LR-05-81-O Safeloc Clip Remover MAINTENANCE MANUAL 1
TABLE OF CONTENTS 1.0 Introduction 1.1 General Information 1.2 Features 1.3 Options 1.4 Safety Summary 1.5 General Safety Precautions 1.6 Warning and Caution Statements 1.7 Training Requirements 2.0 Installation Instructions 2.1 Unpacking Instructions 2.2 Tool Preparations 2.3 Testing 2.4 Hose Requirements 2.5 Hydraulic Fluid Recommendations 2.6 Tool Connecting Procedures 2.7 Work Area Safety Precautions 3.0 Operating Instructions 3.1 Description of Power Unit 3.2 Controls and Graphics 3.3 Connecting Hoses 3.4 Safe Lock Removal 3.5 Wheel Kit 3.6 Disconnecting Hoses 3.7 Cold Weather Operation 3.8 Storage Preparation 4.0 Maintenance Instructions 4.1 Assembly View and Parts List 4.2 Graphic Set Complete 4.3 Tool Maintenance 4.4 Trouble Shooting 4.5 Technical Specification 2
1.0 INTRODUCTION 1.1 General Information This manual presents removal, operation, and maintenance information for PortaCo s model LR-05-81-0 lock remover. The lock remover is designed to remove the safe lock clips from the rail. This tool will help eliminate the use of other methods that increase the likely hood of injury. When properly used this tool will help reduce back strain and also reduce operator fatigue. PortaCo, Inc. reserves the right to make changes at anytime without notice and without incurring any obligation. 1.2 Features The main features of the PortaCo lock remover are as follows. Standard unit: Length 12.25 in/31.1 cm Width 10.00 in/25.4 cm Height 36.25 in/92.0 cm Weight (Dry) 38-lbs/17.2 kg With optional wheel kit: Length 16.00 in/40.6 cm Width 15.25 in/38.7 cm Height 36.25 in/92.0 cm Weight (Dry) 46-lbs/20.8 kg The lock remover is operated from a T style handle. On the T style handle there is a trigger that is used to operate the lock remover. When the trigger is drawn to the handle the trigger link then pushes down on an on/off valve. The on/off valve activates the cylinder that the end ram is attached to. When the end ram moves forward it pulls the grippers along the gripper frame, which will then cause the grippers to clamp around the safe lock clip and pull it off the anchor. After the cylinder has completely extended, release the trigger. When the trigger is released the cylinder retracts causing the grippers to open up, and releases the safe lock clip. Simply lift the lock remover vertically off the rail and the safe lock clip will be sitting on the tie. This tool is designed to remove the safe lock clips from the rail. This tool will help eliminate other methods, which may cause back strain or fatigue. 1.3 Options The lock remover may be equipped with the following options after base model purchase. - 80-3922-00K Wheel Kit 1.4 Safety Summary Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hoses. These safety precautions are given for your safety. Review them 3
carefully before operating the tool and before performing maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations. 1.5 General Safety Precautions The PortaCo Inc. tools are designed to provide safe and dependable service if operated according to the instructions provided in this manual. Read and understand this manual and any stickers attached to the power unit before operating. Failure to do so could result in personal injury or equipment damage. Check the rules and regulations at your location. The rules may include an employer s work safety program. Regulations may identify hazards such as working around utility supply lines or hazardous slopes. Read and understand any manuals for additional or optional equipment, which maybe shipped with the tool. 1.6 Warning and Caution Statements Warning and Caution statements have been strategically placed throughout the text prior to operating or maintenance