Matweld 03900A User manual

03900A
REVERSING RAILSAW
Accessories:
00897 - 14” saw blades
00899 - 16” saw blades
632South3rdStreet
P.O.Box2816•Paducah,KY 42002
270-444-0085
Fax: [phone]
Website:www.matweld.com
Email:[email protected]
The Matweld Reversing Rail Saw
is a hydraulic powered abrasive rail
saw that can cut rail from either side
of the rail safely without disconnect-
ing or realignment. Simply pivoting
the saw to the other side of the rail
gives this saw flexibility and ensur-
ing safety that is needed on track.
B
C
A
MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
FLOW PRESSURE RPM DIMENSIONS WEIGHT
10 gpm 2000 psi 3200 A - 36" SAW
(38 lpm) (140 bar) B - 10" 38 lbs. (17kg)
C - 17"
CLAMP
CLAMP 20 lbs. (9 kg)
L36" x W8" x H11"
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
9/99 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.
9/99
GENERAL SAFETY PRECAUTIONS:
TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLYWITH THE
SAFETY PRECAUTIONS GIVEN IN THIS MANUAL, AND WITH ALL STICKERS AND TAGS AT-
TACHED TO THE TOOLAND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY.
READ TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERATION INSTRUC-
TIONS BEFORE YOU USE OR MAINTAIN THE TOOL. REVIEW THE MANUAL DAILYBEFORE US-
ING THE TOOL. IN ADDITION, FOLLOW ALL SAFETY GUIDELINES GIVEN YOU BY YOUR SU-
PERVISOR. 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
RESULTIN PERSONAL INJURYOR EQUIPMENT DAMAGE.
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
CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOL’S SUITABILITY FOR APARTICU-
LAR FUNCTION. DURING USE OF TOOL, GOOD JUDGEMENT MUST BE USED TO WORK SAFELY
AND EFFICIENTLYWITHOUT ENDANGERING THEMSELVES OR BYSTANDERS. UNDERSTAND-
ING OF THE OPERATION AND MAINTENANCE MANUAL IS ESSENTIAL FOR ANYONE USING
OR MAINTAINING THE TOOL.
•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 FLOW AND PRESSURE ARE
AVAILABLE. NEVER EXCEED FLOWS OR PRESSURES FOR THE TOOL BEING USED. PER-
SONAL INJURYOR 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 UN-
SAFE GRADES, POOR FOOTING AREAS AND OVERHEAD HAZARDS.
•MAINTAIN BALANCE AND PROPER FOOTING AT ALL TIMES. NEVER OVERREACH TO THE
EXTENT THAT A BROKEN PARTOR SUDDEN MOVEMENT OF THE TOOL CAN CAUSE YOU
TO LOSE YOUR BALANCE AND 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.
9/99
•WHEN WORKING NEAR ELECTRICAL CONDUCTORS, ALWAYS ASSUME THAT THE CON-
DUCTORS ARE ENERGIZED AND THATHOSES AND CLOTHING CAN CONDUCT HARMFUL
ELECTRICITY. USE HOSES LABELED AND CERTIFIED AS NON-CONDUCTIVE.
•DO NOT OPERATE THE TOOL AT EXCESSIVE FLUID TEMPERATURES OPERATOR DIS-
COMFORT AND POTENTIAL BURNS CAN RESULT AT HIGH OIL TEMPERATURES.
•NEVER WEAR LOOSE CLOTHING THATCAN 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 EXERTHIGH TORQUE AND
FORCE AND CAN CAUSE SERIOUS INJURYOR DEATH IF IMPROPERLYUSED.
•TO AVOID PERSONAL INJURYOR EQUIPMENT DAMAGE, ALL TOOL REPAIR, MAINTENANCE
OR SERVICE MUST ONLYBE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED
PERSONNEL.
•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.
•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 ACONDITION 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. IMMEDIATELYREPLACE ANY DAMAGED HOSES,
FITTINGS, OR OTHER COMPONENTS SHOWING WIRE BRAID, NICKS, CUTS, DAMAGE OR
ABRASIONS. FAILURE TO DO SO MAYRESULTIN EQUIPMENT DAMAGE AND / OR PER-
SONAL INJURYOR DEATH.
