product user guide - Mabey Hire International
Contents
1. 2400 1500 1600 CP10 075 2600 156 1000 1200 1600 CP10 076 1600 CP10 077 2850 170 1050 1200 1450 TETN CP10 078 3000 1200 Slings NO CP10 079 750 1200 Sia ae CP10 080 1200 CP10 081 3500 1200 CP10 082 3500 1000 1400 CP10 083 3500 1500 CP10 084 3600 209 1200 2800 Angle CP10 085 4000 1500 Pe CP10 086 4000 1200 1500 Single Leg Chain Slings CP10 087 4000 1500 2500 code No Ef Leg Weight ode NO cP10 088 4500 254 1500 2000 2500 Length mm kg cP10 089 4500 1500 2000 CP10 040 600 103 CP10 090 5000 1000 2500 CP10 046 1000 CP10 091 5000 2000 2500 CP10 013 1600 CP10 092 5500 2500 2800 CP10 093 7000 3000 Miscellaneous Accessories P1 4 1 5 Hose Bridal Assembly CP10 015 ern ae 3 0m Hose Extension CP10 060 CP10 095 2850 1200 M12 x 120 long Bolt amp Nut CP10 036 254x254x107 kg m U C Hose Shut off valve assy CP10 045 Page 3 of 7 product user guide QIESEMii part of the mabey family Culvert Puller 10 Tonne ome April 2015 4 Connection Details Body to Chassis 4 No M20 x 75 long Gr 8 8 Galv bolts SHBP M20x75 Outriggers to chassis 2 No M16 x 80 long Gr 8 8 Galv bolts JCBP 045 Cylinder to Body 1 No Tow Bar Pin CP10 008 R Clip Cylinder to Tow Bar 1 No Tow Bar Pin CP10 008 R Clip Tow Bar to Tow Bar 1 No Tow Bar Pin CP10 008 R Clip CP03 Body amp Screw assy CP10 032 to CP03 Top Inner assy CP10 032. user guide ciocoii part of the mabey family Culvert Puller 10 Tonne K April 2015 8 5 Mechanical Pump Details and Procedures for Extending Retracting Walings Con d 8 5 Procedure for retracting the cylinder i e Pulling the culvert Ensure the culvert spreader beam pulling chain and tow bar if required are all in position and all pins and R clips are fitted and secure Set the pump control valve to Neutral and open the air supply valve The pump hoses should still be connected If not follow steps above Set the pump control valve to Retract to pull the culvert into position If two cylinders are being used and it becomes necessary to isolate one cylinder i e if the culvert is not being pulled squarely then close the shut off valve in the retract hose connected to that cylinder On completion of the retraction and when the culvert is in position close off the air supply valve and set the pump control valve to Neutral 9 Typical Assembly Details 9 1 Two Culvert Pulling machines Wheeled Pump Body and Screw Assembly via with Shoes i iy 1 ee OLY A I Cylinder q Spreader Beam 2 Si S Chassis Single Leg Chain Sling Culvert 9 2 Single Culvert Pulling machine Body and Screw Assembly with Shoes B Spreader Beam Chassis 2 Leg Chain Sling 10 General Since our policy is one of continual improvement components may vary in detail from
3. work to be carried out The Culvert Pulling machines are designed to pull pre cast box culvert sections and are not intended for other purposes The CP01 CP02 amp CPO3 Culvert Pulling machines are manufactured by Mabey Hire Ltd Scout Hill Ravensthorpe Dewsbury West Yorkshire WF13 3EJ Refer to Appendix A for details of our Site Demonstrator service Design The CP01 CP02 amp CP03 Culvert Pulling machines have a maximum pull capacity of 10 tonne Component Identification Note All components are common to each type of machine except where shown otherwise ar A Machine type CP02 Machine type CP02 Machine type CP02 Bottom Inner assembly Top Inner assembly Outer Inner Pin Code CP10 B INN Code CP10 T INN 25 dia x 200 long Weight 40 0 kg Weight 60 0 kg Code CP10 027 Weight 0 8 kg Machine Type CP02 Code No Actual Body Culvert Working Weight Length mm range mm kg CP10 019 1252 1775 2150 CP10 020 1627 2150 2525 100 0 5 CP10 021 2002 2525 2900 135 0 Machine type CP02 CP10 022 2377 2900 3275 161 0 Outer Body CP10 055 2752 3275 3650 194 0 Page 1 of 7 product user guide ciocoii part of the mabey family Culvert Puller 10 Tonne K April 2015 3 Component Identification Cont d Note All components are common to each type of machine except where shown otherwise E Cf F Machine type CP01 Machine types CP01 amp Machine types CP01 amp Machine types CP01 amp 1300 1400 Body amp
