PANDROL 05100B Manuale utente

Partners in excellence

15th November 2021

ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01

OPERATION AND MAINTENANCE

MANUAL

Light Weight

Weld Shear

MODEL 05100B

1. Preface

2. Revision

2 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

Thank you for choosing Light Weight Weld Shear!

You are now the owner of a quality product from Pandrol.

This manual aims to help you get to know your new Light Weight Weld Shear, to use it in the best way and to

maintain it properly for a long lifetime. It also presents important safety regulations and warnings.

The manual is intended for people who handle and operate the machine. It is originally written in English and

translated into the local language by Pandrol.

Pandrol reserves the right to change specications, equipment, instructions and maintenance guidelines without

prior notice.

The manual contains instructions about the following topics:

1. Installation

2. Operation

3. Safety features and warnings

4. Maintenance and troubleshooting

(1) refers to a component in a gure/illustration.

IMPORTANT

This manual contains ordered actions, e.g.

1. Do this

2. ...and then this...

3. ...and nally this

These actions must be done in the numerical order presented.

Revision Date Comments

P01 2021-11-15 New Manual

Table of Contents

1. Preface 2

2. Revision 2

3. Safety Information 4

3.1. General 4

3.2. Safety actions 4

3.3. Personal/Safety equipment 5

3.4. Safety precautions 5

3.5. Qualiedpersonnel  6

4. Summary 7

5. Operation 8

5.1. Bladewear  9

5.2. Coldweatheroperation  9

6. Reviewofhydraulicprinciples  10

7. Maintenance 11

7.1. General 11

7.2. Warninglabelsandinformationsymbols 12

8. Limitedwarranty  13

8.1. Exclusionstolimitedwarranty  13

8.2. Limitation of liability 13

9. Customer information 14

10. Assembly  16

10.1. Partsdiagram  16

10.2. Partslist 17

11. Disclaimer 18

12. Contact 18

13. RecyclingandEnvironment  18

3 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

3. Safety Information

3.1. General

• Tooloperatorsandmaintenancepersonnelmustalwayscomplywiththesafetyprecautionsgiveninthis

manual,andwithallstickersandtagsattachedtothetoolandhoses.

• Allsafetyprecautionsaregivenforyoursafety.Readtounderstandandfollowallsafety,maintenanceand

operationinstructionsbeforeyouuseormaintainthetool.

• Reviewthemanualdailybeforeusingthetool.

• Followallsafetyguidelinesgivenyoubyyoursupervisor.Donotusethetoolifyouhaveanyquestionsabout

theoperation,safetyormaintenanceofthistool.Failuretofollowtheseinstructionscanresultinpersonal

injuryorequipmentdamage.

• Pandrolhasnocontroloverthetooluseoroperationonceitleavestheplant.Pandrolhasnocontrolover

operatorormaintainerselection.Thecustomermustassumeresponsibilityforthetoolsuitabilityforaparticular

function.

• Duringuseofthetool,goodjudgementmustbeusedtoworksafelyande󰀩cientlywithoutendangering

themselvesorbystanders.

• Understandingoftheoperationandmaintenancemanualisessentialforanyoneusingormaintainingthetool.

• Warningsandsafetyprecautionsdescribedinthisdocumentshallonlybeconsideredasaminimum.National

conditions,standardsandregulationsoverrideconditions,standardsandregulationsdescribedinthis

document.

• Workwiththemachineisonlytobecarriedoutbyqualiedpersonnel,well-informedandeducatedingeneral

railwayworkmanshipandspecicallyintheconditions,standardsandregulationsonspecicrailtrack.

• Themachinemayonlybeusedforitsspeciedpurpose.

• Anyadjustmentsorserviceonthemachineisonlyallowedtobedonebyqualiedpersonnelthathaveread

andunderstoodthismanualandhavehadtrainingandinformationfromPandrol.

3.2. Safety actions

• Readandunderstandallsafetyregulationsandwarningsbeforeinstallation,operatingorperforming

maintenanceonthismachine.

• 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owandpressureareavailable.Neverexceedowsor

pressuresforthetoolbeingused.Personal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unsafegrades,poorfootingareasand

overheadhazards.

• Usestandardsandregulations,accidentpreventionregulationsandregulationsconcerningspecialambient

conditions(e.g.areaspotentiallyendangeredbyexplosivematerials,heavypollutionorcorrosiveinuences).

• Maintainbalanceandproperfootingatalltimes.Neveroverreachtotheextentthatabroken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.

4 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

• Donotoperatethetoolatexcessiveuidtemperaturesoperatordiscomfortandpotentialburnscanresultat

highoiltemperatures.

