Matweld 00800A User manual

00800A
Rail Saw
TheMatweldRailSawishydrau-
licpoweredabrasiverailsawthat
uses a 14 or 16 inch diameter
bladetocutrail.Asturdypivotarm
securely clamps to the rail and
guidesthesawduringoperation.
Free axis movement of the tool
allowscuttingoneithersideofthe
rail and clean separations aver-
age well under two minutes.
Sturdy construction and quality
componentsensure lowmainte-
nanceandlong life ofthe tool.
Accessories:
00897 - 14” saw blades
00899 - 16” saw blades
FLOW
10 gpm
(38 lpm)
PRESSURE
2000 psi
(140 bar)
RPM
3200
DIMENSIONS
A - 36"
B - 10"
C - 17"
CLAMP
L36" X W8" X H11"
WEIGHT
SAW
35 lbs( 16 kg)
CLAMP
20 lbs. (9 kg)
A
C
B
632South3rdStreet
P.O.Box2816•Paducah, KY 42002
270-444-0085
Fax: [phone]
Website:www.matweld.com
Email:[email protected]
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99 REV.8/04

3
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
GENERAL SAFETY PRECAUTIONS:
TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLYWITH THE
SAFETYPRECAUTIONSGIVENINTHISMANUAL,ANDWITHALLSTICKERSANDTAGSATTACHED
TO THE TOOLAND HOSE. ALLSAFETY PRECAUTIONSARE GIVEN FOR YOUR SAFETY. READ
TOUNDERSTANDANDFOLLOWALLSAFETY,MAINTENANCEANDOPERATION INSTRUCTIONS
BEFOREYOUUSE OR MAINTAINTHETOOL.REVIEWTHEMANUALDAILYBEFOREUSINGTHE
TOOL. IN ADDITION, FOLLOW ALL SAFETY GUIDELINES GIVEN YOU BY YOUR SUPERVISOR.
DO NOTUSE THE TOOLIF YOU HAVEANY QUESTIONSABOUT THE OPERATION, SAFETY OR
MAINTENANCE OFTHIS TOOL. FAILURE TO FOLLOWTHESE INSTRUCTIONS CAN RESULTIN
PERSONALINJURY OREQUIPMENT DAMAGE.
MATWELDHAS NOCONTROLOVERTOOLUSEOROPERATIONONCEITLEAVESTHEMATWELD
PLANT. MATWELD HAS NO CONTROL OVER OPERATOR OR MAINTAINER SELECTION. THE
CUSTOMER MUSTASSUME RESPONSIBILITY FORTHE TOOL’S SUITABILITY FORAPARTICU-
LAR FUNCTION, FOR ANYONE USING THE TOOL OR MAINTAINING THE TOOL REGARDING
THEIR FITNESSTO USETHE TOOLOR REPAIRTHETOOL, UNDERSTANDING OF THE OPERA-
TION AND SAFETY AND MAINTENANCE MANUAL, INTELLIGENCE TO USE GOOD JUDGMENT
NECESSARY TO WORK SAFELY AND EFFICIENTLYWITHOUT ENDANGERING THEMSELVES
OR BYSTANDERS INTHE WORKAREA.
•DO NOT OPERATE THE TOOL UNTIL YOU HAVE BEEN THOROUGHLY AND PROPERLY
TRAINEDOR UNDER THE SUPERVISIONOFAN INSTRUCTOR.
•CHECK POWER SOURCE DAILYTO DETERMINE IF CORRECTFLOWAND PRESSUREARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FORTHE TOOLBEING USED. PER-
SONALINJURYOR DAMAGETO THETOOLCAN RESULT.
•OPERATORS MUST CLEAR THE WORK AREA OF NON-ESSENTIAL PERSONNEL. FLYING
DEBRISCAN CAUSESERIOUS INJURY.
•THE OPERATOR MUST BE FAMILIAR WITH ALL PROHIBITED WORK AREAS SUCH AS UN-
SAFEGRADES, POORFOOTING AREASAND OVERHEADHAZARDS.
•MAINTAIN BALANCE AND PROPER FOOTING AT ALLTIMES. NEVER OVERREACH TO THE
EXTENT THATABROKEN PARTOR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU
TO LOSE YOUR BALANCE AND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONE
ELSE.
