Technical MAT 125 Mass 25 Mass 50 Data Hydraulics Sheet … · All of our hydraulic cylinders...

T E C H N I C A L D A T A S H E E T

Hydraulics

Document Ref: TDSHYD Page No. 1 of 22 THE INFORMATION ON THIS DATA SHEET REMAINS THE PROPERTY OF MABEY HIRE

LTD. AND IS NOT TO BE REPRODUCED WITHOUT WRITTEN PERMISSION. WE RESERVE THE RIGHT TO AMEND THIS DATA AT ANY TIME WITHOUT PRIOR

NOTICE AND YOU SHOULD THEREFORE CHECK OUR WEBSITE TO ESTABLISH ITS VALIDITY .

Issue No: 07 Further Information Tel: +44 (0) 1942 725 343

Issue Date: May 2016

www. mabeyh i r e . co .uk ac t i on@mabeyh i r e . co . uk

Technical Data Sheet Mabey Hire Ltd. Structural Support & Bridging Bridge House, Strange Road, Garswood, Lancashire WN4 0RX United Kingdom Telephone: +44 (0) 1942 725 343 Facsimile: +44 (0) 1942 270 893 Email: [email protected] Website: www.mabeyhire.co.uk

Mass 25 Mass 50 MAT 125

Superprop

Hydraulics

Quickbridge MU Falsework

MU Bridging Compact Bridging BarrierGuard 800

Instrumentation


Hydraulics


LTD. AND IS NOT TO BE REPRODUCED WITHOUT WRITTEN PERMISSION. WE RESERVE THE RIGHT TO AMEND THIS DATA AT ANY TIME WITHOUT PRIOR





Index

Reference Description Page No.

Contents 2

1.0 Introduction 3

2.0 Hydraulic Rams / Equipment

2.1 Plain Ram (PR Series) 4

2.2 Screwed Ram (SR Series) 5

2.3 Screwed Ram with Screwed Base (SR Series) 7

2.4 Screwed Housing Ram (HYMAT) 9

2.5 Low Height (HJ Series) 10

2.6 Double Acting Ram (HD and HR Series) 11

2.7 Climbing Jacks 12

2.8 Hydraulic Ram – Quick Summary Table 13

3.0 Flat Jacks

3.1 Introduction 14

3.2 Description 14

3.3 Temporary Jacks 15

3.4 Permanent Jacks 15

3.5 Specification 16

3.5.1 Flat Jack Selection Table 16

3.6 Timber Wedge Sets 16

4.0 Ancillary Components

4.1 Pumps 17

4.2 Hoses 17

4.3 Pressure Gauges 17

4.4 Manifolds 17

4.5 Dial Test Indicators (DTI) 17

4.6 Non Return Valves 17

4.7 Oil 17

4.8 Hydraulic Circuits 18

4.9 Testing Prior to Operation 18

5.0 Plates and Bolts

5.1 SR Cylinders, Plates and Bolts 19

5.2 HYMAT Cylinders, Plates and Bolts 20

5.2.1 HYMAT Baseplate Capacities 20

5.2.2 HYMAT Configurations 21

5.2.3 HYMAT Connection Details 22

Contents


Hydraulics


LTD. AND IS NOT TO BE REPRODUCED WITHOUT WRITTEN PERMISSION. WE RESERVE THE RIGHT TO AMEND THIS DATA AT ANY TIME WI THOUT PRIOR





Overview

This Technical Data Sheet has been produced and issued to provide technical information on the hydraulic equipment supplied, installed and operated by Mabey Hire Limited (MHL). This includes descriptions of simple hydraulic systems, assemblies and connections. Our extensive range of hydraulic cylinders, flat jacks, ancillaries and control equipment has been developed to provide the construction and allied industries with an unrivalled service for the controlled application of high load hydraulic systems. For each individual project with a hydraulic element our Project Engineers and Hydraulic Technicians will design and detail the cylinder layout, hydraulic pressurising and control system best suited to our clients’ specific application. Further detailed information can be provided for any individually referenced product contained in this data sheet upon request. In addition to monitoring and controlling our own hydraulic equipment and services MHL have now established a dedicated Instrumentation and Monitoring Division. This division enhances MHL capability to design and permanently install movement and temperature monitoring systems to all types of structures. For further information of our Instrumentation and Monitoring provision and services please refer to the Instrumentation Data Sheet Design Codes