procedures, practices, or conditions considered essential for the protection of personnel, equipment, and property. WARNING: HIGHLIGHTS A, ESSENTIAL OPERATING, OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO, OR DEATH OF, PERSONNEL OR LONG TERM HEALTH HAZARDS. CAUTION: HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS. 1.7 Training Requirements Operator training for the lock remover should consist of information found in this manual. In addition the operator must receive instructions, both verbally and through demonstrations for applications in which the tool is going to be used. The new operator must start in an area without bystanders and use the tool until able to fully operate the tool under the conditions for the work area. 2.0 INSTALLATION INSTRUCTIONS 2.1 Unpacking Instructions Upon receiving your lock remover promptly remove it from the shipping container. Always keep top side of container up. Inspect unit for damage which may have incurred during shipping and report it to carrier for claim. 2.2 Tool Preparations 4
The PortaCo G-18D55-53-W power unit is recommended for hydraulic supply. This unit is equipped with two 5-gpm/20 lpm circuits that can be combined for on 10 gpm/40 lpm circuits. If the tool is used in cold weather, preheat the hydraulic fluid by running power source at low engine speed. Fluid temperature should be at or above 50 F/10 C (400-ssu/82 centistroke) before use, when using recommended fluids. Using too thick of fluid may result in tool damage. 2.3 Testing WARNING: NEVER STICK FOREIGN OBJECTS, FINGERS, OR OTHER EXTRMIIES INTO MOVING MECHANISMS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY OR TOOL DAMAGE. Before operating the lock remover it is important to inspect the gripper for obstructions or damage. The grippers remove the safe lock clip from the anchor, so it is very important that these are working properly. Follow all safety precautions and procedures when inspecting tool. Place lock remover on a flat surface and tilt it backwards 90. After you have done this locate the grippers which are located at the base of the tool. Once you have located the grippers operate the tool while monitoring the grippers movement. When monitoring the grippers you should watch for the following. -When the trigger is draw the end ram extends forward causing the grippers to move along the gripper frame. Be sure that the end ram is moving the grippers along the gripper frame free and easily. Once the cylinder has completely extended release the trigger. -When the trigger is released the cylinder will then retract bringing the end ram backward with the grippers following along gripper frame. What the operator should look for is that the end ram is retracting the grippers easily with no hesitation. CAUTION: WHEN TESTING THE LOCK REMOVER, BE SURE TO FOLLOW ALL SAFETY GUIDELINES. 2.4 Hose Requirements It is not often necessary or advisable to use long hoses. All hoses must have an oil resistant inner surface and an abrasion resistant outer surface. Each hose must have male pipe ends for most application. Longer hoses can be used when necessary, but can affect the operation of the engine due to resistance in the hose. If small diameter or long hoses are used, or if restrictive fittings are connected to the supply and return ports, the pressure required to push the fluid through the system and back to the tank will be higher. This will reduce tool power. 5
