CHERNE Test-Ball Mounting instructions

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CHERNE INDUSTRIES INCORPORATED
5700 LINCOLN DRIVE
MINNEAPOLIS, MINNESOTA 55436-1695
PHONE: [phone]
FAX: [phone]
SAFETY &
INSTRUCTION
MANUAL
A Guide to
the safe and
proper use of
Cherne
Pneumatic
Pipe Plugs
KEEP THIS MANUAL WITH PLUG FOR FUTURE REFERENCE
WA R N I N G
MUST READ THIS
MANUAL BEFORE
USING CHERNE
PNEUMATIC
PIPE PLUGS
This manual covers Cherne
Pneumatic Plugs as follows:
Single Size Test-Ball® Plugs (8” & larger)
Multi-Size Test-Ball® Plugs (6” & larger)
Muni-Ball® Plugs
i-Series® Plugs
REMO® Plugs
BIG MOUTH® Plugs
AIR-LOC® Plugs
Factory Replaceable Sleeve
Large Pillow-Style Test Ball® Plugs

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Dedicated to the memory
of Allen D. Mathison
1946 – 1996
WARNING: Plugs must be braced while in use.

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SAFETY INSTRUCTION MANUAL INDEX (REV 12)
I. GENERAL SAFETY AND USAGE
INSTRUCTIONS (ENGLISH) ................................... PAGE 5
II. ALLGEMEINE SICHERHEITS UND
BEDIENUNGSANLEITUNGEN (GERMAN) .................... PAGE 6
III. SÉCURITÉ GÉNÉRALES ET INSTRUCTIONS
D’ UTILISATION (FRENCH) ................................... PAGE 7
IV. ISTRUZIONI GENERALI SULLA
SICUREZZA E L’USO (ITALIAN)............................... PAGE 8
V. INSTRUCCIONES DE SEGURIDAD
GENERAL Y USO (SPANISH) .................................. PAGE 9
VI. (JAPANESE) .................. PAGE 10
1. INTRODUCTION .............................................. PAGE 11
2. DETERMINE THE AMOUNT OF BACK PRESSURE
THE PLUG MUST WITHSTAND FOR THE JOB OR
APPLICATION ................................................. PAGE 12
3. DETERMINE THE USAGE TEMPERATURE AND THE
MEDIA THE PLUG MUST WITHHOLD ....................... PAGE 16
4. MEASURE THE PIPE AND SELECT THE PROPER
PLUG AND RELATED EQUIPMENT .......................... PAGE 17
5. CLEAN PLUG AND RELATED EQUIPMENT BEFORE
EVERY USE AND INSPECT FOR DAMAGE................... PAGE 20
6. SELECT AND USE PROPER SAFETY AND
PROTECTIVE EQUIPMENT................................... PAGE 22
7. RECOMMENDED SAFETY PROCEDURES FOR
ENTRANCE INTO MANHOLES AND OTHER
CONFINED SPACES ........................................... PAGE 24
8. CLEAN PIPE BEFORE PLACING PLUG ...................... PAGE 25
9. ATTACH INFLATION HOSE TO ENABLE PLUG
INFLATION AND DEFLATION FROM OUTSIDE
DANGER ZONE ............................................... PAGE 26

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10. PROPER PLUG PLACEMENT IN PIPE ....................... PAGE 28
11. PROVIDE A BACKUP SYSTEM FOR SAFETY ................ PAGE 32
12. PROPER PNEUMATIC PLUG INFLATION.................... PAGE 33
13. PROPER PNEUMATIC PLUG REMOVAL ..................... PAGE 36
14. CLEAN AND INSPECT PLUG AFTER EVERY USE AND
STORE PROPERLY ............................................ PAGE 38
15. SPECIAL CAUTION TO EMPLOYERS AND
CONTRACTORS............................................... PAGE 39
16. PRODUCT USAGE DATA...................................... PAGE 40
17. SPECIAL USAGE INSTRUCTIONS FOR GRAVITY FLOW
BYPASS APPLICATIONS ...................................... PAGE 52
18. LIMITED WARRANTY ......................................... PAGE 54
The Cherne products described in this manual may be covered by one
or more of the following Patents and trademarks: US Patent Numbers
3,834,422 3,951,173 4,096,977 4,274,206 4,493,344 4,588,110 4,614,206
4,763,511 4,817,6715,035,266 5,076,328 5,209,266 5,234,034 5,329,646
5,353,841DES 300,350 DES 339,405 DES 350,704 DES 351,013 DES 358,871
DES 362,713 DES 369,652DES 370,055 DES 370,715 (additional patents
pending). Trademark Numbers 625,158 717,948 718,126 718,373 737,860
816,386 930,319 906,675 912,238 1,138,344 1,145,721 1,163,062 1,276,011
1,360,285 1,428,285 1,574,687 1,559,813 1,937,973 (additional trademarks
pending). Additional foreign trademarks are not listed.
© Copyright 1991, 1992, 1998, 2000, 2007 All Rights Reserved, Cherne Industries Incorporated

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I. GENERAL SAFETY & USAGE INSTRUCTIONS
1. DEATH, BODILY INJURY AND/OR PROPERTY DAMAGE MAY RESULT IF
PLUG FAILS FOR ANY REASON.
2. READ AND UNDERSTAND THIS SAFETY INSTRUCTION MANUAL BEFORE
USING PLUG.
3. MUST WEAR SAFETY GLASSES AND A HARD HAT.
4. DO NOT ENTER DANGER ZONE WHEN PLUG IS IN USE.
5. MEASURE PIPE DIAMETER BEFORE SELECTING PLUG.
6. INSPECT PLUG FOR DAMAGE BEFORE AND AFTER USE.
7. NEVER USE A PLUG IN A PIPE SIZE DIFFERENT FROM RECOMMENDED
USAGE RANGE (REFER TO THIS SAFETY INSTRUCTION MANUAL).
8. ALWAYS ATTACH AN INFLATION EXTENSION HOSE SO PLUG CAN BE
INFLATED AND DEFLATED FROM OUTSIDE THE DANGER ZONE.
9. NEVER REMOVE THE INFLATION HOSE UNTIL ALL BACK PRESSURE IS
RELEASED AND THE PLUG IS DEFLATED.
10. MUST INFLATE PLUG TO THE PRESSURE SHOWN ON PLUG.
11. ALWAYS USE PROPERLY CALIBRATED PRESSURE GAUGES.
12. DO NOT EXCEED RECOMMENDED MAXIMUM ALLOWABLE
BACK PRESSURE (REFER TO THIS SAFETY INSTRUCTION MANUAL).
13. ALWAYS RELEASE BACK PRESSURE FROM THE PIPE FIRST, BEFORE
DEFLATING PLUG.
CALL 1-800-THE-PLUG OR 1-952-933-5501 IF ADDITIONAL CLARIFICATION IS
REQUIRED.
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