Cembre HTEPE.DET12, HTEPE.DET16 Operation And Maintenance Manual

HYDRAULIC TOOL

HTEPE.DET12 HTEPE.DET16

ENGLISH

OPERATION AND MAINTENANCE MANUAL

19 M 069 E

1

WARNINGS

TG0350

1

1

– Before using the tool, carefully read the instructions in this manual.

– When operating the tool, keep hands away from the danger zone.

2

2

3

3

– Always wear safety gloves when operating.

2

HTEPE.DET12 system consists of:
– Pump unit
– Hydraulic head type RHTEPE-S
– Plunger type OG 13.2T (qty 2)
– GO / NO GO gauge type CAL 22.23
– Plastic case VAL-P14

1. GENERAL CHARACTERISTICS

– Application range:

HTEPE.DET16 system consists of:

– Pump unit
– Hydraulic head type RHTEPE-S16
– Plunger type OG 16.2T (qty 2)
– GO / NO GO gauge type CAL 22.23
– Plastic case VAL-P14

HTEPE.DET12:
M12 bolt (e.g. AR61, AR65, AR261, AR265).

HTEPE.DET16:
M16 bolt (e.g. AR6116, AR6516, AR26116, AR26516).

– Installation force: ........................................................................................................................55 kN

– Rated operating pressure: .......................................................................................................700 bar (10000 psi)

– Flexible hose: length ..................................................................................................................900mm

– Dimensions (pump body): length ........................................................................................285 mm

width ..........................................................................................130 mm

– Dimensions (head): length RHTEPE-S ....................................................................116 mm

length RHTEPE-S16 ...............................................................133 mm

width ..........................................................................................67,5 mm

diameter ...................................................................................48 mm

suitable for installing rail web electrical connection system having

suitable for installing rail web electrical connection system having

– Weight: ............................................................................................................................................3,8 kg

– Recommended oil: ...................................................... TOTAL DIEKAN 1640

– Safety: the tool is provided with a maximum pressure valve.

or equivalent

2. INSTRUCTIONS FOR USE

2.1) Setting

Connect the male coupler of the head to the female coupler on the tool hose; ensure that the couplers
are securely fi tted.

Before connecting or disconnecting the head and the hose, ensure that the ram of the head is

fully retracted.

3

2.2)

Installation procedure for AR61, AR65, AR6116, AR6516 rail web electrical connections

– Drill rail web or, if already drilled, use a suitable reamer to clean the hole (Fig. 1).
– Check the size of the hole with the CAL 22.23 “GO/NO GO” gauge (Fig. 2a):

- 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.
Using the same gauge, check the rail thickness (Fig. 2b):

- If the yellow band protrudes, use the AR65... series.

- If the yellow band does not protrude, use the AR61.... series.

– 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 fi rmly screw and tighten
plunger onto the tool head (Fig. 4).

– Introduce the stem of the plunger into the AR...-1 copper bush from the unfl anged side

tighten the insert of the plunger OG... onto the stem

Plungers OG13.2T and OG16.2T are composed
separate items: insert and stem.

To rapidly execute subsequent extrusion opera
is suffi cient to unscrew the insert, leaving
screwed onto the head.

–

Operate the moveable handle of the tool (Fig. 6) to pull the plunger

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. 7).

the stem fi rmly

tions, it

(Fig. 5) u

of 2

sing the recess in the gauge CAL22.23.

insert stem

OG..

. completely through the

the stem of the

and s

red part

green part

yellow band

crew and

2.3) Conductor assembly

– Crimp the lug onto the conductor.
– Assemble all pieces as shown in Fig. 8.
– Fit the self-locking nut (Fig. 9) and tighten to the torque setting indicated.

FIG. 2a

FIG. 1

NO

FIG. 2b

YES

4

copper
bush

stem

FIG. 3

FIG. 5

FIG. 4

insert

FIG. 6

washer

FIG. 8

FIG. 7

cable

lug

screw

copper bush

self-locking

nut

FIG. 9

5

2.4) Installation procedure for AR261, AR265, AR26116, AR26516 rail web electrical
connections

Drill rail web or, if already drilled, use a suitable reamer to clean the hole (Fig. 1).

–
– Check the size of the hole with the CAL 22.23 “GO/NO GO” gauge (Fig. 2a):

- The hole size is correct only if 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.
Using the same gauge, check the rail thickness (Fig. 2b):

- If the yellow band protrudes, use the AR 265... series.

- If the yellow band does not protrude, use the AR 261... series.

–

Insert the AR2...-1 copper bush into the rail web hole and position the AR2...-2 copper

the opposite web side (Fig. 3).

–

Ensure that the ram in the head is fully retracted and then fi rmly screw and tighten

plunger onto the tool head (Fig. 4).

–

Introduce the stem of the plunger into the AR2...-2 copper washer and tighten the insert

OG... onto the stem (Fig. 5) using the recess in the gauge CAL22.23.

Plungers OG13.2T and OG16.2T are compo
separate items: insert and stem.
To rapidly execute subsequent extrusion opera
it is suffi cient to unscrew the insert, leaving
fi rmly screwed onto the head.

–

Operate the moveable handle of the tool (Fig. 6) to pull the plunger

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. 7).

sed of 2

tions,

the stem

insert stem

OG..