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
•WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CON-
DUCTORSARE ENERGIZEDAND THATHOSESAND CLOTHING CAN CONDUCT HARMFUL
ELECTRICITY. USE HOSES LABELEDAND CERTIFIEDAS NON-CONDUCTIVE.
•DONOTOPERATETHETOOLATEXCESSIVEFLUIDTEMPERATURES OPERATORDISCOM-
FORTAND POTENTIALBURNS CAN RESULTAT HIGH OILTEMPERATURES.
•NEVERWEAR LOOSE CLOTHINGTHATCANGETENTANGLED INTHEWORKING PARTSOF
THETOOLSOR BE CARELESS WITH HANDS, FEETOR OTHER BODYPARTSAROUNDTHE
WORKING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERTHIGH TORQUEAND FORCE
ANDCAN CAUSE SERIOUS INJURYORDEATHIFIMPROPERLYUSED.
•TOAVOID PERSONALINJURYOREQUIPMENTDAMAGE,ALLTOOLREPAIR,MAINTENANCE
ORSERVICEMUSTONLYBEPERFORMEDBYAUTHORIZEDAND PROPERLYTRAINEDPER-
SONNEL.
•ALWAYS WEARSAFETYEQUIPMENTSUCHAS OILINJECTION RESISTANTWORK GLOVES,
SAFETYGLASSES,SAFETYBOOTS,EARPROTECTIONANDOTHER SAFETYAPPARELDIC-
TATEDBYYOUR SUPERVISORAPPLICABLEFORTHE JOBYOUARE DOINGANDTHETOOL
YOUARE USING.
•DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER
SOURCE. ACCIDENTAL ENGAGEMENT OF THE TOOL CAN CAUSE SERIOUS PERSONAL
INJURY.
•OILINJECTION HAZARD EXISTS WITHTHIS TOOL. OILINJECTIONIS A CONDITIONWHERE
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.
•DONOTUSE DAMAGED EQUIPMENT.IMMEDIATELYREPLACEANYDAMAGEDHOSES, FIT-
TINGS,OROTHERCOMPONENTSSHOWING WIREBRAID,NICKS,CUTS,DAMAGE ORABRA-
SIONS. FAILURE TO DO SO MAYRESULTIN EQUIPMENT DAMAGE AND / OR PERSONAL
INJURYORDEATH.
•CLEANUPANYOILORFLUIDSPILLS IMMEDIATELY.
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
HAVESUPERVISORADDADDITIONALPRECAUTIONSRELATINGTOTHESPECIFIC WORK
AREAAND LOCALSAFETY REGULATIONSBELOW:
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REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
00800ARAILSAW
SAFETY PRECAUTIONS:
1. ALWAYSWEAR PROTECTIVEEQUIPMENTSUCHASGLOVES,SAFETYGLASSES,EAR PRO-
TECTIONAND SAFETY SHOES.
2. DO NOTWEAR CLOTHING WHICH MAYBECOME ENTANGLED IN THETOOL.
3. ALWAYS KEEP WORKAREAFREE OF TOOLS ORANYOTHER OBJECTS
WHICHMAYIMPAIRSOUND FOOTING.
4. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS A CONDI-
TIONWHERE THE HYDRAULICOIL IS FORCEDUNDERTHE SKINTHROUGHPRESSURE IN
THE LINE. ALWAYS WEAR GLOVES, DO NOT CARRY THE TOOL BY HYDRAULIC HOSES,
ANDREPAIRLEAKSIMMEDIATELY.
5. NEVER USE THE RAIL SAWASAFREE HAND TOOL.
6. NEVER CHANGE BLADES WITH THE POWER SOURCE VALVE(S) IN THE “ON” POSITION,
TURN THE POWER SOURCE “OFF”.
7. NEVER CARRYTHE RAIL SAW WITH THE POWER SOURCE IN THE “ON” POSITION, TURN
THE POWER SOURCE “OFF”.
8. NEVER TOUCH OR TRY TO STOP A MOVING BLADE.
9. ALWAYS CHECKTHEWORKAREAFORANYTRASHWHICH MAYIGNITE FROMSPARKS.
10. ALWAYS CHECK THE AREA FOR SMOLDERING TIES OR TRASH BEFORE LEAVING THE
SITE.