All of our hydraulic cylinders comply with the accepted industry standard ASME B30.1 - 2009, the American Society for Mechanical Engineers “Safety Code for Jacks”. This document has also been recognised and accepted by the Highways Agency as the appropriate standard for the certification of hydraulic cylinders and jacks for use on the UK Bridging Stock. Testing

In house inspection, testing and maintenance procedures for the hydraulic cylinders, jacks and ancillary equipment have been developed in line with ISO 9001:2000 and PUWER. Records are kept of each inspection, which are carried out prior to each use or every 6 months, whichever is appropriate. All cylinders and jacks have a unique ID No. and are issued with certification. Should the project specification require proof load testing then this is carried out in house by trained and competent technicians using purpose designed test rigs and calibrated instrumentation.

1.0 Introduction


Hydraulics







2.1 Plain Ram Cylinders (PR Series) 2.1.1 Description and Use

Plain Ram (PR series) are general purpose hydraulic cylinders with varying cylinder capacities, retracted heights and available ram strokes. All Jacks in this range are single acting. They can be supplied with bolt-on flat, grooved or

5 spherical head. The principle application is for the pre-loading or raise of Mabey Superprop system. Should positive mechanical load holding be required during normal jacking operations then a secondary packing device should be used or a Screw Ram Cylinder used instead. 2.1.2 Table A: Plain Ram – No locking Collar – Single Acting

Part No.

PR010 PR250A PR250B PR300 PR400

Cylinder Capacity (Metric Tonnes)

10 (101 kN)

51 (498 kN)

51 (496 kN)

51 (496 kN)

51 (500 kN)

Collar Capacity (Metric Tonnes)

N/A N/A N/A N/A N/A

Stroke (mm)

100 (Spring Return)

254 (Spring Return)

250 (Spring Return)

300 (Spring Return)

400

Product Weight (Kg)

3.0 14.4 12.6 15.4 37.4

Oil Capacity

Push Litres 0.14 1.8 1.77 2.12 3.3

Return Litres N/A N/A N/A N/A N/A

Fully Retracted Height (mm)

175 420 365 435 540

Fully Extended Height (mm)

275 670 615 735 940

Outside Diameter (mm)

57 133 130 130 170

Cylinder Eff. Area (cm²)

14.4 71.2 70.9 70.9 78

Working Pressure* (bar)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

640 (9,282 psi)

Make Hi-Force HSS104

Power Team RA5510

EPP Magnus CML50N 250

EPP Magnus CML50N 300

Youngs Lifting

Material Steel Aluminium Aluminium Aluminium Steel

Horizontal Capacity Limited By Ram

Unknown 5%

(at max angle of 5°) Unknown Unknown 5%

(at max angle of 5°)

* Pressure Conversion: 1psi = 0.069 bar, 1 bar = 14.50 psi = 10.0 N/cm

2

PR250A

2.0 Hydraulics Rams / Equipment


Hydraulics







2.2 Screwed Ram Cylinders (SR Series) 2.2.1 Description and Use

Screwed Ram (SR series) Jacks have varying cylinder capacities with different retracted heights and available ram strokes. All Jacks in this range are single acting cylinders with a screw ram onto which is attached a locking nut that provides a mechanical load path when the hydraulic pressure is released. All jacks can be fitted with bolt-on flat, grooved or 5º tilting saddle using 1No. M8x20 Cap Head Screw. (Refer section 5.0 for details of base plate and bolt requirements). 2.2.2 Table B: Screwed Ram – Locking Collar – Single Acting

Part No.

