03100C RAIL PULLER. DIMENSION Overall length 99 (2515mm) Width 34 (864mm) Height 17 (432mm)

Transcription

1 South rd Street P.O. Box Paducah, KY 00 Phone: Fax: Website: C RAIL PULLER The Matweld 000C is a hydraulic actuated 0 ton rail puller. Operators will appreciate the single unit construction allowing quick set up time. The operator station houses an integrated intensifier and control valve manifold. Clamping blocks are captured and this self-aligning design is preloaded hydraulically for a safe and efficient pull. SPECIFICATIONS HYDRAULICS Flow (9 lpm) or 0 gpm ( lpm) Pulling cylinder Pressure: Rated 00 psi ( bar) DIMENSION Overall length 99 (mm) Width (mm) Height 7 (mm) WEIGHT 0lbs ( kg) Clamp cylinder pressure: Rated 000 psi (0 bar) PHONE:(70) -00 FAX:(70) -0 0/

2 CONTENTS. SPECIFICATIONS (COVER). GENERAL SAFETY PRECAUTIONS. OPERATOR LIST OF LOCAL SAFETY REGULATIONS. OPERATION SAFETY PRECAUTIONS. PREPARATION FOR USE. OPERATION INSTRUCTIONS 7. CONVERSION TABLE. MAINTENANCE INSTRUCTIONS 9. REPAIR AND TROUBLE SHOOTING 0. EMERGENCY REMOVAL INSTRUCTIONS. DRAWINGS SECTIONS AND OMITTED THIS PULLER. DECAL LEGEND. REVIEW OF HYDRAULIC PRINCIPLES. GENERAL NOTES 7. WARRANTY INFORMATION. CUSTOMER INFORMATION PHONE:(70) -00 FAX:(70) -0 0/

3 . GENERAL SAFETY PRECAUTIONS: TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLY WITH THE SAFETY PRECAUTIONS GIVEN IN THIS MANUAL, AND WITH ALL STICKERS AND TAGS ATTACHED TO THE TOOL AND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY. READ TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERATION INSTRUCTIONS BEFORE YOU USE OR MAINTAIN THE TOOL. REVIEW THE MANUAL DAILY BEFORE USING THE TOOL. 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 OR MAINTENANCE OF THIS TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE. MATWELD HAS NO CONTROL OVER TOOL USE OR OPERATION ONCE IT LEAVES THE MATWELD PLANT. MATWELD HAS NO CONTROL OVER OPERATOR OR MAINTAINER SELECTION. THE CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOL S SUITABILITY FOR A PARTICULAR FUNCTION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORK SAFELY AND EFFICIENTLY WITHOUT ENDANGERING THEMSELVES OR BYSTANDERS. UNDERSTANDING OF THE OPERATION AND MAINTENANCE MANUAL IS ESSENTIAL FOR ANYONE USING OR MAINTAINING THE TOOL. DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLY AND PROPERLY TRAINED OR UNDER THE SUPERVISION OF AN INSTRUCTOR. CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSURE ARE 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. FLYING DEBRIS CAN CAUSE SERIOUS INJURY. THE OPERATOR MUST BE FAMILIAR WITH ALL PROHIBITED WORK AREAS SUCH AS UNSAFE GRADES, POOR FOOTING AREAS AND OVERHEAD HAZARDS. MAINTAIN BALANCE AND PROPER FOOTING AT ALL TIMES. NEVER OVERREACH TO THE EXTENT THAT A BROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU TO LOSE YOUR BALANCE AND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONE ELSE. NEVER TRANSPORT THE PULLER WITH POWERUNIT ATTACHED PHONE:(70) -00 FAX:(70) -0 0/