*Important Oil should always flow from the male coupler through the female coupler. NOTE: The pressure increase in uncoupled hoses left in the sun may make them difficult to connect. When possible after use, connect the free ends of the operating hoses together. HOSE TYPES Hydraulic hose types authorized for use by PortaCo, Inc. is as follows: 1. Labeled and certified nonconductive 2. Wire braided (conductive) 3. Fabric braided (not certified or labeled non-conductive) Hose 1: Listed above is the only hose authorized for use near electrical conductors. Hoses 2 and 3: Listed above are conductive and must never be used near electrical conductors. HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be at least 175 bar (2500 psi). HYDRAULIC HOSE RECOMMENDATION Table 2.4 FLOW PER CIRCUIT LENGTH EACH HOSE USE INSIDE DIAMETER SAE SPEC HOSE (WIRE DRAID) SAE SPEC HOSE (FIBER BRAID) GPM LPM FEET METERS INCH MM 5 to 8 19 to 30 To 50 To 15 Both ½ 13 SAE 100R1-8 100R7-8 5 to 8 19 to 30 51-100 15 to 30 Both 5/8 16 SAE 100R2-10 SAE 100R8-10 5 to 8 19 to 30 100-300 30 to 90 Pressure Return 5/8 ¾ 16 19 SAE 100R2-10 SAE 100R1-12 SAE 100R8-10 SAE 100R7-12 9 to 12 34 to 45 To 50 To 15 Both 5/8 16 SAE 100R2-10 SAE 100R8-10 9 to 12 34 to 45 51-100 15 to 30 Pressure 5/8 16 SAE 100R2-10 SAE 100R8-10 Return 9 to 12 24 to 45 100-200 30 to 60 Pressure Return ¾ ¾ 1 19 19 25.4 SAE 100R3-12 SAE 100R2-12 SAE 100R1-16 SAE 100R7-12 SAE 100R8-12 SAE 100R7-16 2.5 Hydraulic Fluid Recommendation Inspect hose for cuts, crushing, leaks, or abrasion which maybe a safety hazard or reduce fluid flows. The following fluids work well over a Wide temperature range at startup, Allow moisture to settle out, and resist Biological growth likely in cool operating Hydraulic circuits. These fluids are Recommended by PortaCo inc. Other That meets or exceeds the specifications of these fluids may also be used. Type Hydraulic fluid Chevron Clarity AW 15032 Exxon Univis J 32 Mobil D.T.E. 13 M Gulf Harmony AW-HVI-150-32 Shell Tellus T 32 Texaco Rando HDZ 32 Union Unax AW-WR-32 Amsoil AWH 15032 Sunvis Low Pour H/032-product code 19300 Hydraulic fluid requirements: a) Viscosity (fluid Thickness) USA METRIC 50 F 4450 SSU Max 10 C 95 Centistokes 100 F 130-200 SSU 38 C 27-42 C.S. 140 F 85 SSU Min. 60 C 16.5 C.S, Min. Pour Point- 10 F/-23 C Minimum (for cold startup) 6
Viscosity Index (ASTM D 2220) 140 Minimum Demulsibility (ASTM D-1401) 30 Minutes Maximum Flash Point (ASTM D-92) 340 F/171 C Minimum Rust Inhibition (ASTM D-665 A & B) Pass Oxidation (ASTM D943) 1000 Hours Minimum Pump Wear Test (ASTM D2882) 60 mg Maximum 2.6 Tool Connecting Procedures Stop the engine before connecting the tool and, or hoses to the off power unit, and when switching hoses or tools. Turn the hydraulic on/off valve to the off position before starting the engine. Make sure all hose are connected for correct flow direction to and from the tool being used. When routing hose in the work area, position them where personnel will not be at risk of tripping over them where vehicles can run over the hoses. Do not lay hose over sharp objects. WARNING: PRESSURIZED FLUID ESCAPING FROM A DAMAGED HOSE CAN PENETRATE THE SKIN AND BE INJECTED IN THE BODY CAUSING INJURY OR DEATH. CAUTION: DO NOT PULL ON HOSES TO DRAG POWER UNIT. 2.7 Work Area Safety Precautions - Never operate the tool when you are tired, angry, emotionally disturbed, or under the influence of alcohol, drugs, medications, or anything that could affect your vision, alertness, coordination or judgement. - Establish a training program for all operators to ensure safe operation. - Do no operate the tool unless thoroughly trained or under the supervision of an instructor. - Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals out of the work area. - Always wear safety goggles, ear, leg, and head protection devices, safety footwear, and snug fitting clothes. - Do not operate the tool near energized transmission lines. - Do not overreach. Maintain proper footing and balance at all times. - Always hold the tool with both hands, using a firm grip when activating and operating. - Be sure to keep hands and other parts clear and free from all moving parts. - Keep all body parts away from moving jaws located at the base of this tool - Always connect hydraulic hoses to the tool before activating the hydraulic circuit on your power unit. Check that hydraulic couplers are secure before activating the circuit. - Keep handles clean and dry. 7
