03100c rail puller - railtech matweld · of the puller, always check that the hydraulic power...

632 South 3rd StreetP.O. Box 2816 • Paducah, KY 42002

Phone: 270-444-0085Fax:270-443-6180

Website: www.matweld.comEmail: [email protected]

MATWELD, INC. PHONE:(270) 444-0085 FAX:(270) 443-6180Matweld reserves the right to change parts, features, or specifications without notice.

The Matweld 03100C is a hydraulic actuated 120 ton rail puller. Operators will appreci-ate the single unit construction allowing quick set up time. The operator station housesan integrated intensifier and control valve manifold. Clamping blocks are captured andthis self-aligning design is preloaded hydraulically for a safe and efficient pull.

SPECIFICATIONS

HYDRAULICS

Flow 5 (19 lpm)or

10 gpm (38 lpm)

Pulling cylinder Pressure:Rated 5500 psi (385 bar)

Clamp cylinder pressure:Rated 2000 psi (140 bar)

DIMENSION WEIGHT

03100C RAIL PULLER

1350lbs (612 kg)

Overall length 99” (2515mm)

Width 34” (864mm)

Height 17” (432mm)

01/13

2


01/13

CONTENTS

1. SPECIFICATIONS (COVER)

2. GENERAL SAFETY PRECAUTIONS

3. OPERATOR LIST OF LOCAL SAFETY REGULATIONS

4. OPERATION SAFETY PRECAUTIONS

5. PREPARATION FOR USE

6. OPERATION INSTRUCTIONS

7. CONVERSION TABLE

8. MAINTENANCE INSTRUCTIONS

9. REPAIR AND TROUBLE SHOOTING

10. EMERGENCY REMOVAL INSTRUCTIONS

11. DRAWINGS

SECTIONS 12 AND 13 OMITTED THIS PULLER

14. DECAL LEGEND

15. REVIEW OF HYDRAULIC PRINCIPLES

16. GENERAL NOTES

17. WARRANTY INFORMATION

18. CUSTOMER INFORMATION

3


01/13

2. GENERAL SAFETY PRECAUTIONS:TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLY WITH THESAFETY PRECAUTIONS GIVEN IN THIS MANUAL, AND WITH ALL STICKERS AND TAGS ATTACHEDTO THE TOOL AND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY. READTO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERATION INSTRUCTIONSBEFORE YOU USE OR MAINTAIN THE TOOL. REVIEW THE MANUAL DAILY BEFORE USING THETOOL. IN ADDITION, FOLLOW ALL SAFETY GUIDELINES GIVEN YOU BY YOUR SUPERVISOR.DO NOT USE THE TOOL IF YOU HAVE ANY QUESTIONS ABOUT THE OPERATION, SAFETY ORMAINTENANCE OF THIS TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT INPERSONAL INJURY OR EQUIPMENT DAMAGE.

MATWELD HAS NO CONTROL OVER TOOL USE OR OPERATION ONCE IT LEAVES THEMATWELD PLANT. MATWELD HAS NO CONTROL OVER OPERATOR OR MAINTAINER SELEC-TION. THE CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOL’S SUITABILITY FOR APARTICULAR FUNCTION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORKSAFELY AND EFFICIENTLY WITHOUT ENDANGERING THEMSELVES OR BYSTANDERS. UNDER-STANDING OF THE OPERATION AND MAINTENANCE MANUAL IS ESSENTIAL FOR ANYONE US-ING OR MAINTAINING THE TOOL.

• DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLY AND PROPERLYTRAINED OR UNDER THE SUPERVISION OF AN INSTRUCTOR.

• CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSUREARE AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED.PERSONAL INJURY OR DAMAGE TO THE TOOL CAN RESULT.

• OPERATORS MUST CLEAR THE WORK AREA OF NON-ESSENTIAL PERSONNEL. FLYINGDEBRIS CAN CAUSE SERIOUS INJURY.

• THE OPERATOR MUST BE FAMILIAR WITH ALL PROHIBITED WORK AREAS SUCH AS UN-SAFE GRADES, POOR FOOTING AREAS AND OVERHEAD HAZARDS.

• MAINTAIN BALANCE AND PROPER FOOTING AT ALL TIMES. NEVER OVERREACH TO THEEXTENT THAT A BROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOUTO LOSE YOUR BALANCE AND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONEELSE.

