Installation Manual
Contents
1. their opening by which the dif ferent rail base forms are cover a ed See measure x on the right Because the different clamps are often hardly distinguishable at first sight we have marked the bottom namely with the letters A C wD E 18 4 K N P R81 R82 T U V WE Y5ON or Y60 etc Always make sure you are mounting the correct clamp which is perfectly suitable for your rail In case of uncertainty please refer to the KAGO Clamp Directory which includes information about the different basic clamp types as well as the most common rails Caution If clamps are mounted on unsuitable rails their func tion is not guaranteed due to incomplete fitting or insufficient clamping pressure The worst case is overstretching for ex ample at switches which could even result in clamp breakage 2 Installation of rail contact clamps Caution Use a hammer with the ideal weight bet ween 1 and 2 kilograms for mounting and removal It must not be heavier than 2 kg otherwise the clamp or the spring could be damaged Place the clamp on the rail base and give it a few light taps I so that it gets a bit of tension and Starts to grip Pay attention that you hit the curve and not the head of the clamp while ham mering II Stop Afterwards three hard blows will normally do to mount the clamp sufficiently After reaching the stop Il the clamp will automatical2. mm or flexible cable 4 mm Typ E3 Groove rei type Cable cross section 8mm Wire 8 mm or flexible Cable 50 mm highly flexible 5 mm Wire 5 mm or flexible Cable 16 mm 10mm Flexible cable 50 mm or highly flexible 70 mm 3mm Wire 3 mm or flexible cable 4 mm Before use please check if wire cable fits and in which groove Lay the bright cable or wire into the correct groove l and push the contact spring through the rear slot Il over the cable into the front Slot Now hammer I contact spring to the stop ll the spring an ex is guaranteed the onto the clamp head up Due to the pressure of NA gt cellent electrical contact ar Caution Use only one cable at a time 9 5 2 Cable installation for type E4 Before fixing the cable the contact spring must be removed This is done most eas ily when the clamp is still mounted on the rail namely with gentle taps on the not ches ill left or the small area at the top of the contact spring in the picture bet ween forefinger and thumb Simulta neously slide the spring out of the clamp some connecting possibilities 35 50 70 mm Afterwards lay the stripped cable into the correct groove I and slide the contact spring from behind into the clamp head Il The cable must be slightly clamped by the spring pressure and the contact spring must hold its position by itself Before use please check if cable fits and in whic
3. be used again and again Of course their clamping pressure could slightly decrease with every repeated fastening so thata testing of the clamping pres sure is recommendable be fore using KAGO clamps again After all they have an important role to play in rail way safety which means they must be absolutely de pendable The testing must be done with the KAGO testing gau ge Ifthe clamp holds on the precision pin the function is guaranteed fig a If it falls through it is no longer us able fig b When it comes to railbonds do not forget to take the op portunity to also check the condition of the cables Caution The existing testing gauge loses its validity for clamps with the lot marking C26 see clamp bottom We look forward to offer ing you a new testing gauge for C26 clamps 15 6 2 Testing instructions for KAGO clamps 1 Tighten the testing gauge in a vice 2 Place the clamp onto the precision pin of the testing gauge from above 3a Good Clamp holds on the pin i e it can be re used 3b Bad Clamp falls through i e it is no longer usable schlecht 6 3 Groove cleaning and spring checking only for connecting types E2 E3 E4 7mm 35mm 25 mm 35 50 mm 4 10 mm smm 50 mm 16 mm 35 50 mm 3mm 4 10 mm amp 6 10 mm amp 11 16 mm Y 2 5 5 mm amp 17 21 mm 17 Low voltage connec tions 1 5 12 Volt are only gua
4. h groove Now hammer l the contact spring I onto the clamp head up to the stop II The notches hold it in position Due to the pressure of the spring an excellent electrical contact is guaranteed Caution Not appropriate for stiff cables Use only one cable at a time 10 5 3 Cable installation for type E5 Connecting type E5 has been developed as a complement to type E4 and is delivered with the loose clamping counterpart 1 the hori zontal adjustment part Il a locking plate Ill and a screw M16x50 IV In both grooves steel bronze and copper wires and cables with di ameters between 9 and 14 mm can be clamped This corresponds with cable cross sections of ca 50 120 mm according to the con ductor structure When using big cross sections it is recommendable on the one hand to leave out the washer so that the screw can be screwed in deeply enough on the other hand both grooves should be occupied with the cable to guarantee an optimal contact pressure Caution To avoid loose cable connections make absolutely sure new locking plates are correctly mounted for every re newed cable mounting For mounting tips please refer to the end of chapter 5 4 at the bottom of the next page 11 5 4 Cable installation for types Gl and El Place the cable lug I the locking plate Il and the bolt Ill on the clamp Type GI Suitable for cable lugs up to 150mm Type El Suitable for cable l
