Matweld 01200 User manual

MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01200 SPRING ANCHOR APPLICATOR
TheMatweldSpringAnchorApplicator is a
lightweightandlaborsavingtoolforthe
maintenanceof way crew.Asafeandquick
methodof installing springanchorclips,
whichdoes not require “brute force” for clip
installation.The tool utilizesapivoting foot
designwith seven tons of force available to
installthe toughestclips.Operators will
appreciatethe clear viewduringinstallation.
632South3rdStreet
P.O.Box2816•Paducah,KY42002
Phone:[phone]
Fax:[phone]
Website:www.matweld.com
Email:[email protected]
PRESSURE DIMENSIONS WEIGHT
2000 psi 15”(381mm) x 43”(1092mm) 45 lbs.(20kg)
FLOW
5 gpm(19 lpm)
or
10 gpm(38 lpm) (140 BAR)
ACCESSORIES:
01225-HEAD WORNRAIL KIT

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00 REV.02/06

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
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 AT-
TACHED TO THE TOOL AND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR
SAFETY. READ TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERA-
TION 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 TOOLIF YOU HAVEANY QUESTIONSABOUT
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 SELEC-
TION. THE CUSTOMER MUSTASSUME RESPONSIBILITY FOR THE TOOL’S SUITABILITY FOR
A PARTICULAR FUNCTION, FOR ANYONE USING THE TOOL OR MAINTAINING THE TOOL
REGARDING THEIR FITNESS TO USE THE TOOL OR REPAIR THE TOOL, UNDERSTANDING
OF THE OPERATION AND SAFETY AND MAINTENANCE MANUAL, INTELLIGENCE TO USE
GOOD JUDGMENT NECESSARYTO WORK SAFELYAND EFFICIENTLY WITHOUTENDANGER-
ING THEMSELVES OR BYSTANDERS IN THE WORK AREA.
• 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 FLOWAND PRESSUREARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THETOOLBEING USED. PER-
SONAL 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 UN-
SAFE GRADES, POOR FOOTING AREAS AND OVERHEAD HAZARDS.
• MAINTAIN BALANCEAND PROPER FOOTING ATALLTIMES. NEVER OVERREACH TO THE
EXTENT THATABROKEN 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.
REV.02/06

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
• WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CON-
DUCTORSARE ENERGIZEDAND THAT HOSESAND CLOTHING CAN CONDUCT HARMFUL
ELECTRICITY. 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 PARTS
OF THE TOOLS OR BE CARELESS WITH HANDS, FEET OR OTHER BODYPARTSAROUND
THE WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUE AND
FORCE AND CAN CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLY USED.
• TOAVOIDPERSONALINJURYOR EQUIPMENTDAMAGE,ALLTOOLREPAIR, MAINTENANCE
OR SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED
PERSONNEL.
• ALWAYSWEARSAFETYEQUIPMENTSUCHAS OILINJECTIONRESISTANTWORKGLOVES,
SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETY APPAREL
DICTATED BY YOUR SUPERVISORAPPLICABLE 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.
• OILINJECTION HAZARD EXISTS WITHTHIS TOOL.OILINJECTION ISACONDITION 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 PER-
SONAL INJURY OR DEATH.
• CLEAN UP ANY OIL OR FLUID SPILLS IMMEDIATELY.
REV.02/06

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
HAVE SUPERVISOR ADD ADDITIONAL PRECAUTIONS RELATING TO THE SPECIFIC
WORK AREAAND LOCAL SAFETY REGULATIONS BELOW:
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REV.02/06