• NEVER TRANSPORT THE PULLER WITH POWERUNIT ATTACHED

4


01/13

• WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CON-DUCTORS ARE ENERGIZED AND THAT HOSES AND CLOTHING CAN CONDUCT HARMFULELECTRICITY. USE HOSES LABELED AND CERTIFIED AS NON-CONDUCTIVE.

• DO NOT OPERATE THE TOOL AT EXCESSIVE FLUID TEMPERATURES OPERATOR DIS-COMFORT AND POTENTIAL BURNS CAN RESULT AT HIGH OIL TEMPERATURES.

• NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTSOF THE TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODY PARTS AROUNDTHE WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUE ANDFORCE AND CAN CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLY USED.

• TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL TOOL REPAIR, MAINTENANCEOR SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINEDPERSONNEL.

• ALWAYS WEAR SAFETY EQUIPMENT SUCH AS OIL INJECTION RESISTANT WORK GLOVES,SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETY APPARELDICTATED BY YOUR SUPERVISOR APPLICABLE FOR THE JOB YOU ARE DOING AND THETOOL YOU ARE USING.

• DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWERSOURCE. ACCIDENTAL ENGAGEMENT OF THE TOOL CAN CAUSE SERIOUS PERSONALINJURY.

• OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHEREHYDRAULIC OIL IS INJECTED UNDER THE SKIN FROM PRESSURE IN THE LINE. ALWAYSWEAR GLOVES AND REPAIR ANY LEAKS IMMEDIATELY. NEVER CARRY A TOOL BY THEHOSES.

• DO NOT USE DAMAGED EQUIPMENT. IMMEDIATELY REPLACE ANY DAMAGED HOSES, FIT-TINGS, OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE ORABRASIONS. FAILURE TO DO SO MAY RESULT IN EQUIPMENT DAMAGE AND / OR PER-SONAL INJURY OR DEATH.

• CLEAN UP ANY OIL OR FLUID SPILLS IMMEDIATELY.

5


01/13

HAVE SUPERVISOR ADD ADDITIONAL PRECAUTIONS RELATING TO THE SPECIFIC WORKAREA AND LOCAL SAFETY REGULATIONS BELOW:

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

3. LOCAL SAFETY REGULATIONS

6


01/13

03100C RAIL PULLER

1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCH AS GLOVES, SAFETY GLASSES, EARPROTECTION AND SAFETY SHOES.

2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE IN MOVING PARTSOF THE UNIT.

3. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTSWHICH MAY IMPAIR SOUND FOOTING.

4. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDI-TION WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSUREIN THE LINE. ALWAYS WEAR GLOVES AND REPAIR LEAKS IMMEDIATELY. STAY CLEAR OFALL LEAKS AND SHUT POWER SOURCE DOWN.

5. KEEP HANDS CLEAR OF CLAMPING BLOCKS AND CYLINDER LINKAGE AT ALL TIMES.

6. CAUTION HIGH PRESSURE; DO NOT TRY TO UNCLAMP THE PULLER FROM THE RAILUNLESS THE GAUGE READS 0 PSI. SERIOUS INJURY AND DAMAGE TO THE UNITCOULD OCCUR.

7. NEVER PREFORM MAINTENANCE AND/OR REMOVE FITTINGS OR HOSES WITH THEPULLER UNDER PRESSURE.

8. NEVER OPERATE THE RAIL PULLER UNLESS A QUALIFIED MATWELD REPRESENTATIVEHAS PROPERLY TRAINED YOU.

9. ALWAYS STAY CLEAR OF THE PULLER WHEN IT IS LOADED AND UNLOADED ONTO THE TRUCK.

10. NEVER KNOCK OFF RAIL ANCHORS OR CLIPS WHILE THE PULLER IS UNDER A LOADED CONDITION. IF PULLER REACHES ITS RATED CAPACITY AND THE ANCHORS OR THE COMBINATION OF BOTH MUST BE REMOVED. THE PULLER MUST HAVE ANY BUILT UP PRESSURE RELIEVED AND UNCLAMPED FROM RAIL BEFORE THIS PROCESS TAKES PLACE.

4. OPERATION SAFETY PRECAUTIONS

5. PREPARATION FOR USE PRIOR TO PLACING PULLER ON THE RAIL, VISUALLY CHECK PULLER FOR ANY SIGNS OF

UNDUE WEAR, LEAKING HOSES OR FITTINGS AND CONDITION OF CLAMPING BLOCKS.NOTE: CLAMPING BLOCKS NEED TO BE CLEANED OF ANY METAL SHAVINGS, RUSTOR SCALE PRIOR TO EVERY PULL OPERATION. CLAMPING FEET MUST BE CLEAN TOPROVIDE PROPER OPERATION OF RAIL PULLER. FOLLOW RAILROAD OPERATIONPROCEDURES FOR CLEANING WEB AREA OF RAIL THAT PULLER WILL CLAMP TO.