4 WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CONDUCTORS ARE ENERGIZED AND THAT HOSES AND CLOTHING CAN CONDUCT HARMFUL ELECTRICITY. USE HOSES LABELED AND CERTIFIED AS NON-CONDUCTIVE. DO NOT OPERATE THE TOOL AT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOMFORT AND POTENTIAL BURNS CAN RESULT AT HIGH OIL TEMPERATURES. NEVER WEAR LOOSE CLOTHING THAT CAN GET ENTANGLED IN THE WORKING PARTS OF THE TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODY PARTS AROUND THE WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUE AND FORCE AND CAN CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLY USED. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL TOOL REPAIR, MAINTENANCE OR SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL. ALWAYS WEAR SAFETY EQUIPMENT SUCH AS OIL INJECTION RESISTANT WORK GLOVES, SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETY APPAREL DICTATED BY YOUR SUPERVISOR APPLICABLE FOR THE JOB YOU ARE DOING AND THE TOOL YOU ARE USING. DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER SOURCE. ACCIDENTAL ENGAGEMENT OF THE TOOL CAN CAUSE SERIOUS PERSONAL INJURY. OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHERE HYDRAULIC OIL IS INJECTED UNDER THE SKIN FROM PRESSURE IN THE LINE. ALWAYS WEAR GLOVES AND REPAIR ANY LEAKS IMMEDIATELY. NEVER CARRY A TOOL BY THE HOSES. DO NOT USE DAMAGED EQUIPMENT. IMMEDIATELY REPLACE ANY DAMAGED HOSES, FITTINGS, OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE OR ABRASIONS. FAILURE TO DO SO MAY RESULT IN EQUIPMENT DAMAGE AND / OR PERSONAL INJURY OR DEATH. CLEAN UP ANY OIL OR FLUID SPILLS IMMEDIATELY. PHONE:(70) -00 FAX:(70) -0 0/

5 . LOCAL SAFETY REGULATIONS HAVE SUPERVISOR ADD ADDITIONAL PRECAUTIONS RELATING TO THE SPECIFIC WORK AREA AND LOCAL SAFETY REGULATIONS BELOW: PHONE:(70) -00 FAX:(70) -0 0/

6 000C RAIL PULLER. OPERATION SAFETY PRECAUTIONS. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCH AS GLOVES, SAFETY GLASSES, EAR PROTECTION AND SAFETY SHOES.. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE IN MOVING PARTS OF THE UNIT.. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTS WHICH MAY IMPAIR SOUND FOOTING.. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDITION WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSURE IN THE LINE. ALWAYS WEAR GLOVES AND REPAIR LEAKS IMMEDIATELY. STAY CLEAR OF ALL LEAKS AND SHUT POWER SOURCE DOWN.. KEEP HANDS CLEAR OF CLAMPING BLOCKS AND CYLINDER LINKAGE AT ALL TIMES.. CAUTION HIGH PRESSURE; DO NOT TRY TO UNCLAMP THE PULLER FROM THE RAIL UNLESS THE GAUGE READS 0 PSI. SERIOUS INJURY AND DAMAGE TO THE UNIT COULD OCCUR. 7. NEVER PREFORM MAINTENANCE AND/OR REMOVE FITTINGS OR HOSES WITH THE PULLER UNDER PRESSURE.. NEVER OPERATE THE RAIL PULLER UNLESS A QUALIFIED MATWELD REPRESENTATIVE HAS PROPERLY TRAINED YOU. 9. ALWAYS STAY CLEAR OF THE PULLER WHEN IT IS LOADED AND UNLOADED ONTO THE TRUCK. 0. 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.. 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, RUST OR SCALE PRIOR TO EVERY PULL OPERATION. CLAMPING FEET MUST BE CLEAN TO PROVIDE PROPER OPERATION OF RAIL PULLER. FOLLOW RAILROAD OPERATION PROCEDURES FOR CLEANING WEB AREA OF RAIL THAT PULLER WILL CLAMP TO. PHONE:(70) -00 FAX:(70) -0 0/