- Disconnect tool from hydraulic source before inspection or cleaning. - Only a properly trained person should perform any maintenance, service, and or repairs to a tool. - Never operate a tool that is damaged, improperly adjusted, or not completely and securely assembled. - Do not operate the tool until you have a clear work area and a secure balance. - Never carry or pick this tool up by the hydraulic hose SAFETY REGULATION Enter below any local or other safety regulations required for the operator to follow. Make sure the operator and maintenance personnel have knowledge of these regulations. 8
3.0 Operating Instructions 3.1 Description of Power Tool PortaCo s model LR-05-81-0 lock remover is designed to remove safe lock clips from the anchor to release the rail from the tie, the lock remover reduces the risk to rail road maintenance workers by eliminating the use of other methods which increase the likely hood of injury. When properly used it also reduces operator fatigue. locate and understand them before using this power tool. The lock remover has six decals located on the tool. On the ram end cover there is a CAUTION decal that specifies that the lock remover is rated for a flow of 5 GPM/20 LPM and pressure of 2000 PSI/150 BAR do not exceed these flow / pressure ratings. Also on the decal is a few written warnings improper use may cause severe injury, read and G-18D55-53-W is a versatile power unit that can meet the needs for most hydraulic tools used by the rail road industry. This power unit is capable of powering two tools simultaneously at 5 GPM (20 LPM) or one tool a 10 GPM (40 LPM) all the flows are at 138 BAR (2000 PSI). The maximum pressure of the hydraulic system is limited to 148.3 BAR (2150 PSI). The power source provided the required flow and pressure to operated HTMA type I 15-23 LPM (4-6 GPM) and type RR 34-40 LPM (9-10.5) tools. All which, are OPEN-CENTER tools required an operating pressure of 138 BAR (2000 PSI). 3.2A understand operators manual before operating tool, keep all guards in place, during operation always wear gloves, safe clothing and footwear, and during operation always wear approved safety protection for ears, eyes, and head. (Diagram 3.2A) Diagram 3.2A 3.2 Controls and Graphics The following decals are placed on the tool to aid in its operation and maintenance. The operator should 3.2B 9
At the base of this unit there are four pinch area decals. The base of the tool is where all the moving mechanisms are located, and needs to be approached with caution. (Diagram 3.2B) Diagram 3.2B WARNING: ALWAYS KEEP FOREIGN OBJECTS, FINGERS, AND OTHER EXTREMITIES AWAY FROM THIS AREA. On the inside of the handle next to the manifold is a serial # decal. This decal has the serial number as well as the model number of the unit. Each unit has it s own unique serial number. It is important to keep this decal protected and kept legible. The serial number is needed when ordering replacement parts. (Diagram 3.2C) Diagram 3.2C 3.2C There is an orange strip decal located on the end cap of the cylinder. This orange decal shows the operator where the front of the machine is located. Always keep the orange decal pointing towards the rail when operating. (Diagram 3.2D) Diagram 3.2D 3.3 Connecting Hoses Wipe quick couplers with a clean lint free cloth before connecting them. 1. Connect hoses from power source to the tool. It is recommended that you