7


01/13

03100C RAIL PULLER

· FOLLOW ALL INSTRUCTIONS IN THE ORDER GIVEN BELOW.

1. PLACE RAIL PULLER ON THE RAIL AT DESIRED WORK LOCATION.

2. CHECK THAT THE PRESSURE RELEASE VALVE IS IN CLOSED POSITION (SHUT CLOCKWISE)AND THE FLUID LOCK VALVE IS IN THE OPEN POSITION (KNOB TURNED COUNTER CLOCK-WISE A FEW TURNS). TURN THE POWER SOURCE “ON” TO SUPPLY 5GPM

3. PULL CONTROL LEVER “B” TO EXTEND THE CYLINDERS UNTIL THEY ARE FULLY TO THEOPEN POSITION, THE GAP IN THE RAIL SHOULD BE IN THE CENTER OF THE WORK AREA.

**4. ONCE THE PULLER IS FULLY EXTENDED, PUSH CONTROL LEVER “A” TO CLAMP THE PULLERTO THE RAIL.

5. PUSH CONTROL LEVER “B” TO PULL THE RAIL TO THE DESIRED GAP DIMENSION AND LOCKDOWN BY TURNING THE FLUID LOCK VALVE KNOB CLOCKWISE TO FULLY SHUT.

6. WHEN THE RAIL IS PULLED, WELDED AND GROUND AND ALL WORK IS COMPLETE, RE-CONNECT THE POWER HOSES IF DISCONNECTED, THEN TURN THE FLUID LOCK VALVEKNOB AND PRESSURE RELEASE VALVE KNOB COUNTER CLOCKWISE SEVERAL TURNS.

**7. WHEN THE GAUGE READS ZERO PSI, PULL CONTROL LEVER “A” TO UNCLAMP THE PULLERFROM THE RAIL.

8. CLOSE PRESSURE RELEASE VALVE AND PUSH CONTROL LEVER “B” TO PULL THE CYLIN-DERS TO THE FULLY CLOSED POSITION. OPEN THE PRESSURE RELEASE VALVE. THIS ISTHE TRANSPORT / STORAGE POSITION WHICH PROVIDES PROTECTION FOR THE CYLINDERRODS.

** IF THE CLAMP LEVER DOES NOT ACTIVATE THE CLAMPING CYLINDER, OPEN THE PRES-SURE RELIEF VALVE FOR A SECOND OR TWO THEN SHUT. THIS WILL RELIEVE PRESSURE

THAT MAY NOT SHOW ON THE GAGE AND ALLOW CLAMPING/UNCLAMPING.

6. OPERATION INSTRUCTIONS

8


01/13

7. CONVERSION TABLE

THE FOLLOWING TABLE IS A USER GUIDE TO ALLOW OPERATOR TOCROSS REFERENCE PSI READING ON GAUGE TO TONS OF FORCE

BEING GENERATED BY PULLER.

1000 psi = 23 tons2000 psi = 48 tons3000 psi = 70 tons4000 psi = 93 tons5000 psi = 117 tons5500 psi = 128 tons

DO NOT EXCEED 128 TONS

03100C RAIL PULLER

8. MAINTENANCE INSTRUCTIONSMAINTENANCE SCHEDULE

9


01/13

MAINTENANCE:

1. CHECK TOOL DAILY FOR PROPER OPERATION, LEAKS, OR DAMAGE.

2. INSPECT HOSES DAILY. REPLACE CUT, BURNED, OR OTHERWISE DAMAGED HOSES.

3. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.

4. USE HYDRAULIC FLUIDS THAT COMPLY WITH HTMA SPECIFICATION 5.7, THE HYDRAULICFLUID SHOULD HAVE A VISCOSITY BETWEEN 100 AND 400 SSU (20-82 CENTISTOKES) ATTHE MAXIMUM AND MINIMUM EXPECTED OPERATING TEMPERATURES. PETROLEUM BASEDHYDRAULIC FLUIDS WITH ANTI-WEAR PROPERTIES AND A VISCOSITY INDEX OF OVER140 WORK FOR A WIDE RANGE OF OPERATING CONDITIONS.

THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:AMOCO RYKON MV CITGO A/W ALL TEMPSUNVIS 706 MOBIL D.T.E. 13CHEVRON EP-MV TEXACO “RANDO” HDAZ

OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED.*SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.

5. HAVE TOOL INSPECTED, AT LEAST ANNUALLY, BY MATWELD OR A MATWELD QUALIFIEDSERVICE REPRESENTATIVE TO DETERMINE IF TOOL IS IN NEED OF SAFETY CHANGESOR WORN PART REPLACEMENT.

6. CONTACT MATWELD ON A PERODIC BASIS, AT LEAST ANNUALLY, FOR SERVICE BULLE-TINS, SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THIS TOOL.

03100C RAIL PULLER

10


01/13

9. REPAIR AND TROUBLESHOOTING GUIDEIF SYMPTOMS OF POOR PERFORMANCE DEVELOP, THE FOLLOWING CHART CAN BE USEDAS A GUIDE TO CORRECT THE PROBLEM. WHEN DIAGNOSING PROBLEMS WITH OPERATIONOF THE PULLER, ALWAYS CHECK THAT THE HYDRAULIC POWER SOURCE IS SUPPLYING THECORRECT HYDRAULIC FLOW AND PRESSURE AS LISTED IN THE SPECIFICATIONS. USE AFLOWMETER TO BE ACCURATE. CHECK THE FLOW WITH THE HYDRAULIC OIL TEMPERA-TURE AT LEAST 80°F/27°C.

03100C RAIL PULLER

PULLER SLIPS WHENMAKING PULL OR WILL NOTCLAMP TO THE RAIL

PRE-CLAMP CYLINDEROPERATES SLOWLY ORIRRATICALLY

PULLER IS CLAMPED BUTWILL NOT MAKE INTENDEDPULL

PRECLAMP CYLINDERSWILL NOT UNCLAMP FROMTHE RAIL

PROBLEM CAUSE REMEDYPULLER DOES NOT OPERATE HYDRAULIC POWER SOURCE NOT FUNCTIONING CHECK POWER SOURCE FOR PROPER FLOW

AND PRESSURE (5 GPM 19 LPM @2000 PSI 140BAR

COUPLERS OR HOSES BLOCKED LOCATE AND REMOVE RESTRICTION

HYDRAULIC LINES NOT CONNECTED CONNECT LINES

RAIL SURFACE IS CONTAMINATED CLEAN RAIL SURFACE OF ALL FORIEGN DEBRIS,IE: DIRT, OIL, WATER

CLAMPING BLOCKS WORN REPLACE CLAMPING BLOCKS

CLAMPING BLOCKS ARE DIRTY CLEAN BLOCKS TO REMOVE FOREIGN MATTER

HYDRAULIC FLUID IS COLD RUN POWER SOURCE TO HEAT FLUID

BACK PRESSURE IN PULLING CYLINDERS OPERATE PULL CYLINDER LEVER TO DUMP ALLBACK PRESSURE OR BUILD UP PRESSURE

AIR IN SYSTEM CHECK RESERVOIR OIL LEVEL

INTENSIFIER HAS ACHIEVED MAXIMUM OUTPUT REMOVE MORE RAIL ANCHORS

RUPTURE DISK HAS BURST REPLACE RUPTURE DISC

FLUID BYPASSING DUE TO TRASH IN MANIFOLD QUALIFIED TECH WILL FLUSH SYSTEM

FLUID BY-PASSING DUE TO LEAK IN SYSTEM VISUALLY CHECK FOR FLUID LEAK

TRASH IN SYSTEM BLOCKING VALVE OPERATION QUALIFIED TECH WILL FLUSH SYSTEM

11


01/13

10. EMERGENCY REMOVAL INSTRUCTIONS

03100C RAIL PULLER

(2 MAN OPERATION)

IMPORTANT: THE CONTROLS MUST BE HELD IN THE OPERATING POSITION TO ENABLEHYDRAULIC FLUID TO RETURN TO TANK AS THE CLAMPING BLOCKS ARE PRYED OPEN.

NOTE: BE SURE TO CLOSE SHUT-OFF VALVE PRIOR TO MAKING ANOTHER PULL.CLAMPING CYLINDERS WILL NOT WORK IF SHUT-OFF VALVE IS OPEN.