SR025 SR050 SR100 SR054 SR060/100 SR100/100

Cylinder Capacity (Tonnes)

25 (245KN)

50 (490 kN)

50 (490 kN)

55 (540KN)

68 (664 kN)

95 (929 kN)

Collar Capacity (Tonnes)

25 50 50 55 68 95

Stroke (mm)

30 50 100 50 100 100

Product Weight (Kg)

7 15 18.5 13.5 46 47.6

Oil Capacity

Push Litres

0.19 0.35 0.71 0.39 0.95 1.33

Return Litres

N/A N/A N/A N/A N/A N/A


135 180 230 135 287 294.5


165 230 330 185 387 395.5


95 128 128 130 145 165


38.5 71 71 78.5 95 132.7


700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

Make Youngs Lifting

Youngs Lifting

Youngs Lifting

Youngs Lifting

Enerpac CLL-604

Enerpac CLL-1004

Material Steel Steel Steel Steel Steel Steel


Unknown Unknown Unknown Unknown

5% (at 90% Cylinder stroke)



2

2.0 Hydraulics Rams / Equipment … (Continued)


Hydraulics







2.2.2 Table B: Screwed Ram – Locking Collar – Single Acting (Continued)

Part No.

SR100-50 SR150/100 SR200/100 SR200 SR300


109 (1069 kN)

144 (1409 kN)

192 (1883 kN)

189 (1854 kN)

325 (3188 kN)


109 144 192 189 325

Stroke (mm)

50 100 100 200 200

Product Weight (Kg)

33.5 95 138 160 260

Oil Capacity

Push Litres

0.77 2.01 2.69 5.3 9.0

Return Litres

N/A N/A N/A N/A N/A


184 321 345 441 516


234 421 445 641 716


178 205 235 235 310


153.4 201.1 268.8 226.6 456.2


700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

Make Hi-Force HFG1002

Enerpac CLL-1504

Enerpac CLL-2004

Enerpac CLL-2008

Enerpac CLL-3008

Material Steel Steel Steel Steel Steel








2



Hydraulics







T

L L

2.3 Screwed Ram Cylinders with Screwed Base (SR Series) 2.3.1 Description and Use

Screwed Ram (SR series) Jacks have varying cylinder capacities with different retracted heights and available ram strokes. All Jacks in this range are single acting cylinders with a screw ram onto which is attached a locking nut that provides a mechanical load path when the hydraulic pressure is released. 2.3.2 Table C: Screwed Ram – Locking Collar – Single Acting- Intergrated Baseplates

Part No.

SR300/100 SR500/50 SR500/100


326 (3193KN)

521 (5110 kN)

521 (5110KN)


326 521 521

Stroke (mm)

100 50 100

Product Weight (Kg)

289 366 486

Oil Capacity

Push Litres

4.56 3.65 7.30

Return Litres

N/A N/A N/A


325.5 308 358


425.5 358 458

Baseplate Size (LxT) (mm)

450 x 65 475 x 80 475 x 80


310 400 400


456 730 730


700 (10,153 psi)

700 (10,153 psi)

700 (10,153 psi)

Make Enerpac

CLL3004E106 (Special)

Enerpac CLL5002E104

(Special)

Enerpac CLL5004E107

(Special)

Material Steel Steel Steel






2



Hydraulics







D

L W

T

2.3.2 Table C: Screwed Ram – Locking Collar – Integrated PTFE Temporary Bearings (Continued)

Part No.

TB-SR300-1 TB-SR500-1

Size (L x W x T) (mm)

470 x 450 x 61.5 470 x 450 x 61.5

Capacity (kN)

3000 5000

Transverse Movement (mm)

± 20 ± 20

Longitudinal Movement (mm)

± 50 ± 50

Product Weight (Kg)

