Caldertech 02-31-650 Bedienungsanleitung
Designed and Manufactured in the UK
Hydraulic Squeeze O Tool
63-180mm / 2”-6” / 63-200mm
Operating Instructions
REVISION:
© Copyright Caldervale Technology Ltd.
The copyright for this product and instruction manual is held by Caldervale Technology Ltd.
Any technical specifications, or illustrations part of this manual cannot be reproduced, used
illicitly or distributed in any form for competitive purposes.
Helping you
make the right
connections.
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
01
Contents
01. Introduction 02
02. Safety Instructions 04
03. Operation 05
04. Checking and Filling Oil Level 08
05. Troubleshooting 09
06. Specifications: Hydraulic Squeeze Tool 180mm / 6” IPS 10
07. Parts Diagram: Hydraulic Squeeze Tool 180mm / 6” IPS 11
08. Specifications: Hydraulic Squeeze Tool 200mm 12
09. Parts Diagram: Hydraulic Squeeze Tool 200mm 13
10. Warranty Information 14
11. Service and Repair 15
12. Decommissioning and Disposal 15
EU Declaration of Conformity 17
Certificate of Conformity 18
Page
Contents
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
02
01. Introduction
Introduction
General Description
The tool has been designed to limit the flow in PE pipe from 63mm
to 180mm and 63mm to 200mm (dependant on model), with a range
of SDR squeeze plates for pipe work in accordance with Gas Industry
Standards GIS/PL2-7 Part 7 Squeeze-o tools and equipment.
This product (Caldertech Hydraulically Powered Squeeze Tools) has
been manufactured, inspected and tested in accordance with the
ISO9001 quality control systems and procedures in place at Caldervale
Technology Ltd, Dewsbury.
The unit has rotating pre-sized limiting plates that are used to limit
the squeeze gap and prevent over compression of the PE pipe.
Important!
This tool should be used in accordance with the pipe manufacturers
recommendations and in line with local codes of practice.
This manual outlines the operation of the squeeze o tooling. The
manual forms a part of the product to which it relates. It should be
kept for the life of the product. Any amendments issued by Caldervale
Technology Ltd should be incorporated in the text. The manual should
be passed to any subsequent holder or user of this product.
It is the responsibility of the operator to ensure that the PE pipe is
suitable for squeeze o application if in doubt contact the PE pipe
manufacturer for confirmation.
01.
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
03
01. Introduction
Before Using
Check the level of oil in the jack to ensure at correct level.
It is important to ensure all component parts are present and in
serviceable condition. In addition, the setting of the limit stop (buer)
plates should be checked before every operation to ensure they are
correct for the pipe size and wall thickness rating. Wrongly set buer
plates may cause insuicient or excessive pipe compression leading to
pipe-wall damage, leakage or injury.
First Use Procedure
Before operating the tool for the first time, the jack must have its
hydraulic circuit ‘purged’ to eliminate any possible air in the system.
To Purge the System
1. Open the jack control valve using the jack handle, turning it anti-
clockwise and then, with the aid of the handle operate the hydraulic
jack several times.
2. Close the jack control valve fully using the jack handle. The tool is
now ready for use.
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
04
02. Safety Instructions
Safety Instructions
1. Read and understand the whole booklet before using the tool
2. Read FIRST USE procedure before using the tool.
3. It is imperative that all possible precautions are made to avoid
unexpected movement of the tool during use.
4. Never operate the jack beyond its maximum stroke.
5. The jack is fitted with a safety valve to stop overloading. This is
factory set and MUST NOT be tampered with.
6. The tool is heavy (36-37Kg) care should be taken when in use.
7. To avoid injury the bottom bars should be locked in position with the
jack extended for transportation (see Transport and storage Page 9)
8. Lifting must be by 2 persons.
9. Operatives should wear eye protection, gloves, safety headwear &
footwear when using the equipment.
10. A single squeeze tool cannot be guaranteed to provide 100%
closure, where this is required users are advised to consider using 2
squeeze tools.
02.
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
05
03. Operation
Instructions for Use
1. Unscrew the 2 check screws until the threads are clear of the
threaded blocks.
2. Locate the pressure control valve on the hydraulic jack. The tip of
the jack handle will connect onto this. Unscrew the control valve
until any internal pressure in the jack is released. The jack and
squeeze bar assembly will be retracted under the pressure of the
return springs.