In the event of an unforseen situation in which the puller must be removed from the railw i t h o u t a n o p e r a b l e p o w e r s o u r c e . . . with the power transmission hoses attached:

1. Zero the pressure gage by opening the fluid lock valve and pressure relief valve.2. Open the small valve located in line with the clamping cylinder hosing at the “far end”bulkhead (operator station is considered the “near end”).3. Have an assistant pull the clamp lever and hold in the “unclamp” position.4. Using large leverage bars pry the clamping blocks apart using the bulkhead andclamping cylinder stand-off post as possible pry points.

12


01/13

11. GENERAL ARRANGEMENT

13


01/13

12. HOSING ARRANGEMENT

14


01/13

CONTROL MANIFOLD HOSING ARRANGEMENT

15


01/13

ITEM NO. PART NO. DESCRIPTION QTY.

CONTROL MANIFOLD HOSING PARTS LIST

1234567891011121314151617181920212223242526272829303132333435

0014500146

249-08086801-06-06

0515505154

6400-06-065404-04-04

0314903148-2

03149-303149-6

03149B-103156C0315503156

6500-06-06PT-9675031930319203180

03182-203149B-1-7

03154B6402-06-06

03149B-1-603191

6400-06-046801-06-04

QUICK DISCONNECT COUPLERQUICK DISCONNECT NIPPLE

#8 MOR X #8 M PIPE#6 MOR X #6 MJIC 90 EL

HOSE-5” BRAIDHOSE-10” BRAID

#6 MOR X #6 MJIC ST#4 HEX PIPE NIPPLE

MANIFOLD-LOW PRESSUREVALVE-DIVERTER

VALVE-RELIEFVALVE-CHECK

HANDLE ASSEMBLYGAUGE

HOSE-DIVERTERMANIFOLD-HIGH PRESSUREVALVE-LOCK AND RELEASE

1/4” NPT STREET EL HPRUPTURE DISK HOLDER

RUPTURE DISK#6 MJICX #6 FJIC 90 EL

#6 MP X #6 FP SWIVEL HP1” X 1/2” BELL REDUCER

1” X 4” PIPE NIPPLE1/4” NPT TEE HP

TEST POINTFILTER-REPLACEMENTMANIFOLD BRACKET

#6 MOR x #6FJIC SWIVELVALVE-CLAMP RELIEF

VALVE-FLOW CONTROLFILTER ASSEMBLY

1/2 MP x 45 STREET EL#6 MJIC X #4 M ORING

#6 MJIC X #4 M ORING 90 EL.

11233172112121112211412112111111111

16


01/13

FIG. 1 BULKHEAD ASSEMBLY

1 A1087 1/2-13UNC x 2-1/2”LG 82 A3813 1/2” ID LOCK WASHER 83 A2194 1/2” ID SAE WASHER 84 03103C BULKHEAD 25 03102C-R CLAMPING CAM 46 03108B CAM PLATE 47 A2192 3/8 FLAT WASHER 208 A3811 3/8 LOCKWASHER 209 A1043 3/8-16 X 1-1/4 2010 03186E ALIGNMENT SHOE 2

FIG. 1 PARTS LISTITEM PART NO. DESCRIPTION QTY.

FIG. 2 CLAMP ASSEMBLY

1 GF101 GREASE FITTING 92 RE-200 RET RING 83 03153A CLEVIS PIN 44 A1460 5/8-18 JAM NUT 45 A5642 5/8 SET SCREW 46 03101C CLAMPING BLOCK 4


5

1

6

9

7 8

10

2

3

4

1

2

3

2

5

6

1

4

1

17


01/13

FIG. 3 ROLLER BRACKET ASSEMBLY

FIG. 4 GUARD ASSEMBLYNOTE: GUARD IS SAME ON BOTH ENDS EXCEPTCONTROL END USES ADDITIONAL GUARD (5).

1 03104B BULKHEAD GUARD 22 A2162 1/4 FLAT WASHER 43 A1001 1/4-20 X 3/4 44 A4-6ASD 1/8 X 3/8 RIVET 45 03109B FITTING GUARD 1


2

3

5

9

8

6

32

1

12345

03111BA1082A1043A2194A2192

LIFTING EYE1/2-13 X 1-1/43/8-16 X 1-1/4

1/2 FLAT WASHER3/8 WASHER

24444

FIG. 3 PARTS LIST

PART NO. DESCRIPTION QTY.

18


01/13

FIG. 5 PARTS LIST

FIG. 5 VALVE ASSEMBLY

DESCRIPTION QTY.ITEM PART NO.