connect the return hoses first and disconnect last to minimize or avoid trapping pressure within the tool. 3.2D 2. When connecting the quick couplers, the flow should run from male coupler to the female coupler. The female coupler on the tool is the inlet. Quick couplers are marked with a flow direction arrow. WARNING: PRESSURIZED FLUID ESCAPING FROM A DAMAGED HOSE CAN PENETRATE THE SKIN AND BE INJECTED IN THE BODY CAUSING INJURY OR DEATH. CAUTION: DO NOT PULL ON HOSES TO DRAG POWER UNIT. NOTE: When possible, connect the free ends of uncoupled hoses to prevent build up in the hoses. The sun can also increase pressure in the hoses and make connecting them difficult. 3.4 Safe Lock Removal 3.2D NOTE: Remove any obstructions on or around anchor pad, or anything that is lodged under the safe lock clip itself, before attempting to remove the safe lock clip. 10
1. Place the lock remover squarely over safe lock clip. Be sure the orange decal located at the front of the machine is facing towards the rail. Once you have the lock remover in place, grip the handle firmly with both hands, and draw the trigger to the handle. 2. By drawing the trigger to the handle the jaws will then grab the safe lock and remove it. 3. Once the safe lock clip has been removed release the trigger and lift remover horizontally off the rail. 4. If the jaws do not get a good enough hold of the safe lock the machine will not be able to remove it. The operator should then release the trigger and reposition the lock remover on the safe lock, and try operation again. If the lock remover is still not removing the safe lock clip there is something else wrong. Look to trouble shooting chart on page 17. 3.5 Wheel Kit 1. The lock remover may be equipped with an optional wheel kit. The wheel kit allows you to move from safe lock clip to safe lock clip without picking the lock remover up off the rail. This will help reduce back strain. CAUTION: BE SURE THE OPERATORS ALWAYS KEEP A FIRM GRIP ON THE HANDLE NO MATTER WHAT THE OPERATION IS. 2. After removing safe lock clip tilt the lock remover forward. By tilting it forward the wheels on the wheel kit will catch onto the rail. This allows the operator to roll the lock remover to the next safe lock clip quickly and easily. NOTE: Be sure to keep the machine tilted forward enough so that the base of the machine clears the safe lock clip. 3. When moving to get to the next safe lock clip, position the lock remover over the safe lock clip. Then tilt the lock remover towards the operator. The lock remover will easily come off the rail onto the next safe lock clip. 3.6 Disconnecting Hoses: 1. Stop the hydraulic power source. 2. Depressurize the system 3. Allow system and hydraulic fluid to cool. 4. Disconnect the supply (pressure) hose to the power source (pressure port) from the tool ( IN port). 5. Disconnect the return (tank) hose to the hydraulic power source (return port) from the tool ( OUT port). 6. To prevent contamination, always install dust caps over the hydraulic ports of the tool when disconnected. 11
WARNING: IF INJURY RESULTS FROM ESCAPING HYDRAULIC FLUID, SEEK IMMEDIATE MEDICAL ATTENTION. SERIOUS BODILY INJURY MAY OCCUR IF PROPER MEDICAL ATTENTION IS NOT ADMINISTERED IMMEDIATELY. WARNING: DO NOT ATTEMPT TO LOCATE HYDRAULIC LEAKS BY FEELING AROUND HOSES AND FITTING WITH HANDS. PIN HOLE LEAKS CAN PENETRATE THE SKIN. 3.7 Cold Weather Operation Hydraulic fluids are thicker in cold weather; therefore, run the engine at low idle lone enough to bring the fluid temperature up to minimum of 10 C/50 F or until the top of the hydraulic tank feels warm, before operating tool. 3.8 Storage Preparation Cover male and female hose whips. Store in the upright position. Secure tool to prevent it from being knocked over. Store the lock installer on a smooth level surface. The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes. 12