4. 3 034 1 No Manhole Brace Pin MHB 04 R Clip CP03 Body amp Screw assy CP10 048 to CP03 Top Inner assy CP10 049 050 051 1 No Manhole Brace Pin MHB 04 R Clip CP03 Bottom Shoe CP10 035 to CP03 Body amp Screw assy CP10 032 048 1 No M12 x 120 Ig Gr 8 8 bolt CP10 036 CP01 02 Centre Shoe CP10 002 to CP01 Body amp Screw assy CP10 017 1 No Shoe Pin Code CP10 007 R Clip OR CP02 Bottom Inner assy CP10 B INN CP01 02 Top Shoe CP10 003 to CP01 Body amp Screw assy CP10 017 1 No Shoe Pin Code CP10 007 R Clip OR CP02 Bottom Inner assy CP10 B INN or CP02 Top Inner assy CP10 T INN CP01 02 Bottom Shoe CP10 004 to CP01 Body amp Screw assy CP10 017 1 No Shoe Pin Code CP10 007 R Clip OR CP02 Bottom Inner assy CP10 B INN CP02 Top Inner assy CP10 T INN to CP02 Outer Body CP10 018 019 020 021 022 1 No Outer Inner Pin CP10 027 R Clip CP02 Bottom Inner assy CP10 B INN to CP02 Outer Body CP10 018 019 020 021 022 1 No Outer Inner Pin CP10 027 R Clip Stacking and Handling e Suitable lifting equipment of adequate lifting capacity should be provided for off loading pre assembly work installation and dismantling e Slinging should always be carried out by suitably experienced and competent personnel e Weights of components are given in Section 3 e Return equipment as supplied from Mabey Hire depot Transportation e Ensure cylin
5. CP02 Centre Shoe CP02 Top Shoe CP02 Bottom Shoe Screw assembly Code CP10 002 Code CP10 003 Code CP10 004 Code CP10 017 Weight 15 2 kg Weight 8 1 kg Weight 8 1 kg Weight 120 0 kg Q Machine type CP03 Machine type CP03 Machine type CP03 Machine type CP03 825 1050 Body amp 975 1425 Body amp Body Inner Pin 825 1425 Bottom Shoe Screw assembly Screw assembly 20 dia x 195 long Code CP10 035 Code CP10 048 Code CP10 032 Code MHB 04 Weight 6 7 kg Weight 76 0 kg Weight 80 0 kg Weight 0 6 kg Machine Type CP03 em range mm A B Holes kg T CP10 049 825 855 190 100 1 80 CP10 050 860 950 225 40 3 9 0 sae Tap ner atau Wa 2 j J Wheeled Pump Chassis SS Code SSBA 003 Code CP10 001 Weight 87 0 kg full Weight 104 kg NO Cylinder Cylinder Support Pin Shoe Pin Tow Bar Pin Code CP10 005 25 dia x 400 long 15 dia x 130 long 30 dia x 125 long Weight 93 0 kg Code CP10 006 Code CP10 007 Code CP10 008 Weight 1 5 kg Weight 0 2 kg Weight 0 7 kg Page 2 of 7 product user guide QIEEEN Li part of the mabey family Culvert Puller 10 Tonne ome April 2015 3 Component Identification Cont d Note All components are common to each type of machine except where shown otherwise SS S Tow Bar Le N Hole Ctrs Weight Code No Spreader Beam mm kg 203x203x52 kg m U C CP10 031 1000 CP10 071 1600 96 tonCl 1000 CP10 073 2350 141 1000 CP10 074
6. Limited Please return this completed form to the Mabey Hire depot supplying the equipment Contact details for all the Mabey Hire depots are available both on line at www mabeyhire co uk depot directions and within our brochures From Company Name Site Address Tel No Fax No Re Provision of a Mabey Hire Demonstrator on site We confirm receipt of your User Information Appendix A and that we would like to request the services of your Demonstrator on the following date s Signed Name print Date
7. between the Body and Screw Assembly and the Top Inner Assembly and then the bottom screw should be used for the final adjustment to secure the shoes into the recess between the culvert sections Page 4 of 7 product user guide QIESEMii part of the mabey family Culvert Puller 10 Tonne oan April 2015 7 Site Assembly amp Culvert Installation Cont d 7 1 5 Select one of three connection points the CP03 machines have only one connecting point and pin the cylinder tube into the body using 1 No 30 dia tow bar pin and R clip Ensure the cylinder couplings are facing upwards and the cylinder tube is resting on the support bar at the front of the chassis 7 1 6 Connect both hose shut off valve assemblies between the air pump and cylinder and connect the pump to a suitable air supply 100psi 14 cu ft min Follow the procedure for extending retracting the cylinder in Section 8 When the cylinder has been sufficiently extended and the next culvert section is in position lift the spreader beam complete with 2 leg pulling chain to the required height and attach to the cylinder piston rod using the bow shackle fitted to the master ring Check the top and centre shoe are in position and the body is screwed up tight Check all pins R clips and bolts are in position Check the chassis is in line with the culvert The cylinder can now be retracted to pull the culvert section into position Tow bars are supplied which can be fitted be
8. chanical Pump Details and Procedures for Extending Retracting Walings 8 1 Introduction It is advisable before commencing installation to read the notes below to become familiar with the procedures involved The diagrams below show the pump control gauge hose connections and safety lock off valve referred to in the procedures Fluid Pressure Extend Hose Female R Retract ails Coupling Safety Lock Off N Neutral E Extend 2 Shut off valve Couplin a Pump AirSupply N 12 BSP Claw connector c w i Control Valve Control Valve anti whip check cable 8 2 Preliminaries e Check there is sufficient of the Mabey Hire shoring fluid in the tank Only Mabey Hire shoring fluid can be used Set the pump control valve to Neutral Connect the pump to a suitable air supply 100psi at 14 cu ft min fit the anti whip check cable to the air supply hose and open the air supply control valve on the pump Purge the hoses of air To do this connect the hoses together and run the pump for a few seconds with the control valve set to extend When satisfied that any air has been expelled set the pump control valve to neutral At no time must the pump be left operating whilst unattended 8 3 Mabey Hire Shoring Fluid Temp Range Shoring Fluid Water The pump is normally supplied with a full tank of premixed fluid If the fluid is Degrees C litres litres separately supplied neat in 5 litre orange coloured containers it sho
