Matweld 03900A User manual

632South3rdStreet
P.O.Box2816•Paducah,KY42002
270-444-0085
Fax: [phone]
Website:www.matweld.com
Email:[email protected]
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
Accessories:
00897 - 14” saw blades
00899 - 16” saw blades
The Matweld Reversing Rail Saw is a
hydraulic powered abrasive rail saw
that can cut rail from either side of
the rail safely without disconnecting
or realignment; simply pivoting the
saw to the other side of the rail
provides the flexibility and safety that
is needed on track.
08/09
03900A
REVERSING RAIL SAW
FLOW
10 gpm
(38 lpm)
PRESSURE
2000 psi
(140 bar)
RPM
3200
DIMENSIONS
A-36”
B - 10”
C - 17”
CLAMP
L 36’ x W 8” x H 11”
WEIGHT
38 lbs
(17 kg)
CLAMP
20 lbs
(9 kg)
A
PT
C
B

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
GENERALNOTES:

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
GENERAL SAFETY PRECAUTIONS:
TOOL OPERATORSAND MAINTENANCE PERSONNELMUSTALWAYS COMPLYWITHTHE SAFETY
PRECAUTIONSGIVENINTHIS MANUAL,AND WITHALLSTICKERSANDTAGSATTACHED TOTHE
TOOLAND HOSE. ALLSAFETY PRECAUTIONSARE GIVEN FOR YOUR SAFETY. READ TO UNDER-
STANDAND FOLLOWALL SAFETY, MAINTENANCEAND OPERATION INSTRUCTIONS BEFORE YOU
USE OR MAINTAIN THETOOL. REVIEW THE MANUALDAILY BEFORE USINGTHE TOOL. INADDI-
TION, FOLLOWALLSAFETY GUIDELINES GIVEN YOU BY YOUR SUPERVISOR. DO NOT USE THE
TOOL IFYOU HAVEANYQUESTIONSABOUTTHE OPERATION, SAFETY OR MAINTENANCE OFTHIS
TOOL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONALINJURY OR
EQUIPMENTDAMAGE.
MATWELD HAS NO CONTROL OVER TOOL USE OR OPERATION ONCE IT LEAVES THE MATWELD
PLANT. MATWELD HAS NO CONTROL OVER OPERATOR OR MAINTAINER SELECTION. THE CUS-
TOMER MUSTASSUME RESPONSIBILITY FOR THETOOL’S SUITABILITY FORAPARTICULAR FUNC-
TION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORK SAFELY AND EFFI-
CIENTLYWITHOUTENDANGERINGTHEMSELVES OR BYSTANDERS. UNDERSTANDING OFTHE
OPERATIONAND MAINTENANCEMANUALISESSENTIALFORANYONE USINGORMAINTAININGTHE
TOOL.
• DO NOT OPERATE THE TOOL UNTILYOU HAVE BEEN THOROUGHLYAND PROPERLY TRAINED
OR UNDER THE SUPERVISION OFAN INSTRUCTOR.
• CHECK POWER SOURCE DAILY TO DETERMINE IF CORRECT FLOW AND PRESSURE ARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED. PER-
SONALINJURY OR DAMAGE TO THETOOLCAN RESULT.
• OPERATORS MUST CLEAR THE WORKAREAOF NONESSENTIAL PERSONNEL. FLYING DE-
BRISCANCAUSESERIOUSINJURY.
• THE OPERATOR MUSTBE FAMILIAR WITHALLPROHIBITED WORKAREAS SUCHAS UNSAFE
GRADES, POOR FOOTINGAREASAND OVERHEAD HAZARDS.
• MAINTAIN BALANCEAND PROPER FOOTINGATALLTIMES. NEVER OVERREACHTOTHE EX-
TENT THATABROKEN PART OR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU TO
LOSE YOUR BALANCEAND FALL, OR CAUSE INJURY TO YOUR SELF OR SOMEONE ELSE.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
• WHEN WORKING NEAR ELECTRICAL CONDUCTORS,ALWAYSASSUMETHAT THE CONDUC-
TORSARE ENERGIZEDAND THAT HOSESAND CLOTHING CAN CONDUCT HARMFULELECTRIC-
ITY. USE HOSES LABELEDAND CERTIFIEDAS NONCONDUCTIVE.
