RAILWAY TORQUE WRENCH LDB-10 THE UNIVERSAL GENIUS formerly
RAILWAY TORQUE WRENCH LDB THE CHALLENGE Railway track construction has always been extremely hard work. Heavy-duty, fuel-powered wrenches had to be used to loosen and tighten bolt connections. These machines were so heavy that several workers were required to operate them. Noise and exhaust emissions also had a negative effect on construction workers and inhabitants. A COMPLEX TASK Bolts with two different thread pitches are normally used to fasten rails. When fixing the W-rail system, the sleeper bolt head bolts ten times faster to the sleeper in comparison to the K-rail system due to the larger thread pitch. Various types of fixing equipment are also used which also makes the process complicated. It mainly depends on the skills of the rail track fitter to fasten the bolts quickly yet carefully. A virtually impossible task due to the time restrictions often involved. All rail systems used to be fastened with the same torque setting of approx. 200 Nm. However this setting is suboptimal for the majority of tracks. In practice one torque setting means that rails are incorrectly fastened and can lead to the sleepers breaking and bolts cracking. Different pitch... and it becomes difficult to torque Tightening torque Bolt Rail track system Fixing equipment Bolting classification Torque Summary 200 Nm Clip bolt Sleeper bolt KS-rail system K-rail system W-rail system Rail clips Rail clips Angular guide plates Clamping plates Extremely soft Standard Medium-hard ~100 Nm too low Shifting of sleepers 200 Nm Optimum ~350 Nm too high Cracks in sleepers Cracks in bolts One torque setting for all types of rail track systems produces non-reproducible results.
2 3 ONE SOLUTION FOR ALL CHALLENGES: THE UNIVERSAL LDB-10 RAILWAY TORQUE WRENCH On behalf of and in close cooperation with DB Bahnbau Gruppe, we have developed a compact and powerful answer to this challenge. The LDB-10 is a battery-operated railway torque wrench weighing less than 20 kg. Light enough to be carried by one person. Powerful enough to tighten up to 1,400 rail track bolts. Change of direction right on the handle Select the rail system directly on the large, illuminated colour display Height-adjustable handle adjusts to the operator s height Low-wear, brushless direct current drive with 16 kw maximum output Robust, lockable 48V Lithium Ion battery. For approx. 1,400 bolts on new W-rail system Maximum breakaway torque 1,100 Nm Awarded with the Additional handles, variable attachment COMPETENCE PRIZE BADEN-WÜRTTEMBERG FOR INNOVATION AND QUALITY 2015
RAILWAY TORQUE WRENCH LDB FLEXIBLE USE IS THE FEATURE OF A UNIVERSAL TALENT Vertical. Horizontal. The LDB-10 can be used for tightening and loosening horizontal bolts for insulated rail joints, fishplate joints, check rail bolts, track switch bolts etc. In comparison to the impact wrench, each bolt is opened. Ergonomic. It can be held perfectly balanced in the hand of the operator thanks to the ergonomic, height-adjustable handle. Two handles that can be mounted at variable heights allows the operator to adapt the device depending on the type of work. Lightweight. Balanced. The universal railway torque wrench weighs about 17 kg, a fraction of conventional machines and can easily be operated and moved by one operator. In deep. Alongside bolting, the LDB-10 can also be used to drill sleepers using a suitable drilling adapter.
4 5 IN A NUTSHELL: OUR FORMULA FOR SUCCESS Lightweight & compact for 1-man operation at just 17.2 kg No exhaust and emission with 0.0 g CO2footprint For all types of rail track systems High power for maximum flexibility with 16 kw (22 HP) High bolting precision Reliably prevents concrete sleepers from being damaged Logs all bolt connections (optional) Environmentally-friendly - no noise or emission. Environmentally-friendly battery operation ensures zero-emission working. Advantage: Can be used in tunnels. This tool can be operated during the night as its noise levels are considerably lower than with other drives. Optional documentation. The quality of each single bolt connection must be verified in line with increasing demands on safety and quality. The LDB-10 has been designed with this in mind and stores the type of rail track system, the time of bolting, the torque and the correct tightening. The memory saves up to 50,000 bolting operations and can be conveniently read out on the PC. View the flexible applications here: Precise tightening control. The torque no longer has to be set on the LDB-10. The operator simply has to select the type of rail system from a pre-configured menu. The corresponding torques and bolting speeds have been pre-entered at the factory. The correct setting can be made quickly. And above all: Damages on the sleepers and bolts can be easily avoided. Versatile. The LDB-10 can also be equipped with a universal impact socket. With this, both clip bolts (hexagon 39 mm) and sleeper bolts (square 21/28) and even fishplate bolts (hexagon 41 mm) can be torqued. W-, KS-, K-rail and track switches can be torqued without having to change tools.