7 000C RAIL PULLER. OPERATION INSTRUCTIONS FOLLOW ALL INSTRUCTIONS IN THE ORDER GIVEN BELOW.. PLACE RAIL PULLER ON THE RAIL AT DESIRED WORK LOCATION.. 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 CLOCKWISE A FEW TURNS). TURN THE POWER SOURCE ON TO SUPPLY GPM. PULL CONTROL LEVER B TO EXTEND THE CYLINDERS UNTIL THEY ARE FULLY TO THE OPEN POSITION, THE GAP IN THE RAIL SHOULD BE IN THE CENTER OF THE WORK AREA.. ONCE THE PULLER IS FULLY EXTENDED, PUSH CONTROL LEVER A TO CLAMP THE PULLER TO THE RAIL.. PUSH CONTROL LEVER B TO PULL THE RAIL TO THE DESIRED GAP DIMENSION AND LOCK DOWN BY TURNING THE FLUID LOCK VALVE KNOB CLOCKWISE TO FULLY SHUT.. WHEN THE RAIL IS PULLED, WELDED AND GROUND AND ALL WORK IS COMPLETE, RECONNECT THE POWER HOSES IF DISCONNECTED, THEN TURN THE FLUID LOCK VALVE KNOB AND PRESSURE RELEASE VALVE KNOB COUNTER CLOCKWISE SEVERAL TURNS. 7. WHEN THE GAUGE READS ZERO PSI, PULL CONTROL LEVER A TO UNCLAMP THE PULLER FROM THE RAIL.. CLOSE PRESSURE RELEASE VALVE AND PUSH CONTROL LEVER B TO PULL THE CYLINDERS TO THE FULLY CLOSED POSITION. OPEN THE PRESSURE RELEASE VALVE. THIS IS THE TRANSPORT / STORAGE POSITION WHICH PROVIDES PROTECTION FOR THE CYLINDER RODS. IF THE CLAMP LEVER DOES NOT ACTIVATE THE CLAMPING CYLINDER, OPEN THE PRESSURE RELIEF VALVE FOR A SECOND OR TWO THEN SHUT. THIS WILL RELIEVE PRESSURE THAT MAY NOT SHOW ON THE GAGE AND ALLOW CLAMPING/UNCLAMPING. PHONE:(70) -00 FAX:(70) -0 0/ 7

8 000C RAIL PULLER 7. CONVERSION TABLE THE FOLLOWING TABLE IS A USER GUIDE TO ALLOW OPERATOR TO CROSS REFERENCE PSI READING ON GAUGE TO TONS OF FORCE BEING GENERATED BY PULLER. 000 psi = tons 000 psi = tons 000 psi = 70 tons 000 psi = 9 tons 000 psi = 7 tons 00 psi = tons DO NOT EXCEED TONS. MAINTENANCE INSTRUCTIONS MAINTENANCE SCHEDULE PHONE:(70) -00 FAX:(70) -0 0/

9 000C RAIL PULLER MAINTENANCE:. CHECK TOOL DAILY FOR PROPER OPERATION, LEAKS, OR DAMAGE.. INSPECT HOSES DAILY. REPLACE CUT, BURNED, OR OTHERWISE DAMAGED HOSES.. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.. USE HYDRAULIC FLUIDS THAT COMPLY WITH HTMA SPECIFICATION.7, THE HYDRAULIC FLUID SHOULD HAVE A VISCOSITY BETWEEN 00 AND 00 SSU (0- CENTISTOKES) AT THE MAXIMUM AND MINIMUM EXPECTED OPERATING TEMPERATURES. PETROLEUM BASED HYDRAULIC FLUIDS WITH ANTI-WEAR PROPERTIES AND A VISCOSITY INDEX OF OVER 0 WORK FOR A WIDE RANGE OF OPERATING CONDITIONS. THE FOLLOWING OILS MEET HTMA SPECIFICATION.7: AMOCO RYKON MV CITGO A/W ALL TEMP SUNVIS 70 MOBIL D.T.E. CHEVRON EP-MV TEXACO RANDO HDAZ OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED. SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.. HAVE TOOL INSPECTED, AT LEAST ANNUALLY, BY MATWELD OR A MATWELD QUALIFIED SERVICE REPRESENTATIVE TO DETERMINE IF TOOL IS IN NEED OF SAFETY CHANGES OR WORN PART REPLACEMENT.. CONTACT MATWELD ON A PERODIC BASIS, AT LEAST ANNUALLY, FOR SERVICE BULLETINS, SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THIS TOOL. PHONE:(70) -00 FAX:(70) -0 0/ 9

