hole.
–Insert the AR...-1 copper bush into the rail web hole (Fig. 3).
– Ensure that the ram in the head is fully retracted and then firmly screw and tighten the adaptor
M9M8 onto the tool head (Fig. 4).
– Introduce the plunger into the copper bush from the flanged side and screw and tighten the
plunger OG10.5C onto the adaptor M9M8 (Fig. 4) using the recess in the gauge CAL135.145.
– Operate the moveable handle of the tool (Fig. 5) to pull the plunger completely through the bush
and extrude the bush onto the surface of the hole.
At the end of the operation, press the pressure release lever (20) to retract the ram (01).
– The bush will also extrude itself around the opposite side of the rail web (Fig. 6).
2.3) Conductor assembly
– Crimp the lug onto the conductor.
– Assemble all components as shown in Fig. 7.
–Fit the self-locking nut (Fig. 8) and tighten to the
torque setting indicated in the instruction sheet
of the AR... bush kit.
FIG. 1
FIG. 2 FIG. 3
copper
bush

NO
OK

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FIG. 4
FIG. 7 FIG. 8
screw
self-locking
nut
cable
lug
copper bush

C
FIG. 6FIG. 5
flat
washer


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The tool is robust and requires very little daily maintenance.
Compliance with the following points should help to maintain the optimum performance of the tool:
3.1) Thorough cleaning
Dust, sand and dirt are a danger for any hydraulic device.
Every day, after use, the tool must be wiped with a clean cloth taking care to remove any residual
particles, especially around the moveable parts and the flexible hose.
3.2) Flexible hose
Operate the tool with the hose uncoiled. Do not bend, twist, kink, knot or squash the hose. Before
operation, check the hose for any sign of damage.
When storing the tool, coil the hose in large loops.
High pressure flexible hoses are subject to a natural ageing process which can result in a reduction
in performance potentially affecting safety of the operator. As a result their life span is limited.
In order to ensure safe use of their units, Cembre recommends replacing the hose within 10 years
from the date printed on the fittings.
Before using the pump always check the integrity of the flexible hose and the quick couplers
making sure there are no abrasions, cuts, deformations or swellings.
3.3) Storage
When not in use, the tool and accessories should be stored and transported in the plastic case, to
prevent damage.
Plastic case: type “VAL-P14”, size 496x370x137 mm, weight 2,7 kg.
The case will also store the "CAL135.145" gauge, the adaptor M9M8 and the two plungers OG10.5C.
Air in the hydraulic circuit may affect the performance of the tool; e.g. no ram die advancement, slow
advancement of the ram; ram pulsating.
In this case proceed as follows:
4.1) To purge air bubbles from hydraulic circuit
a– Hold tool upright in a vice with handles open (see Figure).
b– Unscrew the main handle (25) from the body (19) to expose the rubber oil reservoir (18).
c– Remove reservoir cap (03).
d– Operate moveable handle (26) several times, in order to advance the ram (01).
e– Press the pressure release lever (20) to retract the ram, discharge oil pressure from the circuit
and return all oil to the reservoir.
f– Repeat points (d- e) five times, to ensure all air bubbles in the hydraulic circuit are purged into
the reservoir.
g– If the oil level is low, top up as directed in paragraph 4.2.
h– Remove all air from reservoir and fit cap (03).
i– Assemble main handle (25) to tool body.
If the tool continues to malfunction, return the tool for service/repair as detailed in § 7.
3. WARNING
4. MAINTENANCE

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4.2) Oil top up
Every six months check the oil level in the reservoir. If necessary, top up the oil level to the upper lip
of the reservoir and remove all air from the reservoir, see 4.1, points a, b, c, and e, finally, complete
with operations hand i.
Always use clean recommended oil, see § 1.
Do not use old or recycled oil.
Do not use hydraulic brake fluid.
Ensure that disposal of used oil is in accordance with current legislation.
4.3) Replacement of the automatic coupler
To replace the automatic coupler of the hose or head, proceed as follows:
–Remove the old coupler.
–Carefully clean the thread to remove old sealant.
–Apply Teflon tape to the thread
–Fit the new automatic coupler and tighten to 20 Nm (15 lbf ft).
26