CAUTION: USE ONLY GENUINE PORTACO INC PARTS OR EQUIVALENT. THE USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE HYDRAULIC POWER UNIT. 4.0 Maintenance Instruction 4.1 Assembly View and Parts List LR-05-81-O ITEM NO. PARTS NO. DESCRIPTION QTY 1. 1041-00P NUT JAM 4 2. 1044-00P BOLT, ¼ NC X ¾ HH PL 4 3. 1062-0SP NUT ¼ NC NYLOCK 10 4. 1064-00P LOCK WASHER 6 5. 1237-00P FITTING 1 6. 1351-00P NUT, ½ NC HH PL 1 7. 2679-00P SPRING 1 8. 2830-00P BOLT ¼ NC X ½ SHCS 6 9. 1538-00P BOLT 5/16 NC X 1 ALLEN HEAD 8 10. 1733-00P BOLT ¼ NC X ¾ SOCKET HEAD 10 11. 1899-00P NUT 5/16 NC NYLOCK 12 12. 2241-00P COVER COUPLER 1 13. 2301-00P TIE WIRE/HOSE 2 14. 2449-00P WASHER LOCK 6M 6 15. 2489-00P PLUG 1/16 NPT ALLEN HEAD 5 16. 2512-00P COVER COUPLER 1 17. 2554-00P COUPLER HYD. 1 18. 2555-00P COUPLER HYD, 1 19. 2605-00P FITTING 3 20. 2752-00P SCREW SOCK. SET 2 ¼-20 X 3/8 21. 3069-00P GRIP BLUE 1.0 X 6.0 X.060 2 22. 3890-00D PISTON CYLINDER 1 23. 3891-00P BACK UP PISTON 2 13
ITEM NO. PART NO. DESCRIPTION QTY 24. 3892-00P O-RING PISTON 1 (.21 DIA-1.66 ID-2.00 OD) 25. 4477-00P BOLT 3/8 X 1.00 SHCS 1 26. 3894-00D ROD CYLINDER 1 27. 3895-00P -024 O-RING 1 (PISTON TO ROD SEAL) 28. 3896-00D TUBE CYLINDER 1 29. 3897-00P -035 O-RING 2 (CYLINDER TO END CAP) 30. 3898-00P END CAP ROD 1 31. 3899-00P SEAL WIPER 1 32. 3900-00P SEAL ROD 1 33. 3901-00P BACK UP ROD 1 34. 3902-00D END CAP 1 35. 3903-00P BOLT ¼ NC X 5 GRADE 8 4 36. 3904-00D MANIFOLD VALVE 1 37. 3905-00P VALVE CHECK 1 38. 3906-00P VALVE ON/OFF 1 39. 3908-00P BOLT 5/16 X 4 4 (CYLINDER MOUNT) 40. 3916-00W LINK TRIGGER COMP. 1 41. 4362-00W TRIGGER COMPLETE 1 42. 3918-00P BOLT ¼ NC X 1 ¾ SHCS 2 43. 3919-00P HOSE WHIP 3/8 2 44. 3931-00D GRIPPER RIGHT COMP. 1 45. 3932-00D END RAM 1 46. 3933-00W FRAME MAIN COMPLETE 1 47. 3934-00D FRAME GRIPPER 1 48. 3935-00W GRIPPER ARM LEFT COMP. 1 49. 3936-00D COVER RAM END COMP. 1 14
ITEM NO. PART NO. DESCRIPTION QTY 50. 3937-00W HANDLE COMPLETE 1 51. 3938-00D BASE ANGLE LEFT 1 52. 3939-00D BASE ANGLE RIGHT 1 53. 5194-OOP HOSE RETURN 1 54. 5195-OOP HOSE PRESSURE LR 1 55. 3942-00D ORFICE.093 1 56. 3954-00W GUARD/HANDLE 1 57. 3955-00W FOOT REAR ADJ. COMP. 1 58. 3957-00D PIN PIVIT COMPLETE 1 59. 3958-00P BOLT @ PIVIT BLOCK 1 60. 3959-00D GUIDE 2 61. 3972-00P FITTING 90 1 62. 2604-OOP FITTING STRAIGHT 1 63. 3640-OOP ROLL PIN 1 64. 3179-OOP ROLL PIN 1 65. 4361-OOP SAFETY TRIGGER 1 15
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4.3 Care Requirements Maintenance CLEANING AND MAINTENANCE RECOMMENDATIONS Wipe all external surfaces after each use with a clean, lint free cloth to remove surface contaminants from the tool. Daily: 1. Wipe all tool surfaces, fittings, and coupling free of grease, dirt, and foreign materials. WARNING: DO NOT ATTEMPT TO LOCATE HYDRAULIC LEAKS BY FEELING AROUND HOSES AND FITTINGS WITH HANDS. PIN- HOLE LEAKS CAN PENETRATE THE SKIN. 2. Inspect the tool, hydraulic system, hoses, and fittings for signs of leaks, cracks, wear, and/or damage. Replace if necessary. 3. To prevent contamination, always install dust caps over the hydraulic ports when disconnected. 4. Inspect hydraulic hoses and couplings every day. Repair or replace hose and couplings if it is leaking, cracking, wearing or any damage is evident. Weekly: With the tool disconnected from the power source inspect grippers (diagram 4.3) for any cracks or chipping that may be occurring in the metal. If there is any major cracks or chips in the grippers be sure to replace them. Do not operate this tool if the grippers are damaged in any way. If there isn t any damage to the grippers continue use of this product. Diagram 4.3: This picture shows the bottom of the lock remover, this is where the grippers (A) are located. NOTE: Do not attempt to repair this product. Only properly trained person should perform any maintenance, service, and or repair to a tool. Monthly: A 1. Check jaws to make sure they are well lubricated at all times. When lubricating jaws, use good quality lithium grease. 