Goldschmidt SR 310 H User manual

OPERATION MANUAL
RAIL SAW SR 310 H

RAIL SAW SR 310 H OPERATION MANUAL
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RAIL SAW SR 310 H OPERATION MANUAL
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Change overview
Auditing
Date
Comment, including chapter
changed by
01
02
03
04
05-31-2018
05-31-2018
07-09-2018
08-08-2018
Creation
In the table of contents, “maintenance” was spelled
wrong.
Pg. 5 Issued a P/N for the document.
Pg. 10 “note” was spelled wrong.
Pg. 15 Weight miss labeled as Height; split Weight into
two rows, one for Saw only and one for Clamp only.
Updated Title, Tables
Added section 3.6 pg. 14
Sven Kummer
Jesse Bunn
Garrett Lee
Garrett Lee

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1About this manual................................................................................................................................................. 6
2General ................................................................................................................................................................. 7
2.1 General information.............................................................................................................................7
2.2 Designated use.....................................................................................................................................7
2.3 Environment requirements..................................................................................................................8
2.3.1 Operating requirements ...........................................................................................................8
2.3.2 Emissions...................................................................................................................................8
3Safety.................................................................................................................................................................... 9
3.1 Basics....................................................................................................................................................9
Table 1: Signal words and symbols.............................................................................................................10
3.2 Important safety information ............................................................................................................10
3.3 Danger zone .......................................................................................................................................13
3.4 Qualification of the operating and maintenance personnel .............................................................13
3.5 Emergency information / safety devices ...........................................................................................14
3.6 Safety signs.........................................................................................................................................14
Table 2: Safety signs...........................................................................................................................14
4Design and function .............................................................................................................................................15
4.1 Design.................................................................................................................................................15
4.2 Specification.......................................................................................................................................15
Table 3: Specifications .......................................................................................................................15
4.2.1 Hydraulic fluid.........................................................................................................................16
Table 4: Hydraulic fluid data ..............................................................................................................16
Table 5: Suitable hydraulic fluids.......................................................................................................16
4.2.2 Supply, interfaces and connections ........................................................................................16
4.3 Function .............................................................................................................................................16
4.4 Boundaries and interfaces .................................................................................................................16
5Transport, assembly and dismantling...................................................................................................................17
5.1 Mounting the blade ...........................................................................................................................17
6Commissioning and operation..............................................................................................................................19
6.1 General information for start-up .......................................................................................................19
6.1.1 Specification of the hydraulic system .....................................................................................19

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6.2 Operation ...........................................................................................................................................19
6.2.1 Mounting onto rail..................................................................................................................20
6.2.2 Saw operation.........................................................................................................................21
7Maintenance ........................................................................................................................................................23
7.1 Recommended maintenance plan .....................................................................................................23
Table 6: Maintenance plan ................................................................................................................23
7.2 Change of hydraulic fluid ...................................................................................................................23
8Troubleshooting...................................................................................................................................................24
8.1 General information for troubleshooting and repairs.......................................................................24
8.2 Troubleshooting and repairs..............................................................................................................24
Table 7: Troubleshooting...................................................................................................................24
9Shutdown and re-commissioning .........................................................................................................................25
10 Storage.................................................................................................................................................................25
11 Dismantling and disposal .....................................................................................................................................25
Publisher: PortaCo Inc.
1805 2nd Ave N, Moorhead, MN 56560
Phone [phone], Fax [phone]
[email protected], www.portaco.com/
Date of publication: 05-31-2018
Documentation version: 1.0
Document / order number: 6332-OOP EN rev1.0
[JB1]

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1About this manual
This document is the original operation manual for the Rail Saw SR 310 H of PortaCo Inc., 1805 2nd Ave N, Moorhead, MN 56560
The Rail Saw is used for cutting rails which have already been mounted. Rails can be cut from a standing position with the Rail Saw.
The Rail Saw is considered to be a complete machine according to the machinery directive 2006/42/EG.
The operation manual is intended to enable the operator to safely operate the system as intended and warn them of foreseeable
misuse. The manual is intended for the operating company´s specialized staff. In addition to the operation manual, the spare part
catalogue and the maintenance manual of the manufacturers of the individual components are to be observed.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
The explanation of the hazard pictograms is contained in chapter safety.
This document is to be treated as confidential. No portion of the document may be disseminated to another party or reproduced
without written permission from PortaCo Inc. All rights reserved.