65 73



Hydraulics







2.4 Screwed Housing Ram Cylinders (HYMAT) 2.4.1 Description and Use

The HYMAT (HM) cylinder is a lightweight aluminum cylinder designed and manufactured in house by MHL for use with Mabey MAT125 and Mass 50 Support Systems. It is entirely compatible both in terms of load capacity and connection details thereby eradicating the problems associated with off-the-shelf cylinders. The HYMAT can also be used in its own right for safe support of high loads where stability and robustness is required. Unlike conventional screw ram cylinders, the HYMAT has an externally threaded cylinder barrel onto which a locking collar is attached. The outer collar engages with special head plates or spherical heads to provide a mechanical load path when the hydraulic pressure is released. In this way the ram is totally isolated, removing adverse effects of lateral loading. The HYMAT cylinder can be supplied with a variety of head and baseplate attachments suited to the individual application. (Refer section 5.0 for details of plate and bolt requirements.) 2.4.2 Table D: Screwed Housing – Locking Collar – Single Acting

Part No.

HM050 HM100 HM200 HM300

Cylinder Capacity (Tonnes) 75 (736 kN) 75 (736 kN) 75 (736 kN) 75 (736 kN)

Collar Capacity (Tonnes) 150 (1472 kN) 150 (1472 kN) 150 (1472 kN) 150 (1472 kN)

Stroke (mm) 50 100 200 300

Product Weight (Kg) 28 34 51 64

Oil Capacity

Push Litres 0.91 1.83 3.66 5.49

Return Litres N/A N/A N/A N/A

Fully Retracted Height (mm) 215 265 405 505

Fully Extended Height (mm) 265 365 605 805

Outside Diameter (mm) 254 254 254 254

Cylinder Eff. Area (cm²) 182.9 182.9 182.9 182.9

Working Pressure* (psi) 5,950 5,950 5,950 5,950


2

HMHP30 Connecting Head Plate

Depth: 30mm Weight: 13 kg

HMFD20 / 40 Connecting Base Plate

Depth: 20mm Weight: 25 kg Depth: 40mm Weight: 48 kg

HMSH-D / P Spherical Head Plate

Depth: 81mm

Maximum 5 Rotation Weight: 30 kg HYMAT Jack

2.0 Hydraulics Rams / Equipment… (Continued)


Hydraulics







2.5 Low Height Cylinders (HJ Series) 2.5.1 Description and Use

HJ Series cylinders are special low height units with a screw ram and locking collar. They are designed for use where headroom is limited; e.g. for bridge bearing replacement. All jacks in this range with the exception of HJ050 incorporate a 5° spherical head.

2.5.2 Table E: Screwed Ram – Locking Collar – Single Acting

Part No.

HJ050 HJ020 HJ250 HJ520 SR250/10


50 (490 kN)

140 (1370 kN)

260 (2550 kN)

520 (5101 kN)

232 (2312 kN)


80 150 260 520 255

Stroke (mm)

12 20 45 45 10

Product Weight (Kg)

12 26 74 186 60

Oil Capacity

Push Litres

0.18 0.18 1.6 3.3 0.51

Return Litres

N/A N/A N/A N/A N/A


60 115 159 192 90


72 135 204 237 100


175 200 275 400 310


153 198.6 366.8 729.9 510.7


320 (4,641 psi)

690 (10,008 psi)

700 (10,153 psi)

700 (10,153 psi)

500 (7,252 psi)

Make Enerpac Youngs Lifting

Enerpac CLP-2502

Hi-Force HFL5002

Enerpac CLP-2501

Material Steel Steel Steel Steel Steel


Unknown Unknown Unknown Unknown Unknown


2



Hydraulics







HDA060

2.6 Double Acting Ram Cylinders (HD and HR Series) 2.6.1 Description and Use

Hollow Ram Cylinders can be supplied either as single acting with spring return or double acting and are provided with a threaded upper section of cylinder to allow ease of fixity. Both enable the application of either pull or push forces when utilized with threaded bar systems such as Dywidag. 2.6.2 Table F: Double Acting – No Locking Collar

Part No.