9. der is fully retracted e Ensure outriggers are fully closed and bolted to chassis e Ensure rear vertical stabiliser is fully retracted e Ensure all equipment is loaded to the satisfaction of the lorry driver and securely restrained to the vehicle bed Site Assembly amp Culvert Installation There are two typical assemblies 7 1 Single Culvert Pulling machine with 2 leg Pulling Chain 7 1 1 Refer to Section 9 for typical assembly details 7 1 2 The Culvert Puller should be positioned in the centre of the culvert and may be stabilised using the rear vertical screw and side mounted adjustable outriggers as required 7 1 3 Ensure the body is vertical to the chassis adjust by releasing 4 No M20 bolts if necessary 7 1 4 Vertical adjustment should be made as follows e On type CP01 machines adjust the screws at the top and bottom of the Body and Screw Assembly to secure each shoe into the recess between the culvert sections On type CP02 machines initial adjustment should be made by the incremental hole positions between the Outer Body and the Top Inner Assembly and then the top and bottom screws should be used for the final adjustment to secure each shoe into the recess between the culvert sections On type CP03 machines fitted with Body amp Screw Assembly CP10 048 and Top Inner Assembly CP10 049 adjustment is made by the bottom screw only On all other type CP03 machines initial adjustment should be made by the incremental hole positions
10. product user guide ciocoii part of the mabey family Culvert Puller 10 Tonne K April 2015 Contents Page 1 Introduction Design Component Identification Page 2 Component Identification Cont d Page 3 Component Identification Cont d Page 4 Connection Details Stacking and Handling Transportation Site Assembly amp Culvert Installation Page 5 Site Assembly amp Culvert Installation Cont d Page 6 Mechanical Pump Details and Procedures for Extending Retracting Walings Page 7 Mechanical Pump Details and Procedures for Extending Retracting Walings Cont d Typical Assembly Details General Appendix A Provision of a Mabey Hire Site Demonstrator Introduction This booklet is intended to provide basic information for users of the Mabey Hire Type CP01 CP02 amp CP03 Culvert Pulling machines and to draw the client s attention to the practical aspects of handling assembly installation and use which need to be considered in compiling method statements for a safe system of work In particular the client s attention is drawn to the size and weights of the machine components and the need for planning the lifting operations involved All major components of the machines have lifting points for safe slinging It is assumed that clients are familiar with general safe practices applicable to the installation of pre cast box culverts Users should ensure that the height length and pulling capacity of the machines are sufficient for the
11. ssemblies between the air pump and cylinder and connect the pump to a suitable air supply 100psi 14 cu ft min Follow the procedure for extending retracting the cylinder in Section 8 When each cylinder has been sufficiently extended and the next culvert section is in position lift the spreader beam complete with 2 No single leg pulling chains to the required height and attach each chain to it s corresponding cylinder using the bow shackles provided Check all four shoes are in position and each body is screwed up tight Check all pins R clips and bolts are in position Check each chassis is in line with the culvert The cylinders can now be retracted to pull the culvert section into position Note Each hydraulic hose is fitted with a shut off valve so that each cylinder can be isolated if required e g if one cylinder is moving ahead of the other or if the culvert section requires squaring up Tow bars are supplied which can be fitted between each cylinder or pulling chain as required as further culvert sections are placed The short tow bar should be used first This is then removed and replaced with the long tow bar and then both tow bars can be used together This will enable 4 No culvert sections to be placed before moving the chassis All tow bar connections are made using the tow bar pin and R clips Page 5 of 7 product user guide ciocoii part of the mabey family Culvert Puller 10 Tonne K April 2015 8 Me