10 000C RAIL PULLER 9. REPAIR AND TROUBLESHOOTING GUIDE IF SYMPTOMS OF POOR PERFORMANCE DEVELOP, THE FOLLOWING CHART CAN BE USED AS A GUIDE TO CORRECT THE PROBLEM. WHEN DIAGNOSING PROBLEMS WITH OPERATION OF THE PULLER, ALWAYS CHECK THAT THE HYDRAULIC POWER SOURCE IS SUPPLYING THE CORRECT HYDRAULIC FLOW AND PRESSURE AS LISTED IN THE SPECIFICATIONS. USE A FLOWMETER TO BE ACCURATE. CHECK THE FLOW WITH THE HYDRAULIC OIL TEMPERATURE AT LEAST 0 F/7 C. PROBLEM PULLER DOES NOT OPERATE PULLER SLIPS WHEN MAKING PULL OR WILL NOT CLAMP TO THE RAIL PRE-CLAMP CYLINDER OPERATES SLOWLY OR IRRATICALLY PULLER IS CLAMPED BUT WILL NOT MAKE INTENDED PULL PRECLAMP CYLINDERS WILL NOT UNCLAMP FROM THE RAIL CAUSE REMEDY HYDRAULIC POWERSOURCE NOTFUNCTIONING CHECK POWERSOURCE FORPROPERFLOW AND PRESSURE ( GPM9 LPM@000 PSI 0 BAR COUPLERS ORHOSES BLOCKED LOCATE AND REMOVE RESTRICTION HYDRAULIC LINES NOTCONNECTED CONNECTLINES RAIL SURFACE IS CONTAMINATED CLEANRAIL SURFACE OF ALL FORIEGNDEBRIS, IE: DIRT, OIL, WATER CLAMPINGBLOCKS WORN REPLACE CLAMPINGBLOCKS CLAMPINGBLOCKS ARE DIRTY CLEANBLOCKS TOREMOVE FOREIGNMATTER HYDRAULIC FLUID IS COLD RUNPOWERSOURCE TOHEATFLUID BACK PRESSURE INPULLINGCYLINDERS OPERATE PULL CYLINDERLEVERTODUMP ALL BACK PRESSURE ORBUILD UP PRESSURE AIRINSYSTEM CHECK RESERVOIROIL LEVEL INTENSIFIERHAS ACHIEVED MAXIMUMOUTPUT REMOVE MORE RAIL ANCHORS RUPTURE DISK HAS BURST REPLACE RUPTURE DISC FLUID BYPASSINGDUE TOTRASHINMANIFOLD QUALIFIED TECHWILL FLUSHSYSTEM FLUID BY-PASSINGDUE TOLEAK INSYSTEM VISUALLYCHECK FORFLUID LEAK TRASHINSYSTEMBLOCKINGVALVE OPERATION QUALIFIED TECHWILL FLUSHSYSTEM PHONE:(70) -00 FAX:(70) -0 0/ 0

11 000C RAIL PULLER 0. EMERGENCY REMOVAL INSTRUCTIONS ( MAN OPERATION) In the event of an unforseen situation in which the puller must be removed from the rail with the power transmission hoses attached: w 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.... Zero the pressure gage by opening the fluid lock valve and pressure relief valve.. Open the small valve located in line with the clamping cylinder hosing at the far end bulkhead (operator station is considered the near end ).. Have an assistant pull the clamp lever and hold in the unclamp position.. Using large leverage bars pry the clamping blocks apart using the bulkhead and clamping cylinder stand-off post as possible pry points. IMPORTANT: THE CONTROLS MUST BE HELD IN THE OPERATING POSITION TO ENABLE HYDRAULIC 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. PHONE:(70) -00 FAX:(70) -0 0/

12 . GENERAL ARRANGEMENT PHONE:(70) -00 FAX:(70) -0 0/

13 . HOSING ARRANGEMENT PHONE:(70) -00 FAX:(70) -0 0/

14 CONTROL MANIFOLD HOSING ARRANGEMENT PHONE:(70) -00 FAX:(70) -0 0/

15 CONTROL MANIFOLD HOSING PARTS LIST ITEM NO PART NO B- 0C PT B--7 0B B DESCRIPTION QUICK DISCONNECT COUPLER QUICK DISCONNECT NIPPLE # MOR X # M PIPE # MOR X # MJIC 90 EL HOSE- BRAID HOSE-0 BRAID # MOR X # MJIC ST # HEX PIPE NIPPLE MANIFOLD-LOW PRESSURE VALVE-DIVERTER VALVE-RELIEF VALVE-CHECK HANDLE ASSEMBLY GAUGE HOSE-DIVERTER MANIFOLD-HIGH PRESSURE VALVE-LOCK AND RELEASE / NPT STREET EL HP RUPTURE DISK HOLDER RUPTURE DISK # MJICX # FJIC 90 EL # MP X # FP SWIVEL HP X / BELL REDUCER X PIPE NIPPLE / NPT TEE HP TEST POINT FILTER-REPLACEMENT MANIFOLD BRACKET # MOR x #FJIC SWIVEL VALVE-CLAMP RELIEF VALVE-FLOW CONTROL FILTER ASSEMBLY / MP x STREET EL # MJIC X # M ORING # MJIC X # M ORING 90 EL. QTY. 7 PHONE:(70) -00 FAX:(70) -0 0/