1

342

56

7

1112

4

14

65

9

7

13

10

8

0314903154BA1032A2191A2192A3811A104203161CA099903148CA3810A145203149CA2048

LOW PRESSURE MANIFOLD ASSEMBLYMANIFOLD MOUNTING BRACKET5/16-18 X 3 1/2” HEX HEAD BOLT5/16” I.D. FLAT WASHER (SAE)3/8” I.D. SAE FLAT WASHER3/8” I.D. LOCK WASHER3/8-16 X 1” HEX HEAD BOLTHIGH PRESSURE MANIFOLD ASSEMBLY1/4-20 X 5/8 HEX HEAD FLANGE BOLTMANIFOLD COVER BACK PLATE5/16” I.D. LOCK WASHER5/16-18” HEX JAM NUTMANIFOLD COVER5/16-18 NYLOCK HEX NUT

1234567891011121314

11246661212212

19


01/13

12345

ITEM PART NO. DESCRIPTION

FIG. 6 CLAMP CYLINDER ASSEMBLY FIG. 6 PARTS LISTNOTE: PULLER USES ONLY ONE SHUT OFF VALVE LOCATED AT

CLAMPING CYLINDER OPPOSITE CONTROL STATION END.

03100C RAIL PULLEREMERGENCY REMOVAL PROCEDURE

In the event of an unforseen situation in which the puller must be removed from the rail without anoperable powersource...with the power transmission hoses attached:

1. Zero the pressure gage by opening the fluid lock valve and pressure relief valve.2. Open the small valve located in line with the clamping cylinder hosing at the “far end” bulkhead(operator station is considered the “near end”).3. Have an assistant pull the clamp lever and hold in the “unclamp” position.4. Using large leverage bars pry the clamping blocks apart using the bulkhead and clamping cylinderstand-off post as possible pry points.

3

4

5

PRESSURE RELEASE VALVEEMERGENCY REMOVAL

1

2

A206103105A03102B-03A2197A1358

3/4-16 NYLOCK HEX NUTCLAMP CYLINDERSTAND-OFF3/4 FLAT WASHER3/4-16 X 7” GRD. 8 HEX BOLT

20


01/13

FIG. 7 PULL CYLINDER ASSEMBLY

FIG. 7 PARTS LIST

ITEM PART NO. DESCRIPTION

6

16

22

39

10

4

3

1

7

21

4

11

12

21

8

17

14 13

14

19

3

5

6

1814

5

21

20 15

5

1345678910111213141516171819202122

03197A2192A10430319803147A03113031120205003104C03140C03145A1022A219103110BGF10103122A2048A1028A2161A099903189

TUBE GUARD3/8 FLAT WASHER3/8-16UNC x 1-1/4” LG. BOLTDUAL LINE CLAMP w/ BOLTCLAMP SUPPORTRECEIVERCROSSBRACE3/8-16 NYLOCK NUTLEFT CYLINDERRIGHT CYLINDERROD SHIELD5/16-18UNC x 1” LG HEX BOLT5/16 SAE FLAT WASHERFAR END GUARDGREASE FITTINGCROSS BRACE ANCHOR5/16-18 NYLOCK NUT5/16-18UNC x 2-1/2” LG. HEX BOLT1/4 SAE FLAT WASHER8.2 FLG. x 1/4UNC HEX BOLTTUBING GUARD HOLD DOWN BRACKET

184221141148811222251

QTY.

21


01/13

WARNININGGAUGE MUST READ 0 PSIBEFORE THE PULLER WILLUNCLAMP FROM THE RAIL

14. DECAL LEGEND

WARNING

22


01/13

23


01/13

24


01/13

A. TOOL CIRCUIT

1. HYDRAULIC FORMULAS:

CID X RPM GPM X PSI GPM = 231 HP = 1714 (.85)

1456.9

Example: HP required to deliver 10 GPM at 1500 PSI.

10 GPM X 1500 PSI = 15000 = 10.3 HP1456.9 1456.9

(subtract back pressure for tool HP)

Estimated HP delivered by pump or used by tool.