• Donotcleaninspectorrepairthetoolwhileconnectedtothepowersource.Accidentalengagementofthetool

can cause serious personal injury.

• Oilinjectionhazardexistswiththistool.Oilinjectionisacondition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,ttings,orothercomponents

showingwirebraid,nicks,cuts,damageorabrasions.Failuretodosomayresultinequipmentdamageand/or

personalinjuryordeath.

• Cleanupanyoiloruidspillsimmediately.

3.3. Personal/Safety equipment

• Neverwearlooseclothingthatcangetentangledintheworkingpartsofthetoolsorbecarelesswithhands,

feetorotherbodypartsaroundtheworkingpartsofthetools.Hydraulictoolsexerthightorqueandforceand

cancauseseriousinjuryordeathifimproperlyused.

• Whenworkingnearelectricalconductors,alwaysassumethattheconductorsareenergizedandthathosesand

clothingcanconductharmfulelectricity.Usehoseslabeledandcertiedasnonconductive.

• Alwayswearsafetyequipmentsuchasoilinjectionresistantworkgloves,safetyglasses,safetyboots,ear

protectionandothersafetyappareldictatedbyyoursupervisorapplicableforthejobyouaredoingandthetool

you are using.

• Theuseofancompressedair,whichmustbelessthan8BAR(116PSI),toblowpartscleanortoblowthem

dryafterbeingcleanedwithasolventwillcauseparticlesofdirtand/ordropletsofthecleaningsolventtobe

airborne.Theseconditionsmaycauseskinand/oreyeirritation.Whenusinganairjetdonotdirectittoward

anotherperson.Improperuseofairjetcouldresultinbodilyinjury.

3.4. Safety precautions

• Alwayswearsafetyequipmentsuchasgloves,safetyglasses,earprotection,safetyshoes,andotherrequired

safety equipment.

• Donotwearclothingwhichmaybecomeentangledinthetool.

• Keephandsclearofworkareaatalltime.

• Alwayskeepworkareafreeoftoolsoranyotherobjectswhichmayimpairsoundfooting.

• Caution-oilinjectionhazardexistswiththistool.Oilinjectionisaconditionwherethehydraulicoilisforced

undertheskinthroughpressureintheline.Alwayswearglovesandrepairleaksimmediately.

• Becauseofthehigheldweldtemperatures,itisextremelyimportanttocheckforwornhoses,nicks,cuts,

and/orleaksbeforeeachshearoperation.Hydraulicoilhasaashpointofapprox.400DegreeF.Aleak

directedintotheweldarea(1900°F)willcauseareandpossibleseriousinjuryordeath.

• Donotcleanorinspectthetoolwhileitisconnectedtothepowersource.Accidentalengagementofthetool

can cause serious injury.

• Alwayscheckworkareaforanytrashwhichmyignitefromsparks,weldsplatterorslag.

• Alwayschecktheworkareaforsmolderingtiesortrashbeforeleavingsite.

• Neverstrikeholddownswithanyobjecttoloosenshearfromtherail.

5 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

3.5. Qualied personnel

Themachineisonlytobeusedbytrainedpersonnel,thoroughlyfamiliarwithandtrainedingeneralrailway

workmanship.Theequipmentshouldbeoperatedaccordingtotheconditionsandstandardregulationsapplyingto

thetracktheyareworkingon.

Theequipmentmustbeserviced,maintained,orinanywaymodiedonlybytrainedpersonnel,whoarefamiliar

withtheOperation&MaintenanceManualandhavereceivedtrainingandinformationfromPandrol.

Inordertoavoidpersonalinjuryand/ormaterialdamage,everyoneinvolvedwithassembling,starting-upor

overhaulmustpossessrelevantknowledgeoftheequipment,itsuse,maintenancerequirementsandprocedures.

6av19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

4. Summary

ThePandrolWeldShearislightweightandhighlye󰀩cient.

Springcenteredowcontrolvalvepermitssafeandprecision

timedshearingofathermiteweld.Additionalhalfinchof

clearancebetweenbladesensureseasyplacementoverwide

gapwelds.Theshieldtotallyprotectsttingsandhoses.The

adjustableholddownsareselflockingandwillassureasafe

clean cut.

Flow Pressure Dimensions Weight

5GPM(19LPM)

10GPM(38LPM)

2000PSI(140BAR) A-28-5/8"(72.7cm)

B-18-3/4"(47.6cm)

C-15"(38.1cm)

92lbs(41.73kg)

Fig 1.

Fig 2. Fig 3.