. completely through the

red part

green part

yellow band

washer on

the stem of the

of the plunger

2.5) Conductor assembly

– Crimp the two lugs onto the conductors.
– Assemble all pieces as shown in Fig. 8.
– Fit the self-locking nut (Fig. 9) and tighten to the torque setting indicated.

FIG. 1

FIG. 2a

NO

FIG. 2b

YES

6

copper
bush

copper
washer

stem

FIG. 3

FIG. 5

FIG. 4

insert

FIG. 6

washer

self-locking

nut

7

copper

bush

lug

FIG. 7

FIG. 8

bolt

➟

washer

copper washer

FIG. 9

3. WARNING

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 fl exible 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 fl exible hoses are subject to a natural ageing process which can result in a reduction
in performance potentially aff ecting 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 fi ttings.

Before using the pump always check the integrity of the fl exible 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 accessoires 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 "GO / NO GO" gauge, and the two
plungers.

4. MAINTENANCE

Air in the hydraulic circuit may aff ect 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).

8

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) fi ve 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 fi t 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.

03

25

18

20

26

19

39

4.2) Oil top up

Every six months check the oil level in the reservoir. If necessary, to 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, fi nally, complete with
operations h and i.

Always use clean recommended oil, see § 1.
Do not use old or recycled oil.
Do not use hydraulic brake fl uid.

Ensure that disposal of used oil is in accordance with current legislation.

9

4.2) 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 Tefl on tape to the thread.
– Fit the new automatic coupler and tighten to 30 Nm (22 lbf ft).

5. PARTS LIST (PUMP UNIT) (Ref. to Fig. 10)

Code N° Item DESCRIPTION Qty

6620104 01 PUMPING RAM 1
6900641 02 PRESSURE RELEASE SCREW 1
6800040 03 RESERVOIR CAP 1
6890036 04 FLEXIBLE HOSE 1
6650095 05 JUNCTION 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 13 HANDLE GRIP 1
6520520 11 SPRING 1
6600020 15 SPRING 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

6440085 20 PRESSURE RELEASE LEVER 1
6060060 21 CAP 1
6520401 22 SPRING 1
6040160 23 BACK-UP RING 1
6900601 24 COMPLETE SUCTION SCREW 1
6480055 25 MAIN 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
6360250 32 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 37Ø 3x16 SPLIT PIN 1
6740100 38 5/32" BALL 1
6760120 397/32"BALL 2

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

10

05
36
23

21

31

04 30

33

11

10

09

39

38

08
24

19
32
25

12
29

22

01

26

13

39

07

14

16

34

27

37
02

06

15
20

35

18
03

17

FIG. 10
LONGITUDINAL SECTION

11

6. PARTS LIST (TOOL HEAD) (Ref. to Fig. 11)

Code N° Item DESCRIPTION Qty

6060120 01 Q14-MS COUPLER 1
6040240
6840070 03 CUP 1
6360320
6340060 05 M 6x6 GRUB SCREW 1
6232337 06 (TG.0537) METAL LABEL 1
6232247 07 (TG.0447) METAL LABEL 1
6650118 08 ø 2,5x3,5 RIVET 2
6620225 09 RAM 1
6900670 10 SCREW 2
6360268
6232001 12 (TG.0350) WARNING LABEL 1
6120171 13 CYLINDER 1
6520430 14 RAM RETURN SPRING 1
664103815 RHTEPE-S16 WASHER 1
6641038 16 RHTEPE-S12 WASHER 1
6800156 17 PROTECTION CAP 1

 02

 04

 11

BACK-UP RING 1

O-RING 1

O-RING 1

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

12

RHTEPE-S12RHTEPE-S16

04

03

02

11

12

13

14

16

04

03

01

11

12

17

05

13

07

14

08

09

10

15

13

02

01

17

05

06

08

09

10

FIG. 11 LONGITUDINAL SECTION

7. RETURN TO Cembre FOR OVERHAUL

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 the Test Certifi cate supplied by Cembre together with the tool or fi ll in and attach the form

available in the “ASSISTANCE” section of the Cembre website.

NOTES

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14

NOTES

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15

6

Cembre Ltd.

Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (UK)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembre.co.uk

Cembre S.a.r.l.

22 Avenue Ferdinand de Lesseps
91420 Morangis (France)
Tél.: [phone] - Fax: [phone]
CS 92014 - 91423 Morangis Cédex
E-mail: [e-mail]
www.cembre.fr

Cembre España S.L.U.

Calle Verano 6 y 8
28850 Torrejón de Ardoz - Madrid (España)
Teléfono: 91 4852580
Telefax: 91 4852581
E-mail: [e-mail]
www.cembre.es

Cembre GmbH

Heidemannstraße 166
80939 München (Deutschland)
Telefon: [phone]
Telefax: 089 35806777
E-mail: [e-mail]
www.cembre.de

Cembre S.p.A.

Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: [e-mail]
www.cembre.com

Cembre Inc.

Raritan Center Business Park
181 Fieldcrest Avenue
Edison, New Jersey 08837 (USA)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembreinc.com

This manual is the property of Cembre: any reproduction is forbidden without written permission.cod. 6261059

IKUMA GmbH & Co. KG

Boschstraße 7
71384 Weinstadt (Deutschland)
Telefon: [phone] - 60
Telefax: 07151 20536 - 80
E-mail: [e-mail]
www.ikuma.de

www.cembre.com

161