11. ALWAYS KEEPAFIRM GRASP ON THE SAW, WITH BOTH HANDS,ATALLTIMES.
12. WHEN CHANGING BLADES, FOLLOWALLBLADE MANUFACTURERS INSTRUCTIONS FOR
SAFETY AND OPERATION. USE ONLYBLADES THATCOMPLYWITH ANSI STANDARDS.
BEFOREUSING, RUN NEW SAWBLADE FORONEMINUTEATFULLSPEED TOCHECK FOR
DEFECTSOR VIBRATION.
13. NEVER LET THE SAW BLADE CUT INTO ANY MATERIAL (TIE, BALLAST, ETC…) OTHER
THANTHERAIL BEING CUT
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
00800ARAILSAW
14. MOSTHYDRAULICOILS HAVEAFLASHPOINTOFAPPROXIMATELY500DEGREES(F). MAKE
SURE HOSESARE COMPLETELYCLEAR OF SPARKSAND HOT DEBRIS. HAVEAN-OTHER
PERSON STAND CLOSE TO HYDRAULIC POWER SOURCE CONTROLS TO OBSERVE OP-
ERATIONAND FOREMERGENCYSHUTDOWN IF NECESSARY
15. IF THE BLADE STOPS DURING THE CUTTING PROCESS DUE TO RAIL BIND OR OTHER
PROBLEM,IMMEDIATELYTURN OFFTHE POWERSOURCEANDDISCONNECTTHE HOSES
BEFORE ATTEMPTING TO FREE THE BLADE. AFTER FREEING THE BLADE REPLACE IT
WITHANEW BLADE BEFORE CONTINUING THE CUT.
.
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
00800A RAIL SAW
FLOW: 10 GPM (38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX250PSI
RPM: 3200
OPERATION:
1. POSITION SAWCLAMPSQUARELYONRAILAND TIGHTEN.
2. ATTACH THE RAILSAW TO THE CLAMPASSEMBLYAND TIGHTEN.
3. WITH THE POWER SOURCE IN THE “OFF” POSITION, CONNECT THE HOSES. DO NOT
DRAG THE SERVICE HOSE BY PULLING WITH THE TOOL. LOOP THE SERVICE HOSE IN
THEWORKAREAIN SUCHAWAYTORELIEVESTRESS ONTHE HOSEAND QUICKDISCON-
NECT FITTINGS WHILE WORKING. BE AWARE OF HOSE LOCATION AT ALL TIMES. KEEP
HOSESCLEAR OF SPARKS.
4. TURN POWER SOURCE TO THE “ON” POSITION TO SUPPLY10 GPM TO TOOL.
5. GRASP THE SAW FIRMLY AND PULL UP ON THE TRIGGER TO START THE SAW BLADE
ROTATING.BEFORE USING,RUN SAW BLADEFOR ONE MINUTEATFULLSPEEDTOCHECK
FORDEFECTSOR VIBRATIONBEFORETOUCHINGRAIL.THESAWISDESIGNEDTOTHROW
SPARKSAWAYFROMTHE OPERATOR.
6. KEEPTHE SAWOSCILLATINGWHILEMAKINGTHE CUT.THIS WILLREDUCEGLAZINGAND
CUTTING TIME.
7. WHEN THE BLADE HAS WORN TO THE POINT IT WILL NO LONGER “REACH THROUGH”
FROMONE SIDEAND1/2” OR LESS REMAINSTOBECUT, (IFMORETHAN1/2” REMAINSTO
BE CUT CHANGE THE BLADE) TURN THE FLOW TO PRESSURE “OFF”. TURN THE SAW
UPSIDE DOWN AND CAREFULLYSTEP OVER THE RAIL. KEEP CLEAR OF THE TRIGGER
ANDBLADE WHILECHANGING POSITIONS.
8. THESAWCANNOWBECOMPLETEDWITHOUTDISCONNECTINGTHESAWFROMTHECLAMP.
REMEMBER, THE SPARKS WILL NOW GO UP RATHER THAN DOWN IN THIS POSITION.
9. AFTERFINISHINGTHE CUT,TURNTHEPOWER SOURCE “OFF” ANDDISCONNECTHOSES
BEFOREATTEMPTING TO REMOVE THE SAW.