PSI GPM 500 1,000 1,500 2,000 2,500 3,000 3 1.03 2.06 3.09 4.12 5.15 6.18 5 1.72 3.43 5.15 6.86 8.58 10.30 10 3.43 6.86 10.3 13.70 17.20 20.60 15 5.15 10.30 15.40 20.60 25.70 30.90

2. BACK PRESSURE

BACK PRESSURE MEASURED AT THE TOOL RETURN PORT MUST NOT EXCEED THE MANU-FACTURERS BACK PRESSURE RATING. MOST MANUFACTURERS LIST THE MAXIMUM BACKPRESSURE FOR THEIR HYDRAULIC TOOLS AT 250 PSI. BACK PRESSURE MEASURED ONTHE RETURN SIDE OF THE TOOL IS THE FORCE REQUIRED TO GET THE OIL BACK TO THETANK. IN ALMOST ALL CASES THE LOWER THE BACK PRESSURE THE BETTER THE TOOLPERFORMANCE. FIRST, THE BACK PRESSURE IS SUBTRACTED FROM THE MAXIMUM TOOLPRESSURE TO ARRIVE AT A MAXIMUM TOOL OPERATING PRESSURE. FOR EXAMPLE, TOOLSWITH 2000 PSI OPERATING PRESSURE ARE INSTALLED ON A SYSTEM WITH 250 PSI BACKPRESSURE. THIS LEAVES 1750 PSI AS A MAXIMUM TOOL PRESSURE. IMAGINE A SYSTEMWITH 500 PSI BACK PRESSURE. 2000 MINUS 500 PSI BACK PRESSURE LEAVES ONLY 1500PSI FOR THE TOOL. SECOND, TOOLS ARE DESIGNED FOR PRESSURE TO BUILD ON THEPRESSURE SIDE OF THE TOOL. IF TOO MUCH PRESSURE BUILDS ON THE RETURN SIDE,NOT ONLY IS PERFORMANCE EFFECTED, BUT SEALS MAY BLOW. THIS IS WHY IT IS VERYIMPORTANT TO DIRECT THE FLOW INTO THE TOOL CORRECTLY. REVERSING THE HOSESTO TEST MAY RESULT IN BLOWN SEALS, DAMAGE TO THE TOOL, AND PERSONAL INJURY.

15. REVIEW OF HYDRAULIC PRINCIPLES

25


01/13

16. GENERAL NOTES

26


01/13

LIMITED WARRANTY

MATWELD, INC., PADUCAH, KY., WARRANTS TO THE ORIGINAL PURCHASE OF THIS PROD-UCT THAT THE PRODUCT WILL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIPFOR THE PERIOD OF ONE (1) YEAR AFTER THE DELIVERY OF SUCH PRODUCT TO THECUSTOMER. OTHER EQUIPMENT AND PARTS USED, BUT NOT MANUFACTURED BY MATWELDINC. ARE COVERED DIRECTLY BY THE WARRANTY OF THE MANUFACTURER OF THOSE PROD-UCTS. PROOF OF PURCHASE MUST BE DOCUMENTED INCLUDING REFERENCE TO A SERIALNUMBER LOCATED ON EACH TOOL. THE PURCHASER’S ONLY REMEDIES UNDER THIS LIM-ITED WARRANTY SHALL BE LIMITED AT MATWELD’S SOLE OPTION TO THE FOLLOWING: RE-PAIR, REPLACEMENT OR REFUND OF THE PURCHASE PRICE OF THE DEFECTIVE PROD-UCTS. EACH OF THESE REMEDIES REQUIRES TIMELY NOTIFICATION OF THE DEFECT IN THEPRODUCT AND SUBSTANTIATION THAT THE PRODUCT HAS BEEN PROPERLY STORED, MAIN-TAINED AND USED. MATWELD’S OBLIGATIONS HEREUNDER EXTEND ONLY TO THE PUR-CHASER OF THE PRODUCT AND NOT TO ANY THIRD PARTY.

AS A CONDITION PRECEDENT TO MATWELD’S OBLIGATION HEREUNDER, THE DEFECTIVE PROD-UCT MUST NOT HAVE BEEN ALTERED OR MODIFIED WITHOUT THE EXPRESS WRITTEN APPROVALOF MATWELD, INC. THE PRODUCT MUST NOT HAVE BEEN SUBJECTED TO DELIBERATE DAM-AGE, SHIPPING DAMAGE, NEGLECT, TAMPERING BY UNAUTHORIZED PERSONNEL OR DAMAGEBY IMPROPER USE, STORAGE OR MAINTENANCE. SERIAL NUMBERS MUST NOT HAVE BEENALTERED, DEFACED OR REMOVED. SUCH ACTION VOIDS LIMITED WARRANTY.

