Beijing GEARX Limited

I. Overview The device is divided into two main parts: the top push part and the moving part. The top push part consists of a double-acting hydraulic cylinder, clamping mechanism, and hydraulic pump station; the moving part consists of a heavy-duty roller cart and accessories. It is mainly used for the horizontal transportation of large buildings (structures), steel frames, and large bulky items along steel rails. Users must provide their own heavy rails (38kg/m, 43kg/m, 50kg/m). To ensure smooth operation of the moved heavy object, two sets of transfer machines must be used simultaneously.
II. Main Technical Parameters

1. Clamping Pliers Hydraulic Cylinder Technical Parameters (2 sets) Clamping force: 1960 kN @ 700 bar Clamping stroke: 35 mm Double-acting hydraulic cylinder
2. Transfer Hydraulic Cylinder Technical Parameters (2 sets) Thrust: 160 kN @ 700 bar Stroke: 600 mm Double-acting hydraulic cylinder
3. Clamping and Transfer Electric Pump EM1825W (2 sets) Low pressure flow and pressure: 5 L/min @ 70 bar High pressure flow and pressure: 1.8L/min @ 700 bar Motor power: 2.2 kW-4 380 V 50 Hz Oil tank capacity: 25 L Control type: Three-position four-way manual directional valve
4. Swivel Roller Cart OT-50R4-62 (4 sets) Load capacity: 4×50 tons = 200 tons (2 times safety factor) Number of ground rollers: 4×8=32 Roller diameter: 41mm Number of guide wheels: 4×4=16 Guide wheel diameter: 62mm

III. Supply List

Item	Name	Specification and Model	Quantity	Remarks
1	Top Push Device        (including rail clamping cylinder, transfer cylinder, hydraulic hoses, hydraulic pump station)	HPJJ-600	2
2	Moving Device (swivel   roller cart, pins, etc.)	OT-50R4-62 TRP	2

IV. Features and Applications The in-track heavy object transfer machine (referred to as the transfer machine) consists of clamping pliers hydraulic cylinder and transfer hydraulic cylinder. It is a new and useful tool for short-distance moving of heavy objects into position. Due to its large carrying capacity, good stability, and continuous motion capabilities, it can replace the traditional methods of moving heavy objects, such as using sleepers and rollers, within a certain working range, achieving safety, labor-saving, time-saving, and cost-saving effects. This equipment needs to be used in conjunction with an electric pump and can use rails, making it convenient, quick, safe, and precise to move heavy objects like power station transformers, boilers, and other oversized equipment to designated positions. Therefore, it can be widely used in warehouses, workshops, docks, electric construction sites, and other places where heavy objects need to be moved.
V. Working Principle and Hydraulic System The in-track heavy object transfer machine uses a telescoping principle combined with a caterpillar movement mechanism to gradually push the heavy object to the designated placement position. As shown in Figure 3, toggle the handle of the directional valve 6, and the hydraulic oil enters the rodless chamber of the clamping cylinder 9 through the hydraulic lock 8, extending the piston rod of the clamping cylinder to clamp the heavy rail for positioning and pressure maintenance; then toggle the handle of the directional valve 7, and the hydraulic oil passes through the hose to the rodless chamber of the transfer cylinder 10, extending the piston rod of the transfer cylinder, which, through the connected active slider, pushes the passive slider along with the heavy object forward (as shown in Figure 1); after the transfer is in place, toggle the handle of the directional valve 6 in reverse, the hydraulic oil opens the hydraulic lock 8, and the piston of the clamping cylinder retracts, then toggle the handle of the directional valve 7 in reverse, the hydraulic oil to the rod chamber of the transfer cylinder 10, the piston rod of the transfer cylinder retracts, simultaneously pulling the clamping pliers toward the heavy object, thus, the entire device along with the heavy object moves forward one step. Toggle the handle of the directional valve again to enter the next cycle, and so on, repeatedly operating until the heavy object is moved to the destination.
Top push part schematic as follows
 1-Clamping cylinder 2-Heavy rail 3-Transfer cylinder 4-Pin 5-Roller cart 6-Roller cart Moving part schematic
Hydraulic principle diagram
1-Oil tank 2-High-pressure piston pump 3-Motor 4-Pressure regulating valve 5-Pressure gauge 6-Clamping manual valve 7-Transfer manual valve 8-Hydraulic lock 9-Clamping cylinder 10-Transfer cylinder
VI. Usage Method

1. Preparation To ensure smooth operation of the object to be moved, two sets of transfer machines must be used simultaneously. Users need to provide their own heavy rails, which can be selected based on working conditions, either existing tracks or tracks laid on-site, and choose an appropriate site and direction.
2. Positioning of the Object to be Moved First, use several jacks to lift the object to be moved to a certain height, then horizontally pass two heavy rails under the bottom of the object to be moved, then slowly lower the object, while simultaneously placing the roller carts under the object, above the heavy rails. Other methods can also be used to place the object on the roller carts.
3. Installation of the Transfer Machine