HDA050

(Double Acting Solid Ram)

HDA060 (Double Acting Hollow Ram)

HR250 (Double Acting Hollow Ram)

HR150 (Single Acting Hollow Ram)

PUSH - Cylinder Capacity (Tonnes)

50 (489 kN)

58.7 (576 kN)

27 (265 kN)

33 (326 kN)

PULL - Cylinder Capacity (Tonnes)

25 (245 kN)

38.7 (380 kN)

16 (157 kN)

N/A


N/A N/A N/A N/A

Stroke (mm)

330 166 250 155

Product Weight (Kg)

40 35 32 21.8

Oil Capacity

Push Litres 2.4 1.4 1.5 0.7

Return Litres 1.2 0.9 0.87 N/A


521 323 426 330


851 489 680 485


127 159 133 114

PUSH - Cylinder Eff. Area (cm²)

71.2 82.3 58.9 46.6

PULL - Cylinder Eff. Area (cm²)

36.3 54.2 34.4 N/A


700 (10,153 psi)

700 (10,153 psi)

432 (6,262 psi)

700 (10,153 psi)

Hole Diameter In Ram (mm)

Solid 53.8 38 33.3

Make Power Team

RD5513 Enerpac RRH-606

GPA Design Enerpac RCH-306

Material Steel Steel Steel Steel


Unknown 2%

(at 90% Cylinder stroke)

Unknown 6%

(at 90% Cylinder capacity)

* Pressure Conversion: 1psi = 0.069 bar, 1 bar = 14.50 psi = 10.0 N/cm2



Hydraulics







2.7 Climbing Jacks 2.7.1 Description and Use

The Climbing Jacks are high capacity double acting cylinders mounted on special baseplates with the ram facing downwards. The whole assembly sits on machined hardwood (Ekki) timber blocks and a specially designed steel housing for staged raising / lowering applications over greater heights. The Ekki timber stacks are provided within steel guide frames and built up systematically in 90mm stages after each ram stroke to raise to the required level (see 4 stage depiction at bottom of page). 2.7.2 Table G: Climbing Jack – Double Acting (Including Housing)

Part No.

HDA150 HDA300 HDA450


150 (1470 kN)

300 (2945 kN)

450 (4415 kN)


N/A N/A N/A

Stroke (mm)

150 150 150

Product Weight (Kg)

335 450 625

Oil Capacity

Push Litres 4.9 9.8 14.7

Return Litres 1.5 2.4 3.0


460 460 510


610 610 660


250 340 470


327 653.8 980.5


450 (6525 psi)

450 (6525 psi)

450 (6525 psi)


2


STAGE 1

Jack with housing

STAGE 2

Extend ram insert outer Ekki

STAGE 3

Retract ram insert inner Ekki

STAGE 4

Repeat procedure at next level, timber and side

plates at 90 to previous level


Hydraulics







2.8 Hydraulic Ram – Quick Summary Table



Hydraulics







3.1 Introduction MHL Flat Jacks are simple, practical devices for applications in the civil and building industries where the control or application of large forces is required. They can be used in new construction in which they might form part of the structural concept, in remedial works or for the structural repair or modification of existing structures.

3.2 Description

Flat Jacks consist of a mild steel capsule, which is circular in plan and dumb-bell shaped in cross section prior to inflation. The dished portions are fitted with machined thrust plates before the jack is placed between the surfaces to be jacked apart. The thrust plates can be either steel or if a non-corrosive material is specified, epoxy resin plates can be used. The jacks are fitted with two pipes, one inlet and one outlet. The inlet pipe is fitted with an isolator valve as standard and can also be fitted with a pressure gauge. The outlet pipe is fitted with a plug and is normally only used to vent air from the system. When the jack is inflated with a liquid the hydrostatic pressure is transmitted by the flat portions of the capsule through the thrust plates, while the toroidal rim of the jack deforms to allow the flat surfaces to move apart. 3.2.1 Typical Uses