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2General
This chapter contains basic information about the machine and is intended to provide an initial overview.
2.1 General information
Rails which have already been mounted to the track can be cut with the PortaCo Inc. Rail Saw. For this purpose, the Rail Saw is
mounted to the track. It is possible to stand during sawing due to the long operating handle. Cutting discs with a diameter of 350
mm and 400 mm can be used with the saw.
The Rail Saw is hydraulically powered. The hydraulic energy is provided by a hydraulic unit. The hydraulic unit is not part of the
scope of delivery. We recommend the Hydraulic Power Units D-23, E-15, G-18, G-21, G-23 or G-31.
Further design information is shown and described in chapter 4.
Regarding ergonomics, the stresses and strains resulting from the device are typical for a device in the construction industry.
Because the Rail Saw is considered to be a complete machine according to the machinery directive 2006/42/EG, an identification
plate (type plate) is attached.
Figure 1: Identification plate
2.2 Designated use
Rails which have already been mounted to the track can be cut with the PortaCo Inc. Rail Saw. For this purpose, the Rail Saw is
mounted to the track. It is possible to stand during sawing due to the long operating handle. Cutting discs with a diameter of 350
mm (14”) and 400 mm (16”) can be used with the saw.
Cutting rails which have not been mounted, or using the Rail Saw without mounting it on the track is considered misuse and is not
permitted.
In order to use the Rail Saw as intended, all persons who carry out work with the device must observe the guidelines in the
instruction manual.

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2.3 Environment requirements
2.3.1 Operating requirements
The machine is designed for use on construction sites outdoors. It can be used at temperatures between
-20 °C to 45 °C respectively -4 °F to 113 °F. The temperature of the hydraulic fluid should be at least 10 °C respectively 50 °F.
The statutory minimum distance must be observed around power lines and conductor rails. When working in tunnels, the country-
specific safety regulations must be observed.
2.3.2 Emissions
In technically perfect condition, the A-weighted emission sound level at the work place is lower than 70 dB(A). Hearing protectors is
not required.
Other emissions do not occur during regular device operation.
In the event of damage, hydraulic fluid may leak. Should this be the case, eliminate the leak and remove any fluid which has leaked
with the intended binders.

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3Safety
3.1 Basics
The machine corresponds to the generally recognized standards of technology and practice. Nevertheless, knowledge of the
residual risks as well as general knowledge of the device is required to ensure safe and accident-free work.
The safety information is understood to be in addition to the existing accident prevention regulations and laws. The information is
intended to warn operating personnel about foreseeable misuse. Existing safety prevention measures and laws must be followed at
all costs!
The instruction for use must be read and understood by all persons who work on the device. Introduction to the device is to be
documented in writing.
CAUTION
Hazards from the operational environment of the device can lead to injuries of persons.
-No alterations to the device may be made which lead to a change in function.
-All hazards from the environment or from unforeseeable operating conditions of the device cannot be
captured and depicted within this manual.
Modifications to the machine must be made by the distributing company. In this case this instruction for use
and the system documentation of the machine also be adapted.
The chapter on safety regulations serves to:
-explain the depiction of the safety regulations and symbols
-inform users about dangers, residual risks and measures for reducing risks
-specify the minimum requirements of the operating personnel