5. kaufmann www kago com Installation Manual for KAGO rail contact clamps and KAGO cable fastening clamps ee 9 1 3 2 9 0 9 4 99 9 6 6 1 6 2 6 3 List of contents Does the clamp fit your rail profile Installation of rail contact clamps Installation of cable fastening clamps Removal of clamps Cable installation for types E2 and E3 Cable installation for type E4 Cable installation for type E5 Cable installation for types Gl and El Cable installation for type EA Cable laying of railbonds Why testing of rail contact clamps Test instructions before reuse Groove cleaning and spring checking O O O N QOQ fF 11 12 13 14 15 16 1 1 Does the clamp fit your rail profile Important Please read carefully Hundreds of different rails are in use worldwide The already devel oped basic types of KAGO clamps integrate this variety to a large extent The basic types differ in two essential features Firstly in length and number of the existing slots by which it is pos sible to cover different rail base widths See example below 1 slot 125 mm 2 Slot 140 mm 3 slot 150 mm Basic type C Suitable for the following rails 1 sloti S49 Form B S54 SBB I DSB 45 UIC54E SBB IV Form C 2 slot UIC54 SBB III 54 kg 98lb 109lb 110A 113A 113 lb U36 U50 EB50T Ri35G 35GP 3 slot UIC60 SBB VI UNI60 Ri55 Ri53 secondly the clamps differ in
6. ly click into place at the rail base s lower edge Ill If the clamp jumps back which can above all happen with brand new clamps re peat the procedure At first use light taps then hit hard Make sure the clamp is gripping properly at the front and back Don t forget The clamp functions like a spring and therefore has a tremendous inherent strength This is necessary so that the teeth bite firmly and permanently into the rail through brake dust grease rust or other residue Please wear safety goggles and ensure that nobody is standing in front of or behind you during the whole mounting procedure Duration of installation KAGO contact clamps are mainly used for temporary electric connections However they can also stay built in permanently for years or even decades without any problem Even the most intense clamp vibrations can do no harm assuming cor rect installation directions have been followed An oxidisation of the contact points is effectively prevented long term due to the pressure remaining constant over years 3 Installation of cable fastening clamps Fastening clamps are basically mounted in the same way as con tact clamps see chap ter 2 II Stop traverse en b ton traversa di cemento A concrete sleeper Art R39 Falsch Art R38 To protect the pipe from damage caused by tamping or other track maintenance machines mount it next to the sleeper as close as possible as shown i
7. n the pictures A Clamp removal of contact and fastening clamps Contact spring For type E4 remove the spring before detaching the clamp from the rail Using gentle blows on the notches fig I or the small area at the top of the contact spring you can free it and slide it out Please refer chapter 6 2 For type E2 E3 we recom mend the opposite procedure Please refer chapter 6 1 Clamp Detach the clamp from the rail with a well aimed hammer blow from above on the tip of the clamp fig Il Because the mounted clamp is under mechanical pressure it is important that you ensure nobody is standing behind or in front of you during the process Protect yourself by placing the sole of your shoe in the di rection of the clamp head Caution Never strike the side of the clamp fig Ill because this will impair its spring pressure and ruin it for further use as a contact clamp 5 1 Cable installation for types E2 and E3 Before mounting the wire or the O cable first remove the contact spring This is done most easily by gently hammering on the front end of the contact spring before the clamp is mounted to the rail ill left Otherwise knock the spring out by well aimed hits with the pointed end of the hammer ill right Typ E2 Groove Wire type Cable cross section Wire 7 mm Wire 6 mm or flexible cable 25 mm 35 mm Flexible cable 50 mm or highly flexible 70 mm Wire 3
8. ranteed as long as each KAGO clamp is tested after use with the gauge and if dirty grooves have been cleaned by means of a steel brush and a liquid cleaner like paraf fin if required Contact springs can break when mounted carelessly too hard hits cant ing etc They must be treated unlike the clamp itself as wearing parts that have to be replaced when signs of wear and tear like defor mations cracks etc appear 18 19 The policy of KAGO AG is one of continuous development The company therefore reserves the right to change specifications and introduce design improvements at any time and without notice For more detailled information please refer to our KAGO Clamp Directory This installation manual must be strictly obeyed and no KAGO clamps must be modified mechanically or by welding otherwise any product liability will be rejected The latest update of this booklet can be found on http www kago com pdf e 62 mi pdf Copyright by KAGO AG All rights reserved Version 19 11 2012 20
9. ugs up to 240mm Afterwards tighten the bolt according to the dimension of the thread Tightening torque in Nm O t C T 15 To prevent the bolt from loosening even through massive vibrations hammer the longer flap of the locking plate down towards the side of the clamp ill right and the shorter flap up towards the bolt ill left Caution To avoid loose cable connections make absolutely sure that new locking plates are correctly mounted for every renewed cable mounting 12 5 5 Cable installation for type EA Place the cable lug and the re usable self locking nut on the clamp Then tighten the nut according to the dimension of the stud Stud Tightening torque inNm _ 10 0 030 M20 Type EA Suitable for cable lugs up to 240 mm Caution To avoid loose cable connections please ensure that you always apply re usable or new locknuts for every renewed cable mounting 5 6 Cable laying of railbonds N N Le NIS To protect the cable from damage caused by tamping or other track maintenance machines lay it as close as possible to rails and sleepers as shown in the pictures 14 6 1 Why testing of rail contact clamps Buono Good ok Cattivo Bad Schlecht Mauvais KAGO rail contact clamps were not only developed for one way use On the con trary If they are always mounted correctly KAGO clamps have a very long life time and can
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