Structural pre-loading

Pre-stressing

Lifting

Control of settlement

Levelling

Bearing replacement

Underpinning

Weighing of large structures 3.2.2 Key Features

Known forces

Low height for limited access

Low bearing stress

Precise control

Out of parallel tolerance between jacking surface

Light and easy to handle

3.0 Flat Jacks

open

closed

Plan view

Toroidal Rim

Thrust plates

Bearing area


Hydraulics







3.3 Temporary Jacks

When Flat Jacks are used for a limited period of time and are subsequently removed then inflation is generally done using hydraulic oil or water. -- For a small number of jacks that require only a small volume of oil or water then simple hand pumps may be used. Large jacks or large numbers of jacks may require electric or diesel powered pumps. 3.4 Permanent Jacks

When a force is required to be permanently applied to a structure, the Flat Jacks are inflated under pressure with grout by means of a grout injection cylinder. The grout hardens over a period of time to leave the force permanently applied. This type of application is suitable for pre-loading new or additional steelwork in structures, underpinning works and structural bearing installation. The mixing and pumping of grout requires considerable skill and experience. Incomplete mixing with hardener may result in a failure to set. Excessive accelerator may cause premature setting that will cause blockage, frustrate the Flat Jack operation and damage the pumping equipment. For these reasons grout injection equipment in not hired to third parties and MHL Contract Services is strongly recommended. Where the jacks are initially inflated with oil and are subsequently converted to grout filled, there are two alternative techniques used.

a) Transfusion Jacks

These are special Flat Jacks that are purpose designed and manufactured to include an internal pipe inside the toroidal ring. These jacks can be infused with grout, either cementitious or resin under load. The pressure in the Flat Jack is balanced and maintained throughout the transfusion process by means of the outlet needle control valve.

b) Piggyback Jacks

If adequate space is available, two Flat Jacks are installed, one above the other. The first Jack is inflated with hydraulic oil and adjusted as necessary over a period of time until the required condition is achieved. The second Jack is then inflated directly with grout or resin. The pressures in both Flat Jacks are balanced throughout until the oil filled Flat Jack has closed and the inflation is completed on the grout/resin filled Flat Jack. The grout/resin hardens and both Jacks remain in position permanently.

3.0 Flat Jacks… (Continued)


Hydraulics







3.5 Specification

Closed height: 32mm

Minimum access gap: 35mm

Stroke: 25mm

Sizes: 120mm dia. to 600mm dia. **

Capacities: 8 tonnes to 346 tonnes **

Maximum pressure: 150 bar (2175 psi)

Jacks can be oil, water or grout/resin filled.

3.5.1 Flat Jack Selection Table

Part Number Capacity

(Tonnes)

Capacity

(KN)

Diameter

(mm)

Thrust Plate Diameter

(mm)

Closed Height

(mm)

Maximum Stroke

(mm)

Weight ***

(kg)

Volume

(Litres)

FJ12 or FJ12T 8 79 120 70 32 25 1.3 0.3

FJ15 or FJ15T 15 147 150 100 32 25 2.1 0.5

FJ22 or FJ22T 37.5 368 220 170 32 25 5.5 1.0

FJ25 or FJ25T 50 490 250 200 32 25 7.7 1.4

FJ27 or FJ27T 60 588 270 220 32 25 9.1 1.6

FJ30 or FJ30T 80 785 300 250 32 25 11.5 2.0

FJ35 or FJ35T 101 991 350 300 32 25 16.6 2.6

FJ42 or FJ42T 160 1569 420 370 32 25 23.9 3.8

FJ46 or FJ46T 200 1961 460 410 32 25 32.0 4.5

FJ48 or FJ48T 215 2108 480 430 32 25 35.0 5.0

FJ55 or FJ55T 300 2942 550 500 32 25 46.2 6.3

FJ60 or FJ60T 346 3393 600 550 32 25 53.9 7.8

Flat Jacks shown below are available to order on request.

FJ69 or FJ69T 480 4707 690 640 32 25 70.7 10.5

FJ75 or FJ75T 560 5492 750 700 32 25 81.5 12.4

FJ87 or FJ87T 764 7492 870 820 32 25 111.1 16.7

FJ92 or FJ92T 868 8512 920 870 32 25 124.8 18.7

Note: “T” denotes Transfusion Jacks.

