Table of Contents
Related Manuals for Mec Trackpack FP-143-HE
Summary of Contents for Mec Trackpack FP-143-HE
- Page 1 Melvelle Equipment Corp Pty Ltd “ Proud Australian Manufacturers” 143 Trackpack Operation, Training & Maintenance Manual P: +61 2 4951 5244 F: +61 2 4950 1291 E:sales@melvelle.com.au www.melvelle.com.au MEC Part Number – MANUAL-143-TP...
- Page 2 Melvelle Equipment Corp Pty Ltd Address: 10 Rogilla Close MARYLANDNSW 2287 AUSTRALIA Phone: 61 2 49 515 224 Fax: 61 2 49 501 291 Email: sales@melvelle.com.au Web: www.melvele.com.au Notes: ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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Page 3: Table Of Contents
Table of Contents TABLE OF CONTENTS .................................. 3 PREFACE ..................................... 5 SAFETY INFORMATION ............................... 6 SAFETY SYMBOLS ................................7 3.1. & S ............................7 AFETY YMBOLS IGNAL ORDS 3.2................................. 8 AZARD ARNING IGNS 3.3............................10 ERSONAL ROTECTION YMBOLS 3.4. - Page 4 FURTHER DOCUMENTS ..............................60 13.1. 2013)................. 61 RACKPACK PRESSURE ETTING ROCEDURE ERSION 13.2 T – P 2013) ................62 RACKPACK PRESSURE ETTING ROCEDURE URRENT ERSION 13.3 ............................. 63 PERATIONAL SSESSMENT 13.4 ..........................66 ROLLEY TO OWER TTACHMENT 13.5 – P 2017) .....................
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Page 5: Preface
The information provided within this manual is the sole property of Melvelle Equipment Corporation Pty Ltd (MEC) and as such, reproduction or replication of any material contained within is not allowed without the written consent of MEC. -
Page 6: Safety Information
If the training package information conflicts with existing site documentation, then the authorised site and/or end user is to consult with MEC in regards to any possible amendments or modifications required. The following practices and procedures must be adhered to: •... -
Page 7: Safety Symbols
3. Safety Symbols The safety symbols and signal words, as shown below, are used to emphasise all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to the equipment. 3.1. -
Page 8: Hazard Warning Signs
3.2. Hazard Warning Signs This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all instructions to avoid possible injury or death. This is the fire risk symbol. It is used to alert you to the potential of a fire starting if ignition sources are present. - Page 9 This is the hot surface symbol. It is used to alert you that the surfaces may be hot. This is the dangerous gases symbol. It is used to alert you to the presence of dangerous gases. This is the fluid under pressure symbol. It is used to alert you that there are fluids under pressure in this machinery.
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Page 10: Personal Protection Symbols
3.3. Personal Protection Symbols This is the eye protection symbol. It is used when eye protection must be worn. This is the hearing protection symbol. It is used when hearing protection must be worn. This is the head protection symbol. It is used when head protection must be worn. -
Page 11: Prohibition Symbols
This is the face protection symbol. It is used when face protection must be worn. This is the long hair protection symbol. It is used when long hair is required to be contained or restrained. 3.4. Prohibition Symbols This is the naked flame symbol. It is used when there is not to be a fire, naked flame, ignition sources and smoking nearby. -
Page 12: Safety Precautions
4. Safety Precautions To ensure safe operation, please read and understand the following statements and their meanings. Also refer to supporting manuals from the engine manufacturer on specific operation and maintenance of the engine. This manual contains safety precautions which are outlined below. Ensure all personnel operating this equipment are properly trained to ensure safe operation Wear personal protective equipment around Accidental Starts can cause severe death... - Page 13 Carbon monoxide can cause severe nausea, Fuel can cause fires and severe burns. fainting or death. Do not fill the fuel tank while the engine is Avoid inhaling exhaust fumes and never hot or running. operate the engine in a closed or refined area. High Pressure fluids can puncture skin and Explosive gas can cause fires and severe acid cause severe injury or death.