16 FIG. PARTS LIST ITEM PART NO. DESCRIPTION A07 A A9 00C 00C-R 00B A9 A A0 0E /-UNC x -/ LG / ID LOCK WASHER / ID SAE WASHER BULKHEAD CLAMPING CAM CAM PLATE / FLAT WASHER / LOCKWASHER /- X -/ ALIGNMENT SHOE QTY FIG. BULKHEAD ASSEMBLY FIG. PARTS LIST ITEM PART NO. GF0 RE-00 0A A0 A 00C DESCRIPTION GREASE FITTING RET RING CLEVIS PIN /- JAM NUT / SET SCREW CLAMPING BLOCK QTY. 9 FIG. CLAMP ASSEMBLY PHONE:(70) -00 FAX:(70) -0 0/

17 FIG. PARTS LIST 9 PART NO. 0B A0 A0 A9 A9 DESCRIPTION LIFTING EYE /- X -/ /- X -/ / FLAT WASHER / WASHER FIG. ROLLER BRACKET ASSEMBLY FIG. PARTS LIST ITEM PART NO. DESCRIPTION 00B A A00 A-ASD 009B BULKHEAD GUARD / FLAT WASHER /-0 X / / X / RIVET FITTING GUARD QTY. FIG. GUARD ASSEMBLY NOTE: GUARD IS SAME ON BOTH ENDS EXCEPT CONTROL END USES ADDITIONAL GUARD (). PHONE:(70) -00 FAX:(70) -0 0/ 7 QTY.

18 FIG. VALVE ASSEMBLY FIG. PARTS LIST ITEM PART NO B A0 A9 A9 A A0 0C A0999 0C A0 A 09C A0 DESCRIPTION LOW PRESSURE MANIFOLD ASSEMBLY MANIFOLD MOUNTING BRACKET /- X / HEX HEAD BOLT / I.D. FLAT WASHER (SAE) / I.D. SAE FLAT WASHER / I.D. LOCK WASHER /- X HEX HEAD BOLT HIGH PRESSURE MANIFOLD ASSEMBLY /-0 X / HEX HEAD FLANGE BOLT MANIFOLD COVER BACK PLATE / I.D. LOCK WASHER /- HEX JAM NUT MANIFOLD COVER /- NYLOCK HEX NUT QTY. PHONE:(70) -00 FAX:(70) -0 0/

19 EMERGENCY REMOVAL PRESSURE RELEASE VALVE FIG. CLAMP CYLINDER ASSEMBLY NOTE: PULLER USES ONLY ONE SHUT OFF VALVE LOCATED AT CLAMPING CYLINDER OPPOSITE CONTROL STATION END. FIG. PARTS LIST ITEM PART NO. A0 00A 00B-0 A97 A DESCRIPTION /- NYLOCK HEX NUT CLAMP CYLINDER STAND-OFF / FLAT WASHER /- X 7 GRD. HEX BOLT 000C RAIL PULLER EMERGENCY REMOVAL PROCEDURE In the event of an unforseen situation in which the puller must be removed from the rail without an operable powersource...with the power transmission hoses attached:. Zero the pressure gage by opening the fluid lock valve and pressure relief valve.. Open the small valve located in line with the clamping cylinder hosing at the far end bulkhead (operator station is considered the near end ).. Have an assistant pull the clamp lever and hold in the unclamp position.. Using large leverage bars pry the clamping blocks apart using the bulkhead and clamping cylinder stand-off post as possible pry points. PHONE:(70) -00 FAX:(70) -0 0/ 9