3.6 Timber Wedge Sets

Hardwood folding wedge sets can be supplied when Flat Jacks are oil filled and used in temporary applications i.e. low height bearing replacement or level adjustment.

The wedges are installed adjacent to the Flat Jacks as a safety precaution should any jack suffer unforeseen damage.

The allowable bearing pressures on the upper and lower surfaces should be assessed and the appropriate wedge size / contact area used.

Wedge sizes can be supplied by MHL to suit each application.

3.0 Flat Jacks… (Continued)

** Larger Flat Jack sizes up to 920mm dia. with an 868 tonne capacity are available to order on request. See the below table for further details.

*** Weight of capsule and thrust plates only.


Hydraulics







4.1 Pumps

Manual Hand pump (Single Acting)

Electric Pump (Single/Double Acting)

Standard Petrol Driven Pump (Single / Double Acting)

Synchronised Petrol Driven Pump (4 way & 6 way outlets – delivers equal oil to each outlet regardless of pressure)

Double Acting Controllers for synchronised lowering

Enerpac 16 Port EVO-System – the multi-functional synchronous lifting system 4.2 Hoses

3m Hydraulic hose

6m Hydraulic hose

10m Hydraulic hose

15m Hydraulic hose 4.3 Pressure Gauges

600 psi plug in gauge

1,000 psi plug in gauge





10,000 psi plug in gauge All Pressure Gauges read in pounds-per-square-inch (psi), some have dual scales reading in tonnes or bar. Pressure Gauges are regularly calibrated to ensure an accuracy of 5% of the full scale reading. 4.4 Manifolds

2 way manifold with shut off valves

4 way manifold with shut off valves

6 way manifold with shut off valves 4.5 Dial Test Indicators (DTI)

25mm stroke DTI with magnetic stand & adjustable arm

50mm stroke DTI with magnetic stand & adjustable arm Used to measure displacement to an accuracy of 0.01mm, can be fitted directly to structural steelwork or a suitable steel plate bonded to a concrete surface i.e. bridge pier. All calibrated every 12 months or for specific contracts. 4.6 Non Return Valves

When closed allows oil flow in one direction only, opening allows flow in both directions. The valve is fitted directly to the Jack and used to prevent oil escaping from the Jack if a sudden loss in pressure occurs. 4.7 Oil

The jacking system utilises Hydraulic 32 oil. No other oil or fluid should be used with the system.

All hydraulic ancillaries are

rated at 10,000 psi

Manual hand pump shown

4.0 Ancillary Components


Hydraulics







4.8 Hydraulic Circuits Every Hydraulics Circuit will include a Jack, a Pressure Gauge, a Hydraulic Hose and a Hydraulic Pump. More than one Jack may be connected to a Hydraulic Pump by using a Manifold to branch out from the pump (see sketch). Hydraulic Circuits comprising of one pump and two or more Jacks fall into two categories: Simple, which have common pressure, so the force at each Jack is the same, and complex where the pressures and therefore the forces are different at each Jack. Mabey Hire Ltd. offer a specialist jacking service, which can design, plan and operate simple or complex jacking systems. 4.9 Testing Prior To Operation

Once the hydraulic circuit equipment has been connected together it should be tested. Pressurising the circuit by a nominal amount will do this. The circuit should be examined for leaks or blockage. Blockages may be caused by not screwing the couplings together correctly or by the presence of dirt on the coupling. The couplings should be dismantled, cleaned and reconnected. Leaking equipment should be replaced. The taps on the shut-off valves should be closed then opened to ensure they do not bind or stick. Manifolds with defective taps should be replaced. The pressure should then be released from the circuit by opening the control valve on the pump. The Jacks should be examined to ensure they are free to retract when the control valve is open. If, on examination, the oil is not being released from the Jack check for blockages caused by incorrectly connected or dirty couplings and rectify as above.