- Page 14 Beware of toxic and/or hazardous There is not to be a fire, naked flame, ignition substances used within this machinery. Do sources or smoking around any MEC not inhale, swallow or touch machinery. toxic/hazardous substances. Operation Manual | FP-143 Trackpack...
- Page 15 Injury can occur due to terrain and operating speeds. Electrification can occur if used on live To ensure safe work is achieved, do not third rail and/or fourth rail. exceed walking pace whilst operating this Do not use equipment on live third rail equipment.
- Page 16 Vibration Hazard Normal and proper use of this equipment will Noise Hazard. expose the operator to vibration. Vibration Ensure adequate hearing protection is exposure may cause and/or contribute to worn whilst using this machinery. High injury throughout the body. Ensure proper sound levels may cause permanent hearing procedures are followed for vibration loss.
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Page 17: Equipment Stickers & Tags
5. Equipment Stickers & Tags Below are the stickers and tags utilised on this equipment. IDTAG01 – Melvelle Identification Tag IDTAG02 – Model & Serial No. Tag IDTAG07 – Trackpack Pivot Positions IDTAG09 – Lifting Point WLL 100kg Operation Manual | FP-143 Trackpack Version: 1.6... - Page 18 IDTAG10 – Lifting Point WLL 300kg IDTAG15 – Lifting Point WLL 220lb LAB0003 – Melvelle Newcastle Sticker LAB0004 – Melvelle Achieving Excellence Sticker Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 19 LAB0008 – Safety Label LAB0009 – Hydraulic Oil Label LAB0012 – Attention – Key Must Be Turned Off Sticker LAB0013 – Do Not Manually Lift Sticker Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 20 LAB0032 - Four Person Lift Sticker – Trackpacks LAB0116 – Fuel and Choke Sticker LAB0117 – Throttle Lever Sticker LAB0119 – Isolator Does Not Stop Engine Stickers & Tags Locations Refer to Further Documents section: 13.10 (Pg.70) for sticker locations drawings for all models. Operation Manual | FP-143 Trackpack Version: 1.6...
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Page 21: Emergency Stop
6. Emergency Stop This machine has been fitted with an emergency stop to increase the operational safety of MEC machinery. Important information about the Emergency Stop: The emergency stop is designed to stop the engine and hence the workhead in Emergency situations. -
Page 22: Introduction
Melvelle Equipment Corp Pty Ltd (MEC) supply Trackpacks to the rail industry. The 143 Trackpack is designed to supply hydraulic power to MEC workheads and the brake cylinder on the machine trolleys. The Trackpack also acts as a counterbalance for MEC workheads that assemble to it. -
Page 23: Specifications
8. Specifications 8.1. FP-143-HE - HONDA (PETROL) ELECTRIC START Engine 13HP Honda® Petrol Electric Start (Trackpack) Dimensions 2050mm long x 600mm wide x 520mm high Weight (wet) 115kg Pressure (max) 177.5bar / 2574psi @ 21 L/min (2500 rpm) Flow (max) 30L/min @ 170.5 Bar/2473 psi (3600 rpm) Fuel Type Petrol... -
Page 24: Fp-143-Hr - Honda (Petrol) Recoil Start
8.3. FP-143-HR – HONDA (PETROL) RECOIL START Engine 13HP Honda® Petrol Electric Start (Trackpack) Dimensions 2050mm long x 600mm wide x 520mm high Weight (wet) 110kg Pressure (max) 177.5bar / 2574psi @ 21 L/min (2500 rpm) Flow (max) 30L/min @ 170.5 Bar/2473 psi (3600 rpm) Fuel Type Petrol Hydraulic Oil... -
Page 25: Fp-143-Ye - Yanmar (Diesel) Electric Start
8.5. FP-143-YE – YANMAR (DIESEL) ELECTRIC START Engine 7HP Yanmar® Diesel Electric Start (Trackpack) Dimensions 2050mm long x 600mm wide x 520mm high Weight (wet) 115kg Pressure (max) 150.5bar / 2182.8psi @ 15 L/min (2200 rpm) Flow (max) 24L/min @ 100 Bar/1450 psi (3600 rpm) Fuel Type Diesel Battery... -
Page 26: Operation
9. Operation 9.1. Operating Conditions The following outlines the duties and conditions for which the equipment is intended to be operated: • Used on the intended rail line (gauge) • Used within a possession • Not to be used on third and/or fourth rail electrification •... -
Page 27: Pre-Operation Checks
9.2. Pre-Operation Checks Overall Inspection 1. Check that the equipment is free from damage or defects. 2. If damaged, DO NOT USE. Contact MEC for repairs. Engine Oil 1. Check the level and quality of the engine oil and add if required. - Page 28 1. Inspect all guards and stickers/tags are in place and secure – refer to further document drawings for locations. 2. Ensure there is no damage. 3. If damaged, DO NOT use machinery. Contact MEC for repairs. Emergency Stop System 1. Ensure all electrical plugs are connected.