7 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

5. Operation

• Withthepowersourceinthe"OFF"position,connectthehoses.Donotdragtheservicehosesbypulling

withthetool.Looptheservicehoseintheworkareainsuchawaytorelievestressonthehoseandquick

disconnectttingswhileworking.Beawareofhoselocationatalltimes.

• Whentheweldisreadytobecut,positiontwopeople,oneoneachsideoftheshear.Theyshouldcarefully

placetheshearovertheweldandlockitintoplacewiththeholddownlegs.

• Turnthepowersource"ON"tosupply5GPM(19LPM)or10GPM(38LPM)

• Pushthecontrolvalveleverforwardtothelabeledshearpositiontomakethecut.Operatormustholdlever

intheshearpositionfortheentirecycle.Ifoperatorletsgooftheleverthecylinderwillstopduetothespring

centervalvedesign.

• Aftersheariscomplete,pullthecontrolvalveleverbackwardstothelabeledretractpostiontoretractthe

shearblades.Operatormustholdleverintheretractpositionfortheentirecycleduetothespringcentervalve

design.

• Turnpowersource"OFF".

• Toremoveshearfromtherail,loosenholddowns,positiontwopeople,oneoneachsideoftheshear,and

carefullyremovefromtherail.

NOTE!

• Oil temperature can e󰀨ect stroke time. Make sure oil temperature is at least

80°F / 27°C to achieve proper performance of weld shear cycle time.

NOTE!

• The weld shear is equipped with a factory set hydraulic ow cartridge to

assure the time to fully stroke the shear blades during an actual shear

operation shall be between 16 and 18 seconds.

NOTE!

• Place the shear on the rail prior to setting up the weld to adjust the hold

down legs. After hold down legs are adjusted, remove shear from rail to

prepare weld.

8 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

5.1. Blade wear

Asthebladeswear,thegapmaybeclosedbyadjustingthecylinderrodnutsattherearoftheshear.A1/32”gap

isrecommended.

5.2. Cold weather operation

Hydraulicsystemperformanceisa󰀨ectedwhenthetemperaturedropsbelow50°F.Therefore,measuresshouldbe

takentopre-warmtoolsanduidsbeforeoperating.

NOTE!

• Refer to operating procedures of this manual before starting

9 av 19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

6. Review of hydraulic principles

Tool circuit

6.1. Hydraulic formulas

Example:HPrequiredtodeliver10GPMat1500PSI.

EstimatedHPdeliveredbypumporusedbytool

6.2. Back pressure

Backpressuremeasuredatthetoolreturnportmustnotexceedthemanufacturersbackpressurerating.Most

manufacturerslistthe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fromthemaximumtoolpressure

toarriveatamaximumtooloperating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e󰀨ected,butsealsmayblow.Thisiswhyitisveryimportanttodirecttheowintothetool

correctly.Reversingthehosestotestmayresultinblownseals,damagetothetool,andpersonalinjury.

PSI

GPM 500 1000 1500 2000 2500 3000

31.03 2.06 3.09 4.12 5.15 6.18

51.72 3.43 5.15 6.86 8.58 10.30

10 3.43 6.86 10.30 13.70 17. 2 0 20.60

15 5.15 10.30 15.40 20.60 25.70 30.90

10av19

OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021

@Pandrol 2021

Indice

Manuali Taglierina popolari di altre marche

Milwaukee

Milwaukee HEAVY DUTY M12 FCOT Manuale utente

Makita

Makita DCS552 Manuale utente

SignWarehouse.com

SignWarehouse.com Bobcat BA-60 Manuale utente

Makita

Makita 4112HS Manuale utente

GEISMAR STUMEC

GEISMAR STUMEC MTZ 350S Manuale utente

Hitachi

Hitachi CM 4SB2 Guida alla risoluzione dei problemi

Dexter Laundry

Dexter Laundry 800ETC1-20030.1 Manuale utente

GCC Technologies

GCC Technologies AFJ-24S Manuale utente

DeWalt

DeWalt XR LI-ION DCS350N Manuale utente

Baudat

Baudat ES1 Manuale utente

Mafell

Mafell ZAF 200 Guida

Makita

Makita 4100NH Manuale utente

Formax

Formax FD 574 Manuale utente

EINHELL

EINHELL TE-MA 1500 Manuale utente

Husqvarna

Husqvarna Cut-n-Break K 760 Manuale utente

CLEAN ROOM DEVICES

CLEAN ROOM DEVICES CRD130SS Manuale utente

TRI tool

TRI tool 301A Manuale utente

Roller

Roller King 1 1/4 Manuale utente