4.0 Ancillary Components… (Continued)


Hydraulics







5.1 SR Cylinders, Plates and Bolts

5.0 Plates and Bolts

SRHP20 (10kg) 250x250x20mm – sits on top of the spherical platen, located by welded lugs. It is used to Lindapter jacking beams onto the top of the jack. The base of the jack cylinder has two holes equally spaced on a 105mm diameter circle tapped M10 for a depth of 15mm. SRBP20 (10kg) 250x250x20mm – used to connect the jack to a Mass 25, Mass 50 or System 160 column. The plate is bolted to the jack using countersunk M10x30 bolts. This assembly is bolted to the column using two M16x30mm bolts for Mass 25, two M20x60 bolts for Mass 50 or two M16x55 bolts for System 160.

SRHP20

HEAD PLATE

SR100

HYD. JACK

SRBP20

BASE PLATE

M10X30 CSK.


Hydraulics







NB: Exception is 76mm Column Stool which has thinner flange plates use plates to pack out instead.

5.2 HYMAT Cylinders, Plates and Bolts

HYPLT (19kg) 460 x 270 x 20mm - Used to Lindapter jacking beams onto the top of the HYMAT jack.

HMFD20 (25kg) 400 x 400 x 20mm - Used to connect jack to standard MAT column and twin RSJ components.

HMFD40 (48kg) 400 x 400 x 40mm - Used as the HMFD20 in applications where the load has to be distributed over a larger

area. TF029 (10kg) 250 x 250 x 20mm - Used to connect the jack to a Mass 50 column. M20 bolts are used to connect the plate to

the Mass 50. HMSH-P and HMSH-D (30kg) Ø254 x 81mm deep provide a surface against which the locking collar can bear. The upper half of the spherical platen can rotate 5º in any direction. The lower half of the HMSH-D contains two countersunk holes. The

upper half has three holes equally spaced on a 180mm diameter circle tapped M16. HMHP30 (13kg) Ø254 x 30mm deep - Used to provide a bearing surface against which the screw-locking collar of the jack

can be tightened. In addition it also contains three holes equally spaced on a 180mm diameter circle tapped M16 to which connection and base plates may be bolted. MT281 (200kg) 356 x 368 x 177 kg/m UC 815mm long - Used to equally share the load from a HYMAT jack into two MAT

columns.

5.2.1 HYMAT Baseplate Capacities

Capacity (kN)

1 No. HMFD20 625

2 No. HMFD20 720

1 No. HMFD40 1200

5.0 Plates and Bolts… (Continued)


Hydraulics







5.2.2 HYMAT Configurations

Note: HMB001 = M16x50 CSK Bolts HMB003 = M16x40 CSK Bolts

HMB002 = M16x50 CAP Bolts HMB004 = M16x40 CAP Bolts



Hydraulics







5.2.3 HYMAT Connection Details

The ram (or piston) of the HYMAT Jack contains two holes, 80mm apart, tapped M16 for a depth of 30mm. The base of the cylinder has six holes equally spaced on a 180mm diameter circle also tapped M16 for a depth of 30mm.

The following table shows the number, length and type of bolt required for each application. Note that a 10mm Allen Key is required to fit the M16 countersunk bolts and a 14mm Allen Key is required to fit the M16 cap screws.

Applications

Number of Bolts Required

M16 x 40mm Countersunk

M16 x 50mm Countersunk

M16 x 40mm Cap Screw

M16 x 50mm Cap Screw

Connections to Ram:

Ram to HMHP30 2

Ram to HMSH-D 2

Connections to Base:

Base to HYPLT 3

Base to HMFD20 3

Base to HMFD40 3

Base to MT281 4

Base to TF029 3

Connections to Plates:

HMHP30 to HMFD20 3

HMHP30 to HMFD40 3

HMHP30 to HYPLT 3

HMSH-D to HMFD20 3

HMSH-D to HMFD40 3

HMSH-D to HYPLT 3


Date post:	31-Mar-2020
Category:	Documents
Upload:	others
View:	56 times
Download:	3 times

Technical MAT 125 Mass 25 Mass 50 Data Hydraulics Sheet … · All of our hydraulic cylinders...

Documents