• DO NOT OPERATE THE TOOLAT EXCESSIVE FLUID TEMPERATURES OPERATOR DISCOM-
FORTAND POTENTIAL BURNS CAN RESULTAT HIGH OILTEMPERATURES.
• 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 WORK-
ING PARTS OF THE TOOLS. HYDRAULIC TOOLS EXERT HIGH TORQUEAND FORCEAND CAN
CAUSE SERIOUS INJURY OR DEATH IF IMPROPERLY USED.
• TOAVOID PERSONALINJURYOR EQUIPMENTDAMAGE,ALLTOOLREPAIR, MAINTENANCE OR
SERVICE MUST ONLY BE PERFORMED BYAUTHORIZEDAND PROPERLY TRAINED PERSON-
NEL.
• ALWAYS WEAR SAFETY EQUIPMENT SUCHAS OILINJECTION RESISTANT WORK GLOVES,
SAFETY GLASSES, SAFETY BOOTS, EAR PROTECTION AND OTHER SAFETYAPPAREL DIC-
TATED BY YOUR SUPERVISOR APPLICABLE FOR THE JOB YOU ARE DOING AND THE TOOL
YOUAREUSING.
• DO NOT CLEAN INSPECT OR REPAIR THE TOOL WHILE CONNECTED TO THE POWER
SOURCE.ACCIDENTALENGAGEMENT OFTHE TOOLCAN CAUSE SERIOUS PERSONALINJURY.
• OILINJECTIONHAZARDEXISTSWITHTHISTOOL. OILINJECTION ISACONDITION WHERE
HYDRAULIC OILIS INJECTED UNDER THE SKIN FROM PRESSURE IN THE LINE.ALWAYS WEAR
GLOVESAND REPAIRANY LEAKS IMMEDIATELY. NEVER CARRYATOOLBY THE HOSES.
• DONOTUSE DAMAGED EQUIPMENT.IMMEDIATELYREPLACEANYDAMAGEDHOSES,FITTINGS,
OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE ORABRASIONS.
FAILURETO DO SO MAY RESULT IN EQUIPMENTDAMAGEAND / OR PERSONALINJURY OR
DEATH.
• CLEANUPANYOILOR FLUID SPILLSIMMEDIATELY.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
HAVE SUPERVISORADDADDITIONALPRECAUTIONS RELATING TO THE SPECIFIC WORKAREAAND
LOCAL SAFETY REGULATIONS BELOW:
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCHAS GLOVES, SAFETY GLASSES, EAR PRO-
TECTIONAND SAFETY SHOES.
2. DO NOT WEAR CLOTHING WHICH MAY BECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORKAREA FREE OF TOOLS ORANY OTHER OBJECTS WHICH MAY IMPAIR
SOUND FOOTING.
4. CAUTION OILINJECTIONHAZARDEXISTSWITHTHISTOOL. OILINJECTIONISACONDITION
WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSURE IN THE LINE.
ALWAYS WEAR GLOVES, DO NOT CARRY THE TOOLBY HYDRAULIC HOSES, AND REPAIR
LEAKSIMMEDIATELY.
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 CARRY THE RAIL SAW WITH THE POWER SOURCE IN THE “ON” POSITION, TURN THE
POWER SOURCE “OFF”.
8. NEVER TOUCH OR TRY TO STOPAMOVING BLADE.
9. ALWAYS CHECK THE WORKAREAFORANYTRASH WHICH MAY IGNITE FROM SPARKS.
10. ALWAYS CHECK THEAREA FOR SMOLDERING TIES OR TRASH BEFORE LEAVING THE SITE.
11. ALWAYS KEEPA FIRM GRASPON THE SAW, WITH BOTH HANDS,ATALLTIMES.
12. WHEN CHANGING BLADES, FOLLOWALLBLADE MANUFACTURERS INSTRUCTIONS FOR
SAFETYAND OPERATION. USE ONLY BLADESTHAT COMPLY WITHANSI STANDARDS. BEFORE
USING, RUN NEW SAW BLADE FOR ONE MINUTE AT FULLSPEED TO CHECK FOR DEFECTS OR
VIBRATION.