EXCLUSIONS TO LIMITED WARRANTY

THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRIT-TEN OR ORAL, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIEDWARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITED WARRANTY DOES NOT COVER NORMAL WEAR AND TEAR ITEMS SUCH AS FILTERS,HOSES, COUPLERS, BITS, SOCKETS, AUGERS, AND BATTERIES.

LIMITATION OF LIABILITY

EXCEPT AS PROVIDED ABOVE, MATWELD SHALL IN NO EVENT BE LIABLE OR RESPONSIBLEFOR ANY INJURY, LOSS OR DAMAGE, DIRECT, INCIDENTAL OR CONSEQUENTIAL, ARISINGOUT OF THE USE OR MISUSE OR INABILITY TO USE THE PRODUCT, HOWEVER CAUSED ANDON ANY THEORY OF LIABILITY INCLUDING, WITHOUT LIMITATIONS, BREACH OF CONTRACT,TORT, (INCLUDING NEGLIGENCE OR STREET LIABILITY) AND NOT WITHSTANDING ANY FAIL-URE OF ANY REMEDY HEREIN OF ITS ESSENTIAL PURPOSE, EVEN IF MATWELD WAS AWAREOF THIS POSSIBILITY OF SUCH DAMAGE. MATWELD’S LIMITED WARRANTY AS SET FORTHABOVE SHALL NOT BE ENLARGED, DIMINISHED OR AFFECTED BY, AND NO OBLIGATION ORLIABILITY SHALL ARISE OR GO OUT OF THE RENDERING OF TECHNICAL ADVICE OR SERVICEBY MATWELD OR ITS AGENTS. THE FOREGOING MAY NOT BE CHANGED EXCEPT BY WRIT-TEN AGREEMENT SIGNED BY AN AUTHORIZED OFFICER OF MATWELD, THE REMEDIES SETFORTH HEREIN ARE EXCLUSIVE.

17. WARRANTY INFORMATION

27


01/13

Name _____________________________________________________

Company___________________________________________________

Serial # of your Matweld tool___________________________________( Upon receiving your Matweld tool, make sure to list serial number above so that a good record is kept for orderinformation.)

MATWELD HYDRAULIC TOOL LISTAll Matweld Hydraulic Tools operate at

5 or 10 GPM @ 2000 PSI

18. CUSTOMER INFORMATION

POWER UNITS:07000 – HYDRA POWERED MODULAR SYSTEM02900A – DIESEL POWER UNIT00100K – DUAL CIRCUIT POWER UNIT02050 – GASOLINE 1-5 GPM05500 – TWIN POWER DUAL CIRCUIT UNIT 1-10 GPM OR 2-5 GPM & 5000 WATT GENERATOR03700A – ELECTRIC POWER UNIT09800 - TRACK ROVER

TRACK TOOLS:01600A – 5 GPM 1” IMPACT WRENCH02500 - 10 GPM 1” IMPACT WRENCH04500D – ½” IMPACT DRILL00800A – 16” RAIL SAW03900A – REVERSING RAIL SAW01100A – SPIKE PULLER08200 – TIE TAMPER08300 – SPIKE DRIVER01500 – RAIL DRILL01000 – CHAIN SAW03500 – SELF FEED RAIL DRILL03100C - RAIL PULLER02800 - BRIDGE SPREADER05000 - HAND PUMP WELD SHEAR05100A - POWER WELD SHEAR06600 - POWER UNIT TRANSPORT CART07500 - CHAMFER TOOL

OTHER PRODUCTS:HYDRAULIC MANIFOLDSHYDRAULIC TEST GAUGESHOSE REELSHYDRAULIC HOSESACCESSORIES

GRINDERS:04600 & 04650– STRAIGHT STONE CW & TRIGGER VERSION04700 & 04750 – STRAIGHT STONE CCW & TRIGGER VERSION00600 & 00600C - 8” CUPSTONE GRINDER04800 & 04850 – CUPSTONE & TRIGGER VERSION00700 – RAIL SURFACING GUIDE02400 – 10” OR 14” FROG AND SWITCH GRINDER05900 – FROG/PROFILE GRINDER – ON/OFF FLOW CONTROL05950 – FROG/PROFILE GRINDER – SAFETY TRIGGER06000 – PROFILE GRINDER05400 – ANGLE GRINDER05600 – BULL NOSE GRINDER06950 & 06950A - MULTI-PURPOSE GRINDER

03100c rail puller - railtech matweld · of the puller, always check that the hydraulic power...

Documents