3. Remove the Bottom bar from the loops in the mainframe.
4. Set the limit stop (buer) plates to the correct pipe diameter and
rating (SDR) of the pipe to be squeezed. If the plates do not have the
correct sizes, check the other set exchange if necessary. The plates
Operation03.
Hydraulic Jack
Squeeze Tool
Main Frame
Safety Check
Screw Blocks
Safety Check
Screws
Limit Stop
Plates
Hydraulic Jack
Control Valve
Hydraulic Jack
Pump Collar
Jack Handle
Bottom Bar
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
06
03. Operation
are set correctly when the correct end face is pointing downwards
and positioned to contact the bottom bar when this is re-fitted.
5. Position the mainframe over the pipe to be squeezed and slide
the bottom bar into the loops of the mainframe beneath the pipe,
position the pipe centrally between the squeeze bar and bottom bar.
6. Close the Hydraulic Jack control valve by screwing clockwise using
the jack handle.
7. Fit the jack handle into the collar of the pump on the jack.
Commence pumping the jack to apply the squeeze pressure.
8. Continue the pumping action until the squeeze bar has fully closed
the pipe, and the limit stop plates prevent further compression.
9. Screw down both check screws until they are in contact with the
upper edge of the squeeze bar. This will prevent any loss of squeeze
pressure in the event of hydraulic pressure leakage in the jack.
Removal After Squeeze O
On completion of the squeeze o operation, remove the tool as follows:
1. Unscrew the check screws until their threads are clear of the safety
check screws threaded blocks. (If it is diicult to release the check
screws, pump the jack handle 2 or 3 times to replace any loss of
hydraulic pressure).
2. Gently release the hydraulic jack pressure by unscrewing the
pressure control valve anti clockwise with the jack handle. This may
require carrying out in controlled stages to prevent flow surges and
excessive pressure drops in the pipe-work as the system fills up.
3. Allow the jack and squeeze bar to retract fully in the main frame
under the force of the return springs, remove the bottom bar and lift
the main frame clear of the pipe.
4. Allow the section of squeezed pipe to reform to its original shape,
this may take several hours.
5. A selection of post squeeze-o re-rounding tools are available to aid
the pipe in regaining its original shape, vistit www.caldertech.com
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
07
03. Operation
Transport
1. Replace the Bottom Bar into the Frame. Turn the Release Valve fully
clockwise using the jacking handle.
2. Fit the jacking handle into the handle socket and ‘pump’ up the jack.
3. Continue jacking until the Limit Plates just come into contact with
the Bottom Bar. Refit both check screws and tighten against the
Squeeze Bars.
4. Using the Jacking Handle turn the Release Valve on the Hydraulic
Jack in an anticlockwise direction. This will release the oil
pressure in the jack.
Storage
IMPORTANT! When not in use always:
1. Store the tool in an upright position.
2. Ensure the pressure in the jack is released.
3. Ensure the tool is clean and dry before storing.
Routine Maintenance
1. Before each operation, ensure that the jack has suicient oil, remove
the filler plug and check that the oil level is correct.
2. Lubricate all moving parts at regular intervals.
3. Grease check screw threads at regular intervals.
Note: Checking the oil level in any way other than quoted in this
manual may severely limit or render the jack inoperative.
Operating Instructions Hydraulic Squeeze O Tool 180mm / 6” IPS / 200mm
08
04. Checking and Filling Oil Level
Checking and Filling Oil Level
Fill Position
Squeeze tool frame in an upright,
squeeze bars fully open jack piston
completely retracted. These conditions
are necessary for checking and filling
the hydraulic oil level.
Note: Checking the oil level or filling
with the piston extended (squeeze
bars closed) or with the tool
horizontal can lead to overfilling,
this may severely limit the tool or
render the jack inoperative.
Checking Oil Level
Jack filler plug to be removed so oil
level is visible through the small hole.
If the oil level is lower than this hole or
not visible through the hole when the
squeeze tool is retracted and tool in
the upright position, then a top up may
be necessary.
Filling with Oil
In order to top up the oil, remove the
filler plug (as above) and fill with clean
hydraulic oil (type HL or HM 30cSt at
400C) until the oil level is just below
the filler plug.
Replace the filler plug after filling.
04.
Filler Plug
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