a RAILWAY TORQUE WRENCH LDB LÖSOMAT IN USE Three types of application In vertical operation, the LDB-10 can be used in three different ways: Easy and flexible by hand for maintenance and emergency applications. For retrofitting work using an extended handle and a reaction arm on single trolley rail cars. Long tracks can be worked on using the twin trolley rail car and two devices working in parallel. With parallel right and left bolting, longer tracks can be completed quickly and rail tracks with elastic intermediate layers can be assembled according to standards. Handles with variable mounting options ensure comfortable, ergonomic and back-friendly working. ONE SYSTEM AN INFINITE NUM- BER OF COMBINATIONS POSSIBLE Vertical operation Horizontal operation Drilling operation Vertical operation by hand for maintenance and emergencies Reaction arm Universal impact socket 3/4 Single trolley vertical operation in rail cars for retrofitting work Reaction arm Handle extension Twin trolley vertical operation in rail cars for rail track connections Swivel arm Connection kit Horizontal operation for fishplate and check rail connections Double handle: flexible attachment Drilling operation for all wooden sleepers Drilling adapter 3/4 Timber/concrete drill bit: Ø 18, Ø 20 and Ø 40 Special accessories Special sockets for railway crossings Special country-specific sockets: Customised products from steel or light metal In use day and night The device is ideal for working at night or in tunnels with integrated LEDs that light up the bolt connection in vertical and horizontal operation. Technical data 474 mm Thanks to its quiet less than 80 db(a) and zero-emission battery operation, the LDB-10 can be used on night time construction sites close to residential areas without disturbing inhabitants. 602 mm 3/4 130 mm
6 7 ALL-ROUND, RELIABLE BOLTING The LDB-10 is a versatile bolting system for railway construction. With its extreme power capacity and flexible extension options, it is ideal for all types of bolting operations. Type N m lbf ft L B H ~ rpm a min / max min / max mm mm mm LDB-10 150-1100 1 110-810 1 160 ¾ 474 130 602 17.2 1 breakaway torque 2 Without reaction arm, without impact socket, with battery. All rights reserved. Subject to modifications without prior notice. Type C N U L B H mm mm mm Li-Ion phosphate-based battery 10 Ah (480 Wh) 48 V DC 178 130 337 4.6 Type Input voltage Output voltage P L B H mm mm mm 0 0 Charging time Charger with mains cable 100-260V/45-70Hz 48V DC / 1.6A 100 W 218 121 55 1.35 approx. 4.6 h IEC C14 connector, Protective insulation Protection class I (DIN EN 61140) 0 2 Accessories upgraded on a modular basis Impact sockets Universal impact socket 3/4 and special sockets Universal impact socket 3/4 Special reaction arms Drilling adapter with various bits Impact socket 3/4 SW 41 IF spring-based Quick charger for Lithium ion battery Lithium ion battery, 48 V Impact socket 3/4 Vossloh streamline profile LB.TRACK module for documentation Adapter for rail car Impact socket 3/4 SW41 streamline LB.TRACK documentation module Magnetic inductive data interface Inductive USB data transfer cable Software for the documentation Bolting protocol
RAILWAY TORQUE WRENCH LDB SCOPE OF DELIVERY LDB-10 unit reaction arm 3/4 made of light metal with hold function Lithium ion battery (2 x) Double handle Charger with mains cable Factory calibration certificate Operating manual WATCH OUR VIDEO - SEE FOR YOURSELF! Please feel free to contact us: GEDORE Torque Solutions GmbH Bertha-Benz-Straße 12 71665 Vaihingen/ Enz GERMANY Fon +49 7042 94 41-0 Fax +49 7042 94 41-41 info@loesomat.de www.gedore-torque-solutions.com