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Symbol
Meaning
DANGER
DANGER indicates a hazard with a high degree of risk, which when it is not avoided results in death or
serious injury.
WARNING
WARNING indicates a hazard with a medium degree of risk, which when it is not avoided may result in
death or serious injury.
CAUTION
CAUTION indicates a hazard with a low degree of risk, which when it is not avoided may result in minor
or moderate injury.
NOTICE
NOTE, non-compliance may result in environmental or material damage
Attention risk of injury!
General note[JB2] for helpful tips and additions.
Read the safety information before using the machine. Non-compliance may result in injuries and
damage to property.
Table 1: Signal words and symbols
3.2 Important safety information
Read this chapter and observe the safety information before using.
The safety regulations are to be observed by all persons who work on the device. The regulations and instructions for accident
prevention valid at the place of operation are to be observed. Instruction of the operating and maintenance personnel in system
safety is to be documented.
Please pay particular attention to this chapter to avoid accidents!
PortaCo Inc. is not liable for injury to persons or property which result from misuse of the machine.
DANGER
During operation, it is possible to reach into the guiding mechanism of the saw.
-Wear the prescribed personal safety equipment!
-Hold and operate the machine using the handles intended for this.
-Never use the machine without the protective cover and spark barrier.
-Before beginning maintenance work ensure that the cutting disc is not moving and cannot be
accidentally switched on.

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DANGER
The bursting of hydraulic components and uncontrolled whipping of the hydraulic hoses is possible.
-Only use the machine within the prescribed limits.
-Before disconnecting the hydraulic couplings, make sure that the pressure is relieved.
-The machine must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
DANGER
Contact with live parts results in the worker sustaining a lethal electric shock.
-In the case of railway tracks with live rails, the busbar must be shorted or switched off by the control
room of the transport company.
-Check that no voltage is present in the rail system continuously!
DANGER
The operator or persons standing close by can be injured by sparks. Highly flammable objects may ignite.
-Wear flame-retardant work clothing during work.
-Remove highly flammable objects from the surrounding area.
DANGER
The operator inhales aerosol of hydraulic oil.
-Only use the device within the prescribed limits.
-The device must be maintained at regular intervals, the intervals are specified by the operator's risk
assessment.
-In the event of leaks switch the device to a safe state.
DANGER
If an employee is hit by a train or car, severe or fatal injuries may result.
-Pay attention to your own safety!
-Wear work clothing with reflectors and a safety vest!
-The foreman must ensure that the line being worked on has been closed.
-Place a track marshall with a horn on the opposite track.
DANGER
Employees may be severely or fatally injured by lightening during a thunderstorm.
-Stop work during thunderstorms!

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WARNING
As a result of the cutting process, particles may be slung away from the cutting disc.
-Wear the prescribed personal safety equipment!
-Never use the machine without the protective cover and spark barrier.
-Persons who are not working on the machine must stay outside the hazardous area.
WARNING
The machine is heavy. There is a potential for serious injury during transport.
-When carrying the device, use the transport ring which is intended for this purpose.
-Wear safety shoes.
WARNING
In case of poor weather conditions (rain, snow) there is a risk of injury due to poor visibility or slippery
standing surfaces.
-Stop work if standing surfaces are slippery.
-Stop work if visibility is poor.
WARNING
The rail being worked on and the cutting disc are very hot. There is a risk of severe burns if these are
touched.
-Allow the rail and the cutting disc to cool down after cutting.
-Wear work gloves.
WARNING
Improper maintenance or maintenance not carried out on time may result in damage to the machine or
injury to persons.
-Maintenance intervals are to be determined by the operator within the scope of their risk assessment.
-Observe the maintenance intervals and maintenance instructions of the manufacturer and existing
directives.
-Components may only be replaced with identical spare parts. It is imperative that the specifications of
the component manufacturer be followed when mounting the component.
WARNING
Spilled hydraulic oil can lead to an increased risk of fire and environmental pollution.
-Remove spilled hydraulic oil with the prescribed absorbent material.