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
00800A RAIL SAW
MAINTENANCE:
1. CHECK TOOL DAILYFOR PROPER OPERATION, LEAKS, OR DAMAGE.
2. INSPECT HOSES DAILY. REPLACE CUT, BURNED, OR OTHERWISE DAMAGED HOSES.
3. KEEP QUICK DISCONNECT COUPLERS CLEAN AND LUBRICATED.
4. USE HYDRAULIC FLUIDS THATCOMPLYWITH HTMASPECIFICATION 5.7, THE HYDRAULIC
FLUID SHOULD HAVE AVISCOSITY BETWEEN 100 AND 400 SSU (20-82 CENTISTOKES) AT
THEMAXIMUMANDMINIMUMEXPECTEDOPERATINGTEMPERATURES.PETROLEUMBASED
HYDRAULICFLUIDS WITHANTI-WEAR PROPERTIESANDAVISCOSITYINDEX OFOVER 140
WORK FOR AWIDE RANGE OF OPERATING CONDITIONS.
THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:
AMOCORYKON MV CITGOA/WALLTEMP
SUNVIS706 MOBILD.T.E.13
CHEVRONEP-MV TEXACO “RANDO” HDAZ
OTHER FLUIDS THATMEET OR EXCEED THIS SPECIFICATION CAN BE USED.
*SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.
5. HAVE TOOL INSPECTED, AT LEAST ANNUALLY, BY MATWELD OR AMATWELD QUALIFIED
SERVICE REPRESENTATIVE TO DETERMINE IF TOOL IS IN NEED OF SAFETY CHANGES
OR WORN PARTREPLACEMENT.
6. APPLYGREASE TO DISCONNECT BOLT THREADS WEEKLY.
CHANGING BLADES:
1. TURN POWER SOURCE “OFF” ANDDISCONNECT HOSES FROM TOOL.
2. WITHTHEPOWER SOURCE OFF, HOSES DISCONNECTED, SAW BLADEELEVATEDABOVE
THEGROUND OR ONACLEANWORKAREA,REMOVETHE 1/2” LEFTHAND CAPSCREW, 1/
2” FLATWASHER AND THE OUTSIDE FLANGE. INSTALL NEW BLADE, OUTER FLANGE,
WASHERANDTIGHTEN LEFT HAND CAPSCREW.
REV.8/04

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
11/99
00800ARAILSAW
REPAIR TROUBLESHOOTING
1. SAW DOESN’T CUT RAIL FAST ENOUGH…
•CHECK FLOW UNDER LOAD. POWER SOURCE MUST MAINTAIN 10 GPM UNDER NOR-
MALLOAD.INSTALLFLOWMETERANDRESTRICTTOAPPROXIMATELY1500 PSI.FLOW
SHOULD BE 10 GPMAT1500 PSI WORKING PRESSURE.
•DETERMINETHATOPERATORIS USING SAW PROPERLY.THE SAW SHOULDBEOSCIL-
LATED BACKAND FORTH WHILE CUTTING. THE AVERAGE CUTTING TIME IS 1 - 2 MIN-
UTES FOR 132 LB RAIL.
•THE PROPER RPM OF THE MATWELD SAW IS 3200 ( +100) RPM AT 10 GPM.
•THE SAW RPM IS APROPORTIONAL TO THE FLOW PROVIDED. IF THE FLOW DROPS
TO 8 GPM THE RPM OFTHE SAW WILL BE 2400 RPM, MUCH TOO SLOW FOR CUTTING
RAIL.IFTHEFLOWIS INCREASEDTO18GPMTHE SAW RPMWILLBE5500RPM.PROPER
FLOW IS CRITICAL FOR PROPER OPERATION AND SAFETY OF THE OPERATOR. DE-
TERMINE IF THE POWER SOURCE IS DELIVERING THE PROPER FLOW AND RELIEF
PRESSURETOTHESAWANDALLOTHER SPEEDRELATEDTOOLSBYCHECKINGFLOW
WITHAFLOWGAUGE.(MATWELDPARTNUMBER03600–FLOWANDPRESSUREGAUGE,
OREQUIVALENT).
2. THE SAW CUTS CROOKED…
•PLAYINANY OF THE CONNECTIONS ON CLAMPARM.
•BAD,GLAZED, ORDEFECTIVE BLADES.
•LOWFLOW REDUCINGSAWRPM.
•LOOSEARBOR ONSAWMOTOR.
•LOOSEBLADE FLANGES.
•BENT SAW FRAME BETWEENMOTORAND PIVOTPOINT.
•UNTRAINEDOPERATOR
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