20 FIG. 7 PULL CYLINDER ASSEMBLY FIG. 7 PARTS LIST ITEM PART NO. 097 A9 A A C 00C 0 A0 A9 00B GF0 0 A0 A0 A A DESCRIPTION TUBE GUARD / FLAT WASHER /-UNC x -/ LG. BOLT DUAL LINE CLAMP w/ BOLT CLAMP SUPPORT RECEIVER CROSSBRACE /- NYLOCK NUT LEFT CYLINDER RIGHT CYLINDER ROD SHIELD /-UNC x LG HEX BOLT / SAE FLAT WASHER FAR END GUARD GREASE FITTING CROSS BRACE ANCHOR /- NYLOCK NUT /-UNC x -/ LG. HEX BOLT / SAE FLAT WASHER. FLG. x /UNC HEX BOLT TUBING GUARD HOLD DOWN BRACKET QTY. PHONE:(70) -00 FAX:(70) -0 0/ 0

21 . DECAL LEGEND WARNING WARNINING GAUGE MUST READ 0 PSI BEFORE THE PULLER WILL UNCLAMP FROM THE RAIL PHONE:(70) -00 FAX:(70) -0 0/

22 PHONE:(70) -00 FAX:(70) -0 0/

23 PHONE:(70) -00 FAX:(70) -0 0/

24 . REVIEW OF HYDRAULIC PRINCIPLES A. TOOL CIRCUIT. HYDRAULIC FORMULAS: GPM = CID X RPM GPM X PSI HP = 7 (.).9 Example: HP required to deliver 0 GPM at 00 PSI. 0 GPM X 00 PSI = 000 = 0. HP.9.9 (subtract back pressure for tool HP) Estimated HP delivered by pump or used by tool. GPM 0 PSI , , , , , BACK PRESSURE BACK PRESSURE MEASURED AT THE TOOL RETURN PORT MUST NOT EXCEED THE MANUFACTURERS BACK PRESSURE RATING. MOST MANUFACTURERS LIST THE MAXIMUM BACK PRESSURE FOR THEIR HYDRAULIC TOOLS AT 0 PSI. BACK PRESSURE MEASURED ON THE RETURN SIDE OF THE TOOL IS THE FORCE REQUIRED TO GET THE OIL BACK TO THE TANK. IN ALMOST ALL CASES THE LOWER THE BACK PRESSURE THE BETTER THE TOOL PERFORMANCE. FIRST, THE BACK PRESSURE IS SUBTRACTED FROM THE MAXIMUM TOOL PRESSURE TO ARRIVE AT A MAXIMUM TOOL OPERATING PRESSURE. FOR EXAMPLE, TOOLS WITH 000 PSI OPERATING PRESSURE ARE INSTALLED ON A SYSTEM WITH 0 PSI BACK PRESSURE. THIS LEAVES 70 PSI AS A MAXIMUM TOOL PRESSURE. IMAGINE A SYSTEM WITH 00 PSI BACK PRESSURE. 000 MINUS 00 PSI BACK PRESSURE LEAVES ONLY 00 PSI FOR THE TOOL. SECOND, TOOLS ARE DESIGNED FOR PRESSURE TO BUILD ON THE PRESSURE 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 VERY IMPORTANT TO DIRECT THE FLOW INTO THE TOOL CORRECTLY. REVERSING THE HOSES TO TEST MAY RESULT IN BLOWN SEALS, DAMAGE TO THE TOOL, AND PERSONAL INJURY. PHONE:(70) -00 FAX:(70) -0 0/