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WARNING
In case of poor weather conditions (rain, snow) there is a risk of injury due to poor visibility or slippery
standing surfaces.
-Stop work if standing surfaces are slippery.
-Stop work if visibility is poor.
WARNING
Operating errors using the device, e.g. by instruction errors, may lead to personal injury or damage to the
device.
-The instruction for use must be accessible to operators and maintenance personnel at all times!
-A copy of the technical documentation including the instruction for use must be kept in a suitable and
accessible place.
CAUTION
Noise emissions occur during operation of the hydraulic unit.
-Wear ear protection
-Switch the device off if unusual noises occur
NOTE
Inadequate lighting may result in incorrect switching operations or mix-ups.
Adhere to the break and recovery times prescribed by law.
3.3 Danger zone
There is a danger of injury by cutting or sparks during operation of the Rail Saw. The area around the cutting point and the cutting
disc can become very hot. Always operate the Rail Saw with the spark barrier. Wear protective work wear while using the saw.
Allow the rail and the cutting disc to cool after using the saw.
3.4 Qualification of the operating and maintenance personnel
The intended circle of users for the machine includes the operators and maintenance personnel.
Anyone who carries out work on the device must be familiar with the functions and dangers of the machine. Introduction to the
machine is to be documented in writing.
All operators as well as employees that regularly enter the area of the machine should at least be instructed on the following
topics:
-Basic device functions (operators)
-instruction for use (operators)
-Conduct in work area (all)
-Location of safety devices (operators)
-Personal protective equipment (all)

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Furthermore, operators should possess the necessary physical and mental capacities which are required to operate and service the
machine.
The operating personnel must wear personal protective equipment according to the job at hand and dangers of the environment.
The operational procedures as well as the professional association guidelines and safety data sheets are to be observed.
3.5 Emergency information / safety devices
The specification of the Working Conditions Act must be observed when working with the machine. Persons who work with the
machine are required to use their personal protective equipment as intended. In this case that means:
-work gloves
-safety glasses or safety mask
-safety shoes S3
-hearing protection
3.6 Safety signs
Safety sign
Meaning
Mandatory sign “Wear hearing protection”: indicates that while working with the machine hearing
protection must be worn by all persons near to the machine.
Mandatory sign “Wear safety glasses”: indicates that while working the machine safety glasses must
be worn by the operator.
Mandatory sign “Wear protective shoes”: indicates that while working the machine protective shoes
must be worn by the operator.
Mandatory sign “Wear protective gloves”: indicates that while working the machine protective gloves
must be worn by the operator.
Mandatory sign “Wear protective clothing”: indicates that while working the machine protective
clothing must be worn by the operator.
Table 2: Safety signs

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4Design and function
4.1 Design
Figure 2: Rail Saw overall design
No.
Description
1
Accelaration with locking mechanism
2
Connection hydraulic pump (flow and return flow)
3
Mounting base
4
Transport handle
5
Spark barrier
6
Cutting disc
4.2 Specification
Criteria
Value
Width
686 mm / 27 inch
Length
1,143 mm / 45 inch
Height
457 mm / 18 inch
Weight, Saw only
17 kg / 39 lb
Weight, Clamp only
11kg / 24 lb[JB3]
Hydraulic pressure
max. 150 bar / 2,150 psi[JB4]
Hydraulic flow
max. 40 lpm / 10 gpm
Idle speed
4,800 U/min / rpm
Table 3: Specifications

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4.2.1 Hydraulic fluid
The hydraulic fluid should meet the following requirements.
Criteria
Value
Viscosity (at 10 °C / 50 °F)
95 cSt
Viscosity (at 38 °C / 100 °F)
27-42 cSt
Viscosity (at 60 °C / 140 °F)
16,5 cSt
Pour point
-10 °C / 14 °F
Viscosity index (ASTM-D2220)
min. 140
Flash point (ASTM-D92)
min. 171 °C / 340 °F
Pump wear test (ASTM-D2882)
max. 60 mg
Demulsibility (ASTM-D1401)
max. 30 minutes
Table 4: Hydraulic fluid data
The following hydraulic fluids or equivalent are suitable for use.
Manufacturer
Type
Chevron
Clarity AW ISO 32
Mobil
Univis J32
Gulf
Harmony AW-HVI-150-32
Shell
Tellus T32
Table 5: Suitable hydraulic fluids
4.2.2 Supply, interfaces and connections
The machine is powered by a hydraulic unit. There are quick couplings (3/8" flat face) for connecting the hydraulic unit.
4.3 Function
Rails which have already been mounted to the track can be cut with the PortaCo Inc. Rail Saw. For this purpose, the Rail Saw is
mounted on the track. Cutting discs with a diameter of 350 mm (14”) and 400 mm (16”) can be used with the saw.
It is possible to stand during sawing due to the long operating handle. The saw is started as soon as the handle is pressed, and
stopped as soon as the handle is released. An additional lock is provided on the handle to prevent accidental activation of the saw.
The Rail Saw is hydraulically powered. The hydraulic energy is provided by a hydraulic unit. The hydraulic unit is not part of the
scope of delivery. We recommend the Hydraulic Power Units D-23, E-15, G-18, G-21, G-23 or G-31.
4.4 Boundaries and interfaces
The Rail Saw consists of the parts pictured in chapter Design. The battery limit is the connection to the hydraulic unit. Power and
auxiliary equipment are not part of PortaCo Inc.´s scope of delivery. Other parts which are not directly part of the machine are also
excluded.