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Page 29: Assembly Procedures
9.3. Assembly Procedures Before any assembly and/or maintenance are performed, ensure the work head and engine are off and in a neutral position 9.3.1. Machine Trolley (Braked and Un-Braked) 1. Inspect the trolley and ensure it is not damaged and free from defects, and all pre operation checks are done as per section 9.2. -
Page 30: Trackpack Workhead And Power Pack
9.3.2. Trackpack Workhead and Power Pack 9.3.2.1. Connecting Workhead to Trackpack (Fixed boom) – Mechanical Lift Note - 186 E-Clip Remover shown, however all workheads and Trackpacks are connected in a similar manner. 1. Observe all safety precautions. Ensure the operation is being performed on safe and steady ground (no excessive slopes or dangerous terrain). - Page 31 10. By following safe lifting procedures, lift the machine onto the trolley. The cross trolley rollers will sit onto the cross bar (tube). When placing the machine onto the trolley, ensure hands are clear of the cross trolley rollers and cross bar (tube) as personal injury may occur.
- Page 32 3. By following safe lifting procedures, lift the workhead onto ground. A 190 E-Clip workhead weighs approximately 100 kg. MEC Trackpack workhead range from 40kg to 150kg. *See relevant workhead manual for correct lifting procedure. 4. Insert the removable boom onto the...
- Page 33 7. By following safe lifting procedures, lift the Trackpack ensuring it is kept level and easy to move. *See section for information on lifting procedure. 8. Lower the trackpack onto the boom cups. Once the load of the Trackpack is supported by the boom and workhead engage both the boom lockoff pins (Attach the Counterweights for the 186...
- Page 34 10. Remove the slings and/or hooks. The machine can now be moved to either rail for use. This is achieved by raising the workhead off the ground and sliding across the trolley. A second person may be required to assist and push the Trackpack across the trolley.
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Page 35: Operation Procedures
9.4. Operation Procedures Only authorised personnel shall start, operate, or interfere with the normal working of portable machines or trolleys. The user shall be careful to use the machine in the intended way, avoiding over-loading. 9.4.1. Starting the Engine – Electric Start 1. - Page 36 10. Note: if the track-pack has a push button start, ignore key first position steps. Pressing the push button is the same as the key second position. 11. Place throttle in idle (min) position and allow engine to warm up – refer manufacturers manual for required times.