•CLEAN UP ANY OIL OR FLUID SPILLS IMMEDIATELY.
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
9/99
HAVE SUPERVISOR ADD ADDITIONAL PRECAUTIONS RELATING TO THE SPECIFIC
WORK AREA AND 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.
9/99
03900A REVERSING RAIL SAW
SAFETY PRECAUTIONS:
1. ALWAYS WEAR PROTECTIVE EQUIPMENT SUCH AS GLOVES, SAFETY GLASSES, EAR
PROTECTION AND SAFETY SHOES.
2. DO NOT WEAR CLOTHING WHICH MAYBECOME ENTANGLED IN THE TOOL.
3. ALWAYS KEEP WORK AREA FREE OF TOOLS OR ANY OTHER OBJECTS
WHICH MAYIMPAIR SOUND FOOTING.
4. CAUTION OIL INJECTION HAZARD EXISTS WITH THIS TOOL. OIL INJECTION IS ACONDI-
TION WHERE THE HYDRAULIC OIL IS FORCED UNDER THE SKIN THROUGH PRESSURE
IN THE LINE. ALWAYS WEAR GLOVES, DO NOT CARRY THE TOOL BY HYDRAULIC HOSES,
AND REPAIR LEAKS IMMEDIATELY.
5. NEVER USE THE RAIL SAW AS AFREE 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 STOP A MOVING BLADE.
9. ALWAYS CHECK THE WORK AREA FOR ANY TRASH WHICH MAYIGNITE FROM SPARKS.
10. ALWAYS CHECK THE AREA FOR SMOLDERING TIES OR TRASH BEFORE LEAVING THE
SITE.
11. ALWAYS KEEP A FIRM GRASP ON THE SAW, WITH BOTH HANDS, AT ALL TIMES.
12. WHEN CHANGING BLADES, FOLLOW ALL BLADE MANUFACTURERS INSTRUCTIONS FOR
SAFETY AND OPERATION. USE ONLYBLADES THATCOMPLYWITH ANSI STANDARDS.
BEFORE USING, RUN NEW SAW BLADE FOR ONE MINUTE AT FULL SPEED TO CHECK
FOR DEFECTS OR VIBRATION.
13. NEVER LET THE SAW BLADE CUT INTO ANY MATERIAL (TIE, BALLAST, ETC…) OTHER
THAN THE RAIL BEING CUT
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
9/99
03900A REVERSING RAIL SAW
14. MOST HYDRAULIC OILS HAVE AFLASHPOINT OF APPROXIMATELY450 DEGREES (F). MAKE
SURE HOSES ARE COMPLETELYCLEAR OF SPARKS AND HOT DEBRIS. HAVE AN-OTHER
PERSON STAND CLOSE TO HYDRAULIC POWER SOURCE CONTROLS TO OBSERVE OP-
ERATION AND FOR EMERGENCY SHUTDOWN IF NECESSARY
15. IF THE BLADE STOPS DURING THE CUTTING PROCESS DUE TO RAIL BIND OR OTHER
PROBLEM, IMMEDIATELY TURN OFF THE POWER SOURCE AND 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.
9/99
03900A REVERSING RAIL SAW
FLOW:10 GPM (38 LPM)
PRESSURE: 2000 PSI (140 BAR)
BACK PRESSURE: MAX 250 PSI
RPM: 3200
OPERATION:
1.POSITION SAW CLAMP SQUARELYON RAIL AND TIGHTEN.
2. ATTACH THE RAIL SAW TO THE CLAMP ASSEMBLY AND 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 AREA IN SUCH AWAY TO RELIEVE STRESS ON THE HOSE AND QUICK DIS-
CONNECT FITTINGS WHILE WORKING. BE AWARE OF HOSE LOCATION AT ALL TIMES.
KEEP HOSES CLEAR 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 BLADE FOR ONE MINUTE AT FULL SPEED TO CHECK
FOR DEFECTS OR VIBRATION BEFORE TOUCHING RAIL. THE SAW IS DESIGNED TO
THROW SPARKS AWAY FROM THE OPERATOR.