25 . GENERAL NOTES PHONE:(70) -00 FAX:(70) -0 0/

26 7. WARRANTY INFORMATION LIMITED WARRANTY, PADUCAH, KY., WARRANTS TO THE ORIGINAL PURCHASE OF THIS PRODUCT THAT THE PRODUCT WILL BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP FOR THE PERIOD OF ONE () YEAR AFTER THE DELIVERY OF SUCH PRODUCT TO THE CUSTOMER. OTHER EQUIPMENT AND PARTS USED, BUT NOT MANUFACTURED BY MATWELD INC. ARE COVERED DIRECTLY BY THE WARRANTY OF THE MANUFACTURER OF THOSE PRODUCTS. PROOF OF PURCHASE MUST BE DOCUMENTED INCLUDING REFERENCE TO A SERIAL NUMBER LOCATED ON EACH TOOL. THE PURCHASER S ONLY REMEDIES UNDER THIS LIMITED WARRANTY SHALL BE LIMITED AT MATWELD S SOLE OPTION TO THE FOLLOWING: REPAIR, REPLACEMENT OR REFUND OF THE PURCHASE PRICE OF THE DEFECTIVE PRODUCTS. EACH OF THESE REMEDIES REQUIRES TIMELY NOTIFICATION OF THE DEFECT IN THE PRODUCT AND SUBSTANTIATION THAT THE PRODUCT HAS BEEN PROPERLY STORED, MAINTAINED AND USED. MATWELD S OBLIGATIONS HEREUNDER EXTEND ONLY TO THE PURCHASER OF THE PRODUCT AND NOT TO ANY THIRD PARTY. AS A CONDITION PRECEDENT TO MATWELD S OBLIGATION HEREUNDER, THE DEFECTIVE PRODUCT MUST NOT HAVE BEEN ALTERED OR MODIFIED WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRODUCT MUST NOT HAVE BEEN SUBJECTED TO DELIBERATE DAMAGE, SHIPPING DAMAGE, NEGLECT, TAMPERING BY UNAUTHORIZED PERSONNEL OR DAMAGE BY IMPROPER USE, STORAGE OR MAINTENANCE. SERIAL NUMBERS MUST NOT HAVE BEEN ALTERED, 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, WRITTEN OR ORAL, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY 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 RESPONSIBLE FOR ANY INJURY, LOSS OR DAMAGE, DIRECT, INCIDENTAL OR CONSEQUENTIAL, ARISING OUT OF THE USE OR MISUSE OR INABILITY TO USE THE PRODUCT, HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY INCLUDING, WITHOUT LIMITATIONS, BREACH OF CONTRACT, TORT, (INCLUDING NEGLIGENCE OR STREET LIABILITY) AND NOT WITHSTANDING ANY FAILURE OF ANY REMEDY HEREIN OF ITS ESSENTIAL PURPOSE, EVEN IF MATWELD WAS AWARE OF THIS POSSIBILITY OF SUCH DAMAGE. MATWELD S LIMITED WARRANTY AS SET FORTH ABOVE SHALL NOT BE ENLARGED, DIMINISHED OR AFFECTED BY, AND NO OBLIGATION OR LIABILITY SHALL ARISE OR GO OUT OF THE RENDERING OF TECHNICAL ADVICE OR SERVICE BY MATWELD OR ITS AGENTS. THE FOREGOING MAY NOT BE CHANGED EXCEPT BY WRITTEN AGREEMENT SIGNED BY AN AUTHORIZED OFFICER OF MATWELD, THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE. PHONE:(70) -00 FAX:(70) -0 0/

27 . CUSTOMER INFORMATION 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 order information.) MATWELD HYDRAULIC TOOL LIST All Matweld Hydraulic Tools operate at or PSI POWER UNITS: HYDRA POWERED MODULAR SYSTEM 0900A DIESEL POWER UNIT 0000K DUAL CIRCUIT POWER UNIT 000 GASOLINE - GPM 000 TWIN POWER DUAL CIRCUIT UNIT -0 GPM OR - GPM & 000 WATT GENERATOR 0700A ELECTRIC POWER UNIT TRACK ROVER TRACK TOOLS: 000A GPM IMPACT WRENCH GPM IMPACT WRENCH 000D ½ IMPACT DRILL 0000A RAIL SAW 0900A REVERSING RAIL SAW 000A SPIKE PULLER 000 TIE TAMPER 000 SPIKE DRIVER 000 RAIL DRILL 0000 CHAIN SAW 000 SELF FEED RAIL DRILL 000C - RAIL PULLER BRIDGE SPREADER HAND PUMP WELD SHEAR 000A - POWER WELD SHEAR POWER UNIT TRANSPORT CART CHAMFER TOOL GRINDERS: & 00 STRAIGHT STONE CW & TRIGGER VERSION & 070 STRAIGHT STONE CCW & TRIGGER VERSION & 0000C - CUPSTONE GRINDER & 00 CUPSTONE & TRIGGER VERSION RAIL SURFACING GUIDE 0 OR FROG AND SWITCH GRINDER FROG/PROFILE GRINDER ON/OFF FLOW CONTROL FROG/PROFILE GRINDER SAFETY TRIGGER PROFILE GRINDER ANGLE GRINDER BULL NOSE GRINDER & 090A - MULTI-PURPOSE GRINDER OTHER PRODUCTS: HYDRAULIC MANIFOLDS HYDRAULIC TEST GAUGES HOSE REELS HYDRAULIC HOSES ACCESSORIES PHONE:(70) -00 FAX:(70) -0 0/ 7