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
01200 SPRING ANCHOR APPLICATOR
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCH AS GLOVES, SAFETY GLASSES, EAR
PROTECTION AND SAFETY SHOES.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTS
WHICH 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 PRESSURE
IN THE LINE.ALWAYS WEAR GLOVES, DO NOT CARRYTHE TOOLBY HYDRAULIC HOSES,
AND REPAIR LEAKS IMMEDIATELY..
5. DO NOT CARRY THE TOOL BY THE PIGTAIL HOSES.
6. NEVER PUT YOUR FINGERS OR ANY OTHER OBJECT NEAR THE CLIPFOOT WHILE THE
TOOL IS CONNECTED TO A POWER SOURCE.
7. NEVER USE YOU FINGERS TO DISLODGE A SPRING ANCHOR, EVEN WITH THE TOOL
DISCONNECTED FROM THE POWER SOURCE, THERE COULD STILL BE PRESSURE IN
THE SPRINGANCHOR WHICH COULD CAUSE SUDDEN MOVEMENT OF THE CLIP FOOT.
8. NEVER PERFORMMAINTENANCEONTHETOOLWHILEITIS CONNECTEDTOTHE POWER
SOURCE.
9. NEVER EXCEED MAXIMUM TOOL FLOW OR PRESSURE RATINGS. DAMAGE TO TOOL OR
PERSONALINJURYOR DEATH MAY RESULT.
FLOW: 5 OR 10 GPM (19 OR 38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX250PS
10. NEVER LEAN ON TOOL OR USE IT FOR PRYING.
REV.02/06

7
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
01200 SPRING ANCHOR APPLICATOR
FLOW: 5 OR 10 GPM (19 OR 38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX250 PSI
OPERATION:
1. WITH WITH THE POWER SOURCE IN THE “OFF” POSITION,CONNECT THE HOSES.
DO NOTDRAG THE SERVICE HOSE BYPULLING WITH THE TOOL. LOOPTHE SER-
VICE HOSE IN THE WORK AREA IN SUCH A WAY TO RELIEVE STRESS ON THE
HOSEAND QUICK DISCONNECT FITTINGS WHILE WORKING. BEAWARE OF HOSE
LOCATION AT ALL TIMES.
2. CONNECT THE TOOL TO THE POWER SOURCE.
3. TURN THE POWER SOURCE “ON” TO SUPPLY 5 OR 10 GPM TO TOOL.
4. SET THE SPRING ANCHOR APPLICATOR TOOL DOWN ON THE PRE-SET SPRING
ANCHORTOBE INSTALLED. MAKE SURESPRINGANCHOR IS FULLY ENGAGED ON
RAIL BASE AND CLIP FOOT IS POSITIONED BEHIND EAR OF SPRING ANCHOR AS
SHOWN IN PICTURE BELOW.
5. DEPRESS TRIGGER TO INSTALL SPRINGANCHOR, HOLD TRIGGER UNTIL FULLY
SEATED.
6. RELEASE TRIGGERAND APPLICATOR FOOT WILL AUTOMATICALLY RETRACT.
7. REMOVE SPRINGAPPLICATOR AND MOVE TO NEXT PRE-SETSPRING ANCHOR
TO BE INSTALLED.
CAUTION:ALWAYS MAINTAIN SECURE FOOTINGAND USE PROPER BODY POSITION.
HOLD THE TOOL AWAY FROM YOUR BODY AND KEEP ARMS RELAXED AND FREE TO
FLEX, SHOULD MINOR JERKING OF THE TOOL OCCUR DURING OPERATION.
REV.02/06
RAIL
SPRING ANCHOR
CLIP FOOT
RUB PLATE
EAR
NOTE:AFTER YOU HEAR SPRINGANCHOR SNAPINTO PLACE, IMMEDIATELY
RELEASETRIGGER.CONTINUED DEPRESSING OF TRIGGERCOULDDAMAGE
THESPRINGANCHOR CAUSING POSSIBLE PREMATUREFAILURE.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
01200 SPRING ANCHOR APPLICATOR
OPERATION CONT.:
REV.02/06
USE OF SPRING ANCHOR APPLICATOR ON HEAD WORN RAIL
ON HEAD WORN RAIL, IT IS POSSIBLE FOR THE TOOL TO RUN OUT OF CYLINDER
STROKE BEFORE THE SPRINGANCHOR SNAPS INTO PLACE. FOR INSTANCES WHERE
THE TOOL IS BEING USED ON HEAD WORN RAIL, MATWELD OFFERS KIT #01225
WHICH INCLUDES TWO RUB BLOCKS OF DIFFERENTTHICKNESS ANDAN EXTRA
MOUNTINGBOLTANDFLATWASHER.
THE TOOL IS SUPPLIED WITH THE STANDARD #01201-04 RUB BLOCK (COLOR CODE -
YELLOW). THE #01225 KIT INCLUDES (1) #01201-04A RUB BLOCK (COLOR CODE -
WHITE) WHICH ISA1/4” THICKER THAN THE STANDARD BLOCKAND (1) #01201-04B
RUB BLOCK (COLOR CODE - GREY) WHICH IS 1/2” THICKER THAN THE STANDARD
BLOCK.
IT WILLBE THE OPERATORS RESPONSIBILITY TO DETERMINE WHICH RUB BLOCK IS
REQUIRED FOR THE EXTENT OF HEAD WEAR PRESENCE. RUB BLOCKS ARE
CHANGED OUT BY LOOSENINGAND REMOVING THE 1/2-13 x 1-1/4” LG. HEX HEAD BOLT
(ITEM #26), SWITCHING TO THE CORRECT RUB BLOCK , REPLACING BOLT,AND TIGHT-
ENING.
26
22
01201-04
01201-04A
01201-04B
KIT #01225