First, slide the clamping cylinder's jaw over one end of the heavy rail, then connect the transfer machine and the active slider using a pin as shown in Figure 1. 4. Pump Station Adjustment Connect the power supply (motor rotation clockwise), loosen the pressure regulating nut of the relief valve (counterclockwise) to put the pump in an unloaded state, then start the oil pump. Toggle the handle of the directional valve, making the handle cover arrow point to either of the two oil ports, slowly rotate the pressure regulating nut clockwise, watch the pressure gauge pointer change, when it points near 10MPa, toggle the handle of the directional valve to the middle position, then loosen the pressure regulating nut of the relief valve (counterclockwise), and then toggle the handle of the directional valve, making the handle cover arrow point to either of the two oil ports, slowly rotate the pressure regulating nut clockwise. Watch the pressure gauge pointer change, when it points near 50MPa, cut off the power supply for standby. 5. Transfer Operation

1. Connect the power supply, the pump station starts working. Toggle the handle of the directional valve to supply oil to the rodless chamber of the transfer machine, achieving the "clamp-transfer" action; toggle the handle of the directional valve in reverse, to supply oil to the rod chamber of the transfer machine, achieving the "release-retract" action.
2. The pump station is designed for a pressure of 700Bar, and the factory-set pressure is 700Bar. In subsequent transfer operations, the working pressure may still change. When the pressure is insufficient, use the pump station adjustment method to correct it. Note that the working pressures of the two sets of transfer machines may be different, so it is necessary to frequently monitor the working pressures of each set during operation.
3. Correction and Deflection a. Correction During the transfer operation, due to multiple steps of transfer, the transfer distances of the two sets of transfer machines may accumulate errors. This phenomenon can cause the moved object to run non-parallel, leading to pressure loss in the transfer machine. At this time, manual arrangement of the individual actions of the two sets of transfer machines, one stopping and one moving, can achieve the purpose of correction. b. Deflection During the transfer operation, sometimes the moved object needs to turn, at this time, manual arrangement of the individual actions of the two sets of transfer machines, one stopping and one moving, can achieve the purpose of deflection. Note: When the weight of the moved object exceeds 50% of the rated transfer force, other methods need to be used for correction or deflection.
4. Reasons and Impacts of Different Working Pressures in Two Sets of Transfer Machines Under ideal working conditions, the working pressures of the two sets of transfer machines should be the same. However, due to various factors in actual work, such as improper installation position of the transfer machine, non-parallel placement of the two heavy rails, uneven center of gravity of the moved object, etc., the forces on the two transfer hydraulic cylinders may be uneven. Generally, as long as the working pressures of their respective pump stations are properly adjusted, it will not affect the transfer operation. Only when the weight of the moved object approaches the maximum working capacity of the transfer machine will it affect normal operation. At this time, it is necessary to eliminate the above-mentioned influencing factors to make the working conditions approach the ideal state, fully utilize the working capacity of the transfer machine, and ensure normal operation. Otherwise, it will affect the critical working state and lifespan of the transfer machine.

VII. Precautions

1. Pump Station Operation Precautions

1. Operators must carefully read the operation manual of the ultra-high pressure oil pump station, understand the basic knowledge and operation methods of the pump station before starting the machine.
2. Because the ultra-high pressure oil pump station is not suitable for continuous long-term operation, during the transfer operation, when the transfer machine is not in operation, the pump station should be promptly closed to allow the heat generated during operation to dissipate in time, reducing the wear of the pump components and aging of the seals, thereby extending the lifespan of the pump station. When the oil temperature exceeds 70°C, operations should generally be paused until the temperature decreases before resuming. 3) In outdoor operations during summer, the oil pump station should be shaded to prevent direct sunlight.

2. Transfer Machine Operation Precautions

1. Operators must undergo job training (refer to this manual), understand and master the usage and operation methods of the on-track heavy object transfer machine to prevent improper use that could cause equipment failure and personal injury.
2. Throughout the entire operation process, operators should record each step of the transfer operation, such as the pressure at each pump station and the travel distance of each transfer, and use this data to adjust the next step of the transfer operation.
3. Since this transfer machine is an ultra-high pressure hydraulic device, it is necessary to keep the connectors clean when installing or removing quick connectors, wiping off any dirt, dust, etc., to prevent it from entering the oil tube and contaminating the oil.
4. Maintain the cleanliness of the system oil, promptly remove any debris accumulated inside the oil tank or cylinders. If the hydraulic oil becomes emulsified with water, it should be replaced. The system uses "YB-N46 Anti-wear Hydraulic Oil".