25
18
03
19
39
20

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The guarantee is void if parts used are not Cembre original spares.
When ordering spare parts always specify the following:
- code number of item
- name of item
- type of tool
- tool serial number
Code N° Item DESCRIPTION Qty
6620104 01 PUMPING RAM 1
6900641 02 PRESSURE RELEASE SCREW 1
6800040 03RESERVOIR CAP 1
6890036 04 FLEXIBLE HOSE 1
665009505JUNCTION 1
6520280 06 SPRING 1
6600100 07 BALL POSITIONING DOWEL 1
6641020 08 M6 WASHER 1
6520160 09 SUCTION SPRING 1
6520200 10 SPRING 1
6340590 11 PIN 1
6560262 12 MOVEABLE HANDLE PIN 2
6380200 13HANDLE GRIP 1
6520520 11 SPRING 1
6600020 15SPRING LOADED PIN 1
6800020 16 PRESSURE TESTING CAP 1
6090060 17 HANDLE LATCH 1
6720050 18 RESERVOIR 1
6160070 19 BODY 1
Code N° Item DESCRIPTION Qty
644008520 PRESSURE RELEASE LEVER 1
6060060 21 CAP 1
6520401 22 SPRING 1
6040160 23BACK-UP RING 1
6900601 24 COMPLETE SUCTION SCREW 1
6480055 25MAIN HANDLE ASSY 1
6480910 26 MOVEABLE HANDLE 1
6895046 27 COMPLETE VALVE 1
6700060 29 CIRCLIP 4
6060122 30 Q14-F COUPLER 1
6360240 31 O-RING 1
636025032 O-RING 1
6360268 33 O-RING 1
6360022 34 O-RING 1
6232001 35 TG0350 LABEL 1
6040422 36 Ø 20 CIRCLIP 1
6760100 37Ø3x16 SPLIT PIN 1
6740100 385/32" BALL 1
6760120 397/32"BALL 2
5. PARTS LIST (PUMP UNIT) (Ref. to Fig. 10)

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FIG. 10
LONGITUDINAL SECTION
05
36
23
21
31
33
11
10
39
19
32
25
18
03
09
38
08
24
22
01
26
13
17
12
29
04 30
39
07
14
16
34
27
37
02
06
15
20
35

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The items () are those Cembre recommend replacing if the head is disassembled.
The guarantee is void if parts used are not Cembre original spares.
When ordering spare parts always specify the following:
- code number of item
- name of item
- type of tool
- tool serial number
FIG. 11
LONGITUDINAL SECTION
Code N° Item DESCRIPTION Qty
6060120 01 Q14-MS COUPLER 1
6040240 02 BACK-UP RING 1
6840070 03CUP 1
6360320 04 O-RING 1
6340060 05M 6x6 GRUB SCREW 1
6232337 06 (TG.0537) METAL LABEL 1
6650118 07 ø 2,5x3,5RIVET 2
662022508 RAM 1
6900670 09 SCREW 2
6360268 10 O-RING 1
6120171 11 CYLINDER 1
6232001 12 (TG.0350) WARNING LABEL 1
652043013RAM RETURN SPRING 1
6641038 14 RHTEPE-S16 WASHER 1
680015615PROTECTION CAP 1
6. PARTS LIST (TOOL HEAD) (Ref. to Fig. 11)
04
03
02
14
13
11
12
10
01
05
06
07
08
09
15

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In the case of a breakdown contact our Area Agent who will advise you on the problem and give
you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible,
attach a copy of theTest Certificate supplied by Cembre together with the tool or fill in and attach
the form available in the “ASSISTANCE” section of the Cembre website.
7. RETURN TO Cembre FOR OVERHAUL
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NOTES

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This manual is the property of Cembre: any reproduction is forbidden without written permission.cod.6261298
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