PANDROL 05100B User manual

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
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OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021
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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
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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.
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• 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.
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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.
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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)
or
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.
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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.
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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
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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