13. NEVER LETTHE SAW BLADE CUT INTOANY MATERIAL (TIE, BALLAST, ETC…) OTHER THANTHE
RAILBEINGCUT.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
14. MOST HYDRAULIC OILS HAVEAFLASH POINT OFAPPROXIMATELY 450 DEGREES (F). MAKE
SURE HOSES ARE COMPLETELY CLEAR OF SPARKS AND HOT DEBRIS. HAVE ANOTHER
PERSON STAND CLOSE TO HYDRAULIC POWER SOURCE CONTROLS TO OBSERVE OPERA-
TIONAND FOR EMERGENCYSHUTDOWN IF NECESSARY
15. IF THE BLADE STOPS DURING THE CUTTING PROCESS DUE TO RAIL BIND OR OTHER PROB-
LEM, IMMEDIATELY TURN OFF THE POWER SOURCEAND DISCONNECT THE HOSES BEFORE
ATTEMPTING TO FREE THE BLADE. AFTER FREEING THE BLADE REPLACE IT WITH ANEW
BLADE BEFORE CONTINUING THE CUT.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
FLOW: 10 GPM (38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX250PSI
RPM: 3200
OPERATION:
1.POSITIONSAW CLAMPSQUARELYON RAILAND TIGHTEN.
2. ATTACH THE RAILSAW TOTHE CLAMP ASSEMBLYAND 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 THE WORK
AREAIN SUCHAWAY TO RELIEVE STRESS ON THE HOSEAND QUICK DISCONNECTFITTINGS
WHILE WORKING. BE AWARE OF HOSE LOCATION AT ALLTIMES. KEEP HOSES CLEAR OF
SPARKS.
4. TURN POWER SOURCE TO THE “ON” POSITION TO SUPPLY 10 GPM TO TOOL.
5. GRASP THE SAW FIRMLYAND PULL UP ON THE TRIGGER TO STARTTHE SAW BLADE ROTAT-
ING. BEFORE USING, RUN SAW BLADE FOR ONE MINUTEAT FULLSPEED TO CHECK FOR
DEFECTS OR VIBRATION BEFORE TOUCHING RAIL. THE SAW IS DESIGNED TO THROW
SPARKS AWAY FROM THE OPERATOR.
6. KEEPTHE SAW OSCILLATING WHILE MAKING THE CUT. THIS WILL REDUCE GLAZINGAND
CUTTINGTIME.
7. THE OPERATOR CAN START FROM EITHER SIDE OF THE RAIL OR ROTATE TO THE OPPOSITE
SIDE OF THE RAIL TO COMPLETE THE CUT. TO ROTATE THE SAW, RELEASE THE TRIGGER TO
STOP THE SAWAND WITHOUT MOVINGTHE CLAMPSIMPLY PIVOTTHE SAW OVERAND MOVE
TO THE OPPOSITE SIDE OF THE RAIL. YOUR SAWING POSITION WILL CHANGE BUT ITIS DE-
SIGNED SO THAT YOU WILLSTILLBE PULLING UP ON THE TRIGGER TO RESUME CUTTING.
KEEP CLEAR OF THE TRIGGERAND BLADE WHILE CHANGING POSITIONS. ENSURE HOSE IS
ROUTED AWAY FROM SPARKS.
8. AFTER FINISHING THE CUT, TURN THE POWER SOURCE “OFF” AND DISCONNECT HOSES
BEFORE ATTEMPTING TO REMOVE THE SAW.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
MAINTENANCE:
1. CHECK TOOL DAILY FOR 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. USEHYDRAULIC FLUIDSTHATCOMPLYWITHHTMASPECIFICATION5.7,THEHYDRAULICFLUID
SHOULD HAVEAVISCOSITYBETWEEN 100AND 400 SSU (20-82 CENTISTOKES)ATTHE MAXI-
MUMANDMINIMUMEXPECTEDOPERATINGTEMPERATURES.PETROLEUMBASEDHYDRAULIC
FLUIDS WITHANTI-WEAR PROPERTIES ANDAVISCOSITY INDEX OF OVER 140 WORK FORA
WIDE RANGE OF OPERATING CONDITIONS.
THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:
AMOCORYKONMV CITGOA/WALLTEMP
SUNVIS706 MOBILD.T.E.13
CHEVRONEP-MV TEXACO“RANDO”HDAZ
OTHER FLUIDS THAT MEET OR EXCEED THIS SPECIFICATION CAN BE USED.
*SEE COLD WEATHER OPERATION HYDRAULIC OIL NOTE.
5. HAVE TOOLINSPECTED, AT LEASTANNUALLY, BY MATWELD ORAMATWELD QUALIFIED SER-
VICE REPRESENTATIVE TO DETERMINE IF TOOLIS IN NEED OF SAFETY CHANGES OR WORN
PARTREPLACEMENT.
6. CONTACT MATWELD ONAPERIODIC BASIS,AT LEASTANNUALLY, FOR SERVICE BULLETINS,
SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THISTOOL.
7. APPLY GREASE TO DISCONNECT BOLTTHREADS WEEKLY.
CHANGING BLADES:
1. TURN POWER SOURCE “OFF” AND DISCONNECT HOSES FROM TOOL.
2. WITH THE POWER SOURCE OFF, HOSES DISCONNECTED, SAW BLADE ELEVATED ABOVE
THE GROUND OR ONACLEAN WORKAREA, REMOVETHE ¾” JAM NUT, NYLON WASHERAND
THE OUTSIDE FLANGE. BE CAREFULNOTTO MISPLACE THE NYLON WASHER. THIS WASHER
MUST BE ON FOR SAFE OPERATION. INSTALL NEW BLADE, OUTER FLANGE, NYLON WASHER
ANDTIGHTEN JAMNUT.

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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice. 08/09
03900AREVERSING RAIL SAW
REPAIR TROUBLESHOOTING:
1. SAW DOESN’T CUT RAIL FAST ENOUGH:
• CHECK FLOW UNDER LOAD. POWER SOURCE MUST MAINTAIN 10 GPM UNDER NORMAL
LOAD. INSTALL FLOW METERAND RESTRICTTO APPROXIMATELY 1500 PSI. FLOW SHOULD BE
10 GPMAT 1500 PSI WORKING PRESSURE.
• DETERMINE THAT OPERATOR IS USING SAW PROPERLY. THE SAW SHOULD BE OSCIL-
LATED BACKAND FORTH WHILE CUTTING. THEAVERAGE CUTTINGTIME IS 1 - 2 MINUTES FOR
132LBRAIL.
• THE PROPER RPM OF THE MATWELD SAW IS 3200 ( + 100) RPM AT 10 GPM.
• THE SAW RPM IS PROPORTIONAL TO THE FLOW PROVIDED. IF THE FLOW DROPS TO 8
GPM THE RPM OF THE SAW WILL BE 2400 RPM, MUCH TOO SLOW FOR CUTTING RAIL. IF THE
FLOW IS INCREASED TO 18 GPM THE SAW RPM WILL BE 5500 RPM. PROPER FLOW IS CRITI-
CAL FOR PROPER OPERATION AND SAFETY OF THE OPERATOR. DETERMINE IF THE POWER
SOURCE IS DELIVERING THE PROPER FLOWAND RELIEF PRESSURE TO THE SAW AND ALL
OTHER SPEED RELATED TOOLS BY CHECKING FLOW WITH A FLOW GAUGE. (MATWELD PART
NUMBER 03600 – FLOWAND PRESSURE GAUGE, OR EQUIVALENT).
2. THE SAW CUTS CROOKED:
•PLAYINANYOF THE CONNECTIONS ON CLAMPARM.
•BAD, GLAZED, OR DEFECTIVE BLADES.
•LOW FLOW REDUCING SAW RPM.
•LOOSE ARBOR ON SAW MOTOR.
•LOOSE BLADE FLANGES.
•BENT SAW FRAME BETWEEN MOTORAND PIVOT POINT.
•UNTRAINED OPERATOR