Summary of Contents for PANDROL 05100B
- Page 1 Light Weight Weld Shear MODEL 05100B OPERATION AND MAINTENANCE MANUAL ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 15th November 2021 Partners in excellence...
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Page 2: Preface
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 specifications, equipment, instructions and maintenance guidelines without prior notice. -
Page 3: Table Of Contents
Review of hydraulic principles Maintenance 7.1. General 7.2. Warning labels and information symbols Limited warranty 8.1. Exclusions to limited warranty 8.2. Limitation of liability Customer information 10. Assembly 10.1. Parts diagram 10.2. Parts list Disclaimer Contact 13. Recycling and Environment OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 3 av 19... -
Page 4: Safety Information
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 efficiently 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 qualified personnel, well-informed and educated in general railway workmanship and specifically in the conditions, standards and regulations on specific rail track. • The machine may only be used for its specified purpose. • Any adjustments or service on the machine is only allowed to be done by qualified personnel that have read and understood this manual and have had training and information from Pandrol. 3.2. Safety actions •... -
Page 5: Personal/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 field weld temperatures, it is extremely important to check for worn hoses, nicks, cuts, and/or leaks before each shear operation. Hydraulic oil has a flash point of approx. 400 Degree F. A leak directed into the weld area (1900°F) will cause a fire 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. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 5 av 19... -
Page 6: Qualified Personnel
3.5. Qualified 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 modified 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. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 6 av 19... -
Page 7: Summary
The Pandrol Weld Shear is lightweight and highly efficient. Spring centered flow 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 fittings and hoses. The adjustable hold downs are self locking and will assure a safe clean cut. Fig 1. Fig 2. Fig 3. Flow Pressure Dimensions Weight 5 GPM (19 LPM) 2000 PSI (140 BAR) A - 28 - 5/8" (72.7 cm) 92 lbs (41.73 kg) B - 18 - 3/4" (47.6 cm) 10 GPM (38 LPM) C - 15" (38.1 cm) OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 7 av 19... -
Page 8: Operation
Oil temperature can effect stroke time. Make sure oil temperature is at least 80°F / 27°C to achieve proper performance of weld shear cycle time. • 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. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 8 av 19... -
Page 9: Blade Wear
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 affected when the temperature drops below 50°F. Therefore, measures should be taken to pre-warm tools and fluids before operating. NOTE! • Refer to operating procedures of this manual before starting OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 9 av 19... -
Page 10: Review Of Hydraulic Principles
8.58 10.30 3.43 6.86 10.30 13.70 17.20 20.60 5.15 10.30 15.40 20.60 25.70 30.90 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 effected, but seals may blow. This is why it is very important to direct the flow into the tool correctly. Reversing the hoses to test may result in blown seals, damage to the tool, and personal injury. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 10 av 19... -
Page 11: Maintenance
7.1. General Maintenance and overhaul is to be carried out by qualified personnel only Warranty is based on parts and spares delivered by Pandrol. Check tools DAILY for proper operation, leaks, or damage. Inspect hoses DAILY. Replace cut, burned, or otherwise damaged hoses. -
Page 12: Warning Labels And Information Symbols
7.2. Warning labels and information symbols Below are examples of warning labels and information symbols on the machine. If any of these labels become damaged or lost, they are to be replaced with new original warning labels that are available from Pandrol. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 12 av 19... -
Page 13: Limited Warranty
As a condition precedent to Pandrol’s obligation hereunder, the defective product must not have been altered or modified without the express written approval of Pandrol. The product must not have been subjected to deliberate damage, shipping damage, neglect, tampering by unauthorized personnel or damage by improper use, storage or maintenance. Serial numbers must not have been altered, defaced or removed. Such action voids limited warranty. 8.1. Exclusions to limited warranty This limited warranty is exclusive and is in lieu of any other warranty, written or oral, expressed or implied, including, without limitation, any implied warranty or merchantability or fitness for a particular purpose. Limited warranty does not cover normal wear and tear items such as filters, hoses, couplers, bits, sockets, augers, and batteries 8.2. Limitation of liability Except as provided above, Pandrol shall in no event be liable or responsible for any injury, loss or damage, direct, incidental or consequential, arising out of the use or misuse or inability to use the product, however caused and on any theory of liability including, without limitations, breach of contract, tort, (including negligence or street liability) and not withstanding any failure of any remedy herein of its essential purpose, even if Pandrol was aware of this possibility of such damage. Pandrol’s limited warranty as set forth above shall not be enlarged, diminished or affected by, and no obligation or liability shall arise or go out of the rendering of technical advice or service by Pandrol or its agents. The foregoing may not be changed except by written agreement signed by an authorized officer of Pandrol, the remedies set forth herein are exclusive. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 13 av 19... -
Page 14: Customer Information
9. Customer information Name Company Serial # of your Pandrol tool Upon receiving your Pandrol tool, make sure to list serial number above so that a good record is kept for order information. Pandrol hydraulic tool list All Pandrol Hydraulic Tools operate at 5 GPM (19 LPM) or 10 GPM (38 LPM) @ 2000 PSI (140 BAR) Power units: 00100K – Gasoline powered (1) 10 GPM or (2) 5 GPM circuits... - Page 15 Track tools: 03900A – Reversing rail saw 05100A & 05100B – Power weld shear 03500 – Self feed rail drill 04500D – 1/2” Hydraulic drill impact wrench 08200 – Tamper 02800A – 60 Ton bridge spreader 01200 – Spring anchor applicator 01100A – Spike puller (Single, 2 stage & trigger versions available) 00800A – 16” Rail saw 05000 – Hand pump weld shear 02500 – 10 GPM 1” Impact wrench 08300 – Spike driver 01600A – 5 GPM 1” Impact wrench 01100RM – Light-weight spike puller Other products: Hydraulic manifolds Hydraulic test gauges Hose reels Hydraulic hoses Accessories Drill bits Shear Blades Saw Blades Grinding Stones Sockets OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021...
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Page 16: Assembly
10. Assembly 10.1. Parts Diagram OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 16 av 19... -
Page 17: Parts List
10.2. Parts List OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 17 av 19... -
Page 18: Disclaimer
11. Disclaimer Pandrol exempts itself from liability in the event of usage that deviates from that recommended in this manual. 12. Contact Address Phone Internet and E-mail www.Pandrol.com 13. Recycling and Environment Sustainable environment is a great part of Pandrol. All components of the product can either be: • Recycled • Taken care of • Be re-used We recommend you to follow your local region regulations of environmental and recycling policies. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_LIGHT_WEIGHT_WELD_SHEAR_P01 I 15th November 2021 @Pandrol 2021 18 av 19... - Page 19 Find out more at pandrol.com Pandrol ©Pandrol Partners in excellence...