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Page 37: Starting The Engine - Recoil Start
9.4.2. Starting the Engine – Recoil Start 1. Observe all safety precautions 2. Ensure all pre-operation checks have been conducted 3. Ensure the workhead and Trackpack are on safe and steady grounding (no excessive slopes or dangerous terrain conditions) 4. Attach tooling hoses to power pack. Ensure the snap connectors are clean and tool is in ‘NEUTRAL’ position (both handles released) 5. -
Page 38: Equipment Operation
9.4.3. Equipment Operation As the Trackpack is used as a means of providing power to the coupled workheads, the operating instructions are detailed in the assembly and starting procedures. 9.4.4. Stopping the Engine 1. Place tooling and power pack to “NEUTRAL” position 2. -
Page 39: Disassembly Procedures
9.5. Disassembly Procedures 9.5.1. Removal of Trackpack from Track 1. Observe all safety precautions 2. Ensure engine is off and no hydraulic flow is operating to cylinder. 3. Disconnect the brake hose from the trolley cylinder. 4. Disconnect the chain from the retaining profile to release the machine from the trolley. -
Page 40: Lifting The Machinery
9.5.2. Lifting the Machinery 9.5.2.1. Mechanical lifting of Trackpack 1. DO NOT manually lift machinery with fixed booms 2. Observe all safety precautions 3. Ensure all pre-operation checks have been conducted 4. Attach slings or hooks into lifting points on the machinery – see below 5. - Page 41 Removeable boom version Lifting Diagrams on this page and the next two pages: Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 42 Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 43 9.5.2.2. Manual lifting of Trackpack – Removavle boom 1. Manual lifting of this Tracking should only be used if mechanical lifting is not possible, MEC recommends using mechanical lifting only. 2. Observe all safety precautions. 3. Ensure all pre-operation checks have been conducted.
- Page 44 Operation Manual | FP-143 Trackpack Version: 1.6...
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Page 45: Storage & Transport
9.6.1. Storage of Trolley MEC equipment should be stored in a secure, safe, dry location to ensure the equipment is not damaged and maintained in good working order. If possible, machines may be placed onto racks or placed on the ground for storage. Storing the machines in the storage/transport frames will also help to keep the equipment free from damage and allow it to sit level. - Page 46 9.6.2.2. Transport And Stowage Of Trackpack (Removable Boom) In Operation Position The Trackpack can be stored or transported with the boom in the normal operation position. This is how the Trackpack in used with a workhead. Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 47 9.6.2.3. Transport And Stowage Of Trackpack In Stowage Position The Trackpack can be stored or transported with the boom in the stowage position. This is with the boom rotated up in the stowage position on the front of the Trackpack. This position reduces the footprinted taken up by the Trackpack but increases its height.
- Page 48 9.6.2.4. Transport And Stowage Of Trackpack With Boom Removed The Trackpack can be stored or transported with the boom completely removed from the Trackpack. This position reduces the footprinted taken up by the Trackpack but the boom must still be transported separately. This position allows for easier storage on racking.
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Page 49: Equipment Protection & Care
• Always keep critical tool markings such as warning stickers and tags legible. • Power pack and tooling repairs and/or service work must only be performed by MEC or certified and authorised dealer. • Do not use the power pack and/or tooling for applications for which it is not intended. -
Page 50: Maintenance
11. Maintenance Before any maintenance of the machine or trolley is performed, ensure the workhead and engine are off and in a neutral position. Ensure all potential energy is released from the system (springs, cylinders, etc). Ensure maintenance is performed by a competent and authorised person. 11.1. - Page 51 • Soft Face Mallet • Phillips Head Screwdriver • Flat Blade Screwdriver • Multimeter • Ruler and/or Verniers • Long Nose Pliers • Torque Wrench and Sockets Operation Manual | FP-143 Trackpack Version: 1.6...
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Page 52: Maintenance Spares
11.2. Maintenance Spares 143 Yanmar Trackpack (FP-143-YE) Spares Below is a list of spares that may be required for general maintenance during the life of the 143 Yanmar Trackpack. Item MEC Part Number Description 1081289-01 Hydraulic Oil Filter Element 1430122 In-line Pressure Filter 1/2”... - Page 53 143 Honda Trackpack (FP-143-HE) Spares Below is a list of spares that may be required for general maintenance during the life of the 143 Honda Trackpack. Item MEC Part Number Description 1081289-01 Hydraulic Oil Filter Element 1430122 In-line Pressure Filter 1/2” BSPP...