2. Perform a detailed inspection of the system hoses and fittings according to the hydraulic hose operator s manual and as stated in SAE standard j1273, May 1989 or latest revision. Replace the hoses and/or fittings if necessary. SERVICE COMPLETE DIASSEMBLY OF THE TOOL IS NOT RECOMMENDED. RETURN TO PORTACO, INC. FOR REPAIRS. 18
4.4 Trouble Shooting The following chart can be used as a guide to correct any problem you may experience with the tool. To determine the problem in operation of the safe lock installer always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the tool as listed in the table. Be sure you are using an accurate flow meter. Check the flow with the hydraulic fluid temperature at least 80 F/27 C. NOTE: Stop and depressurize the hydraulic system before connecting or disconnecting a tool. Failure to follow these instructions can lead to severe personal injury. Read and follow the instructions in this manual for the proper way to connect and disconnect tools from the hydraulic systems. PROBLEM CAUSE REMEDY Tool will not actuate Power source Check power source flows and pressure (5gpm/20 lpm at 2000 psi/150 bar) Coupler or Hose Check for /remove obstruction Obstruction in application mechanisms Inspect application mechanisms/remove any If jaws move but not enough power to remove clip Remover slips or comes off clip Trigger (ON/OFF) hard to press Too high back pressure Maybe a leaky seal Adjustable foot requires adjusting obstructions Test power source and repair or replace as required Check seal Replace as required Adjust foot so jaws are parallel to top of safe lock clip Back pressure too high Should not exceed 250 psi/17 bar at 10 gpm/38 lpm Pressure and return reversed Correct for proper flow direction ON/OFF valve blocked check valve at manifold remove obstruction if present NOTE: After reviewing trouble shooting chart and still unable to determine problem call the service department at PortaCo Inc. (218-236-0223) for advice. 19
4.5 Technical Specifications Lock Remover/Base Unit Lock Remover/Wheel Kit Max Pressure Max Flow 38-lbs/17.2 kg 46-lbs/20.8 kg 2000 psi/150 bar 5 gpm/20 lpm Consumable Items List Description Part Number Source Coupler HYD FF-372-6FP M 2554-00P PortaCo Inc. Coupler HYD FF-371-6FP F 2555-00P PortaCo Inc. Cover Coupler # NR-37 BRUNNING 2241-00P PortaCo Inc. Cover Coupler # NR-50 2512-00P PortaCo Inc. Blue Grips 1.0 X 6.0 X.060 3069-00P PortaCo Inc. 20
Hydraulic Fluid Requirements Viscosity (Fluid Thickness) METRIC U.S.A. 10 C 95 Centistokes 50 F 450 SSU Max 38 C 27-42 C.S. 100 F 130-200 SSU 60 C 16.5 C.S., Min. 140 F 85 SSU Min. Pour Point 10 F/-23 C Minimum (for cold startup) Viscosity Index (ASTM D 2220) 140 Minimum Demulsibility (ASTM D-1401) 30 Minutes Maximum Flash Point (ASTM D-92) 340 F/171 C Minimum Rust Inhibition (ASTM D-665 A & B) Pass Oxidation (ASTM D943) 1000 Hours Minimum Pump West Test (ASTM D2882) 60 mg Maximum Recommend Hydraulic Fluids Type Hydraulic fluid Chevron Clarity AW ISO 32 Exxon Univis J 32 Mobil D.T.E. 13 M Gulf Harmony AW-HVI-150-32 Shell Tellus T 32 Texaco Rando HDZ 32 Union Unax AW-WR-32 Amsoil AWH ISO 32 Sunvis Low Pour H/032-product code 193000 Coupler recommendation: 3/8 inch FLAT FACE HTMA couplers rated at 2500 psi working pressure. Threads are to match fittings used on hoses or fittings used as adapters. Bolt Size #10-32 ¼-20 5/16-18 3/8-16 Torque 38 in. lbs. 76 in. lbs. 13 ft. lbs. 23 ft. lbs 21
SERVICE AND REPAIR NOTES 22