12. the descriptions given in this publication Page 7 of 7 pmiabjely User Information Appendix A Provision of a Mabey Hire Site Demonstrator Mabey Hire can subject to availability offer the services of a Site Demonstrator However the Customer should note the following A1 The Customers Responsibilities A safe system of work remains the Customers responsibility at all times It is his responsibility to prepare for organise and direct the operation including A1 1 Site induction for the demonstrator A1 2 Preparation of a method statement A1 3 Arisk assessment A1 4 Selection of lifting equipment and any other equipment required to undertake the work A1 5 Positioning of the crane or lifting appliance A1 6 Banking the crane A1 7 Slinging the components A1 8 Assembling the components and installing them A2 Activities which the Mabey Hire Demonstrator is authorised to carry out Mabey Hire Demonstrator is authorised to A2 1 Assist in indentification of Mabey Hire components A2 2 Explain how they fasten together A2 3 Point out slinging points and special methods of lifting as noted in the user information A2 4 Demonstrate how to attach hoses and use pumps to extend retract hydraulic braces A2 5 Draw attention to the content of the user information A2 6 Clarify queries with Mabey Hire scheme drawings The Demonstrator is NOT AUTHORISED to take over or direct the installation To Mabey Hire
13. tween the cylinder and pulling chain as required as further culvert sections are placed The short tow bar should be used first This is then removed and replaced with the long tow bar and then both tow bars can be used together This will enable 4 No culvert sections to be placed before moving the chassis All tow bar connections are made using the tow bar pin and R clips 7 2 Two Culvert Pulling machines with two single leg Pulling Chains 7 2 1 Refer to Section 9 for typical assembly details 7 2 2 Each Culvert Puller should be positioned either side of the culvert centreline at the same centres as the pulling points on the spreader beam and may be stabilised using the rear vertical screw and side mounted adjustable outriggers as required 7 2 3 Note that the bottom shoes may be slightly angled and should be positioned to reflect the slope on the culvert base Ensure each body is vertical to its chassis adjust by releasing 4 No M20 bolts if necessary 7 2 4 Vertical adjustments should be made in the same way as described in the section on vertical adjustment for Single Culvert Pulling Machines 7 2 5 Select one of three connection points the CP03 machines have only one connecting point on each body and pin one cylinder tube onto each body using 1 No 30 dia tow bar pin and R clips Ensure the cylinder couplings are facing upwards and the cylinder tube is resting on the support bar at the front of the chassis Connect both hose bridle a
14. uld be Ab 0 5 7 poured into the pump and cold clean water added according to the prevailing ove 8 weather conditions see table to the right Protective gloves should always 6 to 0 20 be worn when handling shoring fluid Note A shoring fluid safety data sheet is available on request from Mabey Hire Ltd 10 and below Neat Only 8 4 Procedure for extending the cylinder Ensure the cylinder is safely pinned to the body using 1 No 30 dia tow bar pin and R clips the couplings are facing upwards and the cylinder is horizontal and supported at the front of the chassis Set the pump control valve to Neutral and ensure the air supply valve is open Connect the pump hoses between the pump and cylinder If two cylinders are being used attach an additional hose between each bridle and cylinder Ensure the safety lock off valve on the cylinder is open by rotating anti clockwise Open all shut off valves on the pump hoses Set the pump control valve to Extend Allow the cylinder to extend to the required length If two cylinders are being used and it becomes necessary to isolate one cylinder i e if one cylinder is extending ahead of the other then close the shut off valve in the extend hose connected to that cylinder Shut down the pump by closing off the air supply valve and set the pump control valve to Neutral The pulling chain and or tow bar can now be attached to the cylinder Page 6 of 7 product
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