6. KEEP THE SAW OSCILLATING WHILE MAKING THE CUT. THIS WILL REDUCE GLAZING
AND CUTTING TIME.
7. THE OPERATOR CAN STARTFROM EITHER SIDE OF THE RAIL OR ROTATE TO THE OPPO-
SITE SIDE OF THE RAIL TO COMPLETE THE CUT. TO ROTATE THE SAW, RELEASE THE
TRIGGER TO STOP THE SAW AND WITHOUT MOVING THE CLAMP SIMPLYPIVOT THE
SAW OVER AND MOVE TO THE OPPOSITE SIDE OF THE RAIL. YOUR SAWING POSITION
WILL CHANGE BUT IT IS DESIGNED SO THAT YOU WILL STILL BE PULLING UP ON THE
TRIGGER TO RESUME CUTTING. KEEP CLEAR OF THE TRIGGER AND 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.
9/99
03900A REVERSING 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 HTMA SPECIFICATION 5.7, THE HYDRAULIC
FLUID SHOULD HAVE AVISCOSITY BETWEEN 100 AND 400 SSU (20-82 CENTISTOKES) AT
THE MAXIMUM AND MINIMUM EXPECTED OPERATING TEMPERATURES. PETROLEUM BASED
HYDRAULIC FLUIDS WITH ANTI-WEAR PROPERTIES AND AVISCOSITY INDEX OF OVER 140
WORK FOR AWIDE RANGE OF OPERATING CONDITIONS.
THE FOLLOWING OILS MEET HTMA SPECIFICATION 5.7:
AMOCO RYKON MV CITGO A/W ALL TEMP
SUNVIS 706 MOBIL D.T.E. 13
CHEVRON EP-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. CONTACT MATWELD ON APERODIC BASIS, AT LEAST ANNUALLY, FOR SERVICE BULLE-
TINS, SAFETY NOTICES, OR OTHER IMPORTANT INFORMATION PERTAINING TO THIS TOOL.
7. APPLYGREASE TO DISCONNECT BOLT THREADS 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 ON ACLEAN WORK AREA, REMOVE THE ¾” JAM NUT, NYLON WASHER
AND THE OUTSIDE FLANGE. BE CAREFUL NOT TO MISPLACE THE NYLON WASHER. THIS
WASHER MUST BE ON FOR SAFE OPERATION. INSTALL NEW BLADE, OUTER FLANGE,
NYLON WASHER AND TIGHTEN JAM NUT.
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MATWELD, INC. PHONE:[phone] FAX:[phone]
Matweld reserves the right to change parts, features, or specifications without notice.
9/99
03900A REVERSING RAIL SAW
REPAIR TROUBLESHOOTING
1. SAW DOESN’T CUT RAIL FAST ENOUGH…
•CHECK FLOW UNDER LOAD. POWER SOURCE MUST MAINTAIN 10 GPM UNDER NOR-
MAL LOAD. INSTALL FLOW METER AND RESTRICT TO APPROXIMATELY1500 PSI. FLOW
SHOULD BE 10 GPM AT 1500 PSI WORKING PRESSURE.
•DETERMINE THATOPERATOR IS USING SAW PROPERLY. THE SAW SHOULD BE OS-
CILLATED BACK AND 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 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 CRITICAL FOR PROPER OPERATION AND SAFETY OF THE OPERATOR. DETER-
MINE IF THE POWER SOURCE IS DELIVERING THE PROPER FLOW AND RELIEF PRES-
SURE TO THE SAW AND ALL OTHER SPEED RELATED TOOLS BY CHECKING FLOW WITH
AFLOW GAUGE. (MATWELD PARTNUMBER 03600 – FLOW AND PRESSURE GAUGE, OR
EQUIVALENT).
2. THE SAW CUTS CROOKED…
•PLAYIN ANY OF THE CONNECTIONS ON CLAMP ARM.
•BAD, GLAZED, OR DEFECTIVE BLADES.
•LOW FLOW REDUCING SAW RPM.
•LOOSE ARBOR ON SAW MOTOR.
•LOOSE BLADE FLANGES.
•BENT SAW FRAME BETWEEN MOTOR AND PIVOT POINT.
•UNTRAINED OPERATOR
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