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00 REV.02/06
01200 SPRING ANCHOR APPLICATOR
MAINTENANCE:
1. CHECK TOOL FOR OVERALL WORKING CONDITION DAILY.
2. INSPECTHOSES DAILY.ATFIRSTSIGN OFANYABRASION OR CUTTOCOVER,THEHOSES
MUST BE CHANGED.
3. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.
4. USE ONLY RECOMMENDED HYDRAULIC OILS. NEVER USEATF OR MOTOR OILS.
SUGGESTED HYDRAULIC OILS:
AMOCO RYKON MV CITGO A/W ALL TEMP
SUN 2105 MOBIL D.T.E. 15
CHEVRON EP-MV TEXACO “RANDO” HZ
IF YOUR LOCAL DISTRIBUTOR DOES NOT CARRYANY OF THE ABOVE SUGGESTED HY-
DRAULIC OILS USE THE FOLLOWING GUIDELINES:
VISCOSITY @ 100° F ………………………………………………….100-190SUS
VISCOSITY INDEX………………………………………………………MIN. 150
EACH APPLICATION IS DIFFERENT, IF THERE ARE ANY QUESTIONS CONCERNING THE
RIGHTCHOICE FORYOUR PARTICULARAPPLICATIONCALLMATWELD FORASSISTANCE.
5. HAVE TOOL INSPECTED, AT LEASTANNUALLY, BYA MATWELD OR MATWELD QUALIFIED
SERVICE REPRESENTATIVE TO DETERMINE IF TOOL IS IN NEED OF SAFETY CHANGES
OR WORN PART REPLACEMENT.
6. CONTACT MATWELD ON A PERIODIC BASIS, AT LEASTANNUALLY, FOR SERVICE BULLE-
TINS, SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THIS
TOOL.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
01/00
REVIEW OF HYDRAULIC PRINCIPLES
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 HP
1456.9 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. MOSTMANUFACTURERS LISTTHE MAXIMUM BACK
PRESSURE FOR THEIR HYDRAULIC TOOLS AT 250 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 FROMTHE MAXIMUM TOOL
PRESSURETOARRIVEATAMAXIMUMTOOLOPERATING PRESSURE. FOR EXAMPLE,TOOLS
WITH 2000 PSI OPERATING PRESSURE ARE INSTALLED ON A SYSTEM WITH 250 PSI BACK
PRESSURE. THIS LEAVES 1750 PSI AS A MAXIMUM TOOL PRESSURE. IMAGINE A SYSTEM
WITH 500 PSI BACK PRESSURE. 2000 MINUS 500 PSI BACK PRESSURE LEAVES ONLY 1500
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.
REV.02/06