- Page 54 143 Kohler Trackpack (FP-143-KE) Spares Below is a list of spares that may be required for general maintenance during the life of the 143 Kohler Trackpack. Item MEC Part Number Description 1081289-01 Hydraulic Oil Filter Element 1430122 In-line Pressure Filter 1/2” BSPP...
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Page 55: Maintenance Period
*If heavy machine use, the service period may be less. (1) After the first 50 hrs of use. (2) Only to be performed by MEC or certified and authorised dealer. (3) A thorough inspection is required. If hoses undamaged, may leave in service. However, replace hoses every 3 years of operation. -
Page 56: Recommended Fluids
11.4. Recommended Fluids 11.4.1. Engine Oil Below are all the recommended engine oils based of ambient temperature. Unsuitable engine oil considerably reduces engine service life. Only use engine oil that fulfills the specifications stipulated below. Operation Manual | FP-143 Trackpack Version: 1.6... - Page 57 11.4.2. Hydraulic Oil Below are all the recommended hydraulic oils viscosities based of ambient temperature. Unsuitable hydraulic oil or using the wrong viscosity oil can considerably reduce hydraulic component service life and result in poor performance of tools. Only use hydraulic oil that fulfills the specifications stipulated below. Operation Manual | FP-143 Trackpack Version: 1.6...
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Page 58: Troubleshooting
Check both fuel filters Check cabling, listen for pump Fuel pump not functioning activating when attempting to start Fuel injection nozzle not Contact MEC or Hatz functional Check diagnostic screen for Warning on screen warnings. Accept warnings or investigate Check starter is getting current... - Page 59 Emergency stop does not work Switch Damaged Check/Replace switch Blown fuse Check fuse panel Check workhead and/or Defective relay Worklights do not turn on powerpack relays Check light on 12V Deflective light Contact MEC for replacement Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 60 13. Further Documents Please refer to the further documents within for drawing, risk assessment and other related information. Further documents for the 143 Trackpack: Document No. Description Type 143-OPRA Operational Risk Assessment Document 143-PRESSURE1 Trackpack pressure Setting Procedure (Old Version - Pre 2013) Document 143-PRESSURE2 Trackpack pressure Setting Procedure (Current Version - Post 2013)
- Page 61 13.1. Trackpack pressure Setting Procedure (Old Version - Pre 2013) Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 62 13.2 Trackpack pressure Setting Procedure (Current Version – Post 2013) Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 63 13.3 Operational Risk Assessment Operation Manual | FP-143 Trackpack Version: 1.4...
- Page 64 Operation Manual | FP-143 Trackpack Version: 1.4...
- Page 65 Operation Manual | FP-143 Trackpack Version: 1.4...
- Page 66 13.4 Trolley to Power Pack Attachment Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 67 13.5 Trackpack Boom Adjustment (Old Version – Pre April 2017) Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 68 13.6 Trackpack Boom Adjustment (Current Version – Post April 2017) Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 69 13.7 Trackpack Boom Adjustment (Removable Boom) Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 70 13.8 Trackpack Honda Electric Start Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 71 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 72 13.9 Trackpack Yanmar Electric Start Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 73 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 74 13.10 Trackpack Sticker Assembly Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 75 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 76 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 77 13.11 Trackpack Hydraulic Circuit Diagram Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 78 13.12 Honda Trackpack Electric Schematic Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 79 13.13 Yanmar Trackpack Electric Schematic Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 80 13.14 Trackpack Yanmar Electric Start with Purifier Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 81 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 82 13.15 Honda Recoil Start Braked Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 83 13.16 Trackpack Honda Electric Start – Imperial Version (USA) Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 84 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 85 13.17 Trackpack Kohler Electric Start – Imperial Version (USA) Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 86 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 87 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
- Page 88 Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Operation Manual | FP-143 Trackpack Version: 1.6...
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