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5Transport, assembly and dismantling
The machine must be disconnected from the hydraulic unit for transport. For this purpose, the hydraulic unit must be switched off
and the system depressurized. After that the hydraulic hose couplings can be detached. Then the machine can be transported fully
assembled without being taken apart.
The Rail Saw is equipped with transport handles. Use the handles for transport.
5.1 Mounting the blade
Cutting discs with a diameter of 350 mm (14”) or 400 mm (16”) can be used with the Rail Saw. When using bushings, ensure that
the bushings do not extend beyond the cutting disc. Otherwise there is a danger that the safety mechanisms cannot properly hold
the cutting disc.
1. Remove the nuts and the dished spring.
Figure 3 & 4: Change the cutting disc
2. Place the cutting disc on the axle.
3. Fasten the cutting disc with the dished spring and nut. Ensure that dished spring is mounted so that it is level.

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Figure 5 & 6: Change the cutting disc

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6Commissioning and operation
6.1 General information for start-up
DANGER
Incorrect operation of the machine or disregard of safety instructions may lead to
endangerment of persons or damage to the machine.
-Familiarize yourself with the complete instruction for use before beginning work on the
machine. Pay particular attention to chapter 3!
NOTE
A thorough, visual inspection of the machine is to be carried out by the operator before start-up.
Start-up of the machine may only be carried out by qualified specialist personnel. The start-up engineer must be acquainted with
the machine. Requirements for start-up are:
-the Rail Saw have been tested and is ready for operation
-safety devices have been tested and are ready for operation
-all detachable connections have been checked and tightened if necessary
6.1.1 Specification of the hydraulic system
The hydraulic power unit should have a flow rate of at least 38 liters per minute and ensure pressure between 100 bar and 140 bar
respectively 40 gallons per minute and ensure pressure between 1,450 psi and 2,031 psi. The pressure must be limited to 155 bar /
2,248 psi. The counter-pressure of the hydraulic system should be less than 17 bar / 247 psi, measured at the return flow output of
the Rail Saw. The measurements must be taken at the minimum temperature of the hydraulic fluid (10 °C / 50 °F). Warm up the
hydraulic fluid if necessary.
The temperature of the hydraulic fluid must be limited to 60 °C / 140 °F.
The hydraulic fluid must be filtered with a 25 µm filter.
We recommend the use of the hydraulic power units D-23, E-15, G-18, G-21, G-23 or G-31 from PortaCo Inc.
6.2 Operation
A visual inspection is to be carried out before beginning work. In the event of damage, no work may be carried out. Install hydraulic
hoses away from walking and transport routes. Ensure that hydraulic hoses are not installed over sharp edges. Make sure that the
environment is well lit; set up additional work lights if necessary.

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6.2.1 Mounting onto rail
1. Mount the rail clamp on the rail. Ensure that the clamp is in full contact with the rail.
Figure 7: Mounting the rail clamp
2. Mount the Rail Saw on the boom of the pedestal.
Figure 8: Mounting the Rail Saw on the pedestal