MODEL WS-00-60- WELD SHEAR HAND PUMP OPERATION, MAINTENANCE, AND REPAIR MANUAL 805 nd AVENUE NORTH * MOORHEAD, MN, USA 56560-30 PHONE (8) 36-03 * FAX (8) 33-58 E-MAIL ADDRESS; info@portaco.com * INTERNET ADDRESS: www.portaco.com
TABLE OF CONTENTS.0 Introduction. General Information. Features.3 Safety Summary. General Safety Precautions.5 Warning and Caution Statements.6 Training Requirements.0 Installation Instructions. Unpacking Instructions. Tool Preparations.3 Testing. Hydraulic Fluid Recommendations.5 Work Area Safety Precautions 3.0 Operating Instructions 3. Description of Power Unit 3. Controls and Graphics 3.3 Before Operating 3. Positioning on Rail 3.5 Operating Instructions 3.6 Storage Preparation.0 Maintenance Instructions. Assembly View and Parts List. Graphic Set Complete.3 Tool Maintenance. Trouble Shooting.5 Technical Specification
.0 INTRODUCTION. General Information This manual presents removal, operation, and maintenance information for PortaCo s model WS-00-60- Weld Shear Hand Pump version. The tool is designed to remove the excess material when performing Thermit and Buta type welds. It's light weight compact size allows for use inside rail pulling equipment. All hydraulic plumbing is protected by a one piece guard to prevent damage and to contain any leaks if any damage occurs. When properly used this tool will help reduce back strain and also reduce operator fatigue. PortaCo, Inc. reserves the right to make changes at anytime without notice and without incurring any obligation.. Features The main features of the PortaCo Weld Shear Model WS-00-60- are as follows. Standard unit: Length 6.38 in/ 67.0 cm Width 7.75 in/ 5. cm Height 8.57 in/.7 cm Weight 96-lbs/ 3.5 kg (includes blades) Upper ambient operating temperature 0 F (3 C), lower ambient operating temperature -0 F (-8 C). PortaCo, Inc.'s weld shear features a hand pump operating system which advances the cylinder in both stroke directions, with built in handle storage. A Figure.A A rotating control valve changes the direction of the cutting blades. (figure.a arrow A) The hydraulic plumbing is protected by a one-piece guard to prevent damage and to contain any leaks that occur. Roller hold-downs, provide a secure mount to the rail and allows smooth operation during the shearing process. The roller height is set with a jam nut providing a snug fit on any size rail. (figure.a arrow B) The roller assembly is easily removed for replacement of any component of the hold-down assembly. (figure.a arrow C) D Handles incorporated into the frame allow for even balance and level transportation for quick positioning on the rail. (figure.a arrow D) C B 3
.3 Safety Summary Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hoses. These safety precautions are given for your safety. Review them carefully before operating the tool and before performing maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.. General Safety Precautions The PortaCo Inc. tools are designed to provide safe and dependable service if operated according to the instructions provided in this manual. Read and understand this manual and any stickers attached to the power unit before operating. Failure to do so could result in personal injury or equipment damage. Check the rules and regulations at your location. The rules may include an employer s work safety program. Regulations may identify hazards such as working around utility supply lines or hazardous slopes. Read and understand any manuals for additional or optional equipment, which maybe shipped with the tool..5 Warning and Caution Statements or maintenance procedures, practices, or conditions considered essential for the protection of personnel, equipment, and property. WARNING: HIGHLIGHTS A, ESSENTIAL OPERATING, OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN INJURY TO, OR DEATH OF, PERSONNEL OR LONG TERM HEALTH HAZARDS. CAUTION: HIGHLIGHTS AN ESSENTIAL OPERATING OR MAINTENANCE PROCEDURE, PRACTICE, CONDITION STATEMENT, ETC. WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF, EQUIPMENT OR LOSS OF MISSION EFFECTIVENESS..6 Training Requirements Operator training for the weld shear should consist of information found in this manual. In addition the operator must receive instructions, both verbally and through demonstrations for applications in which the tool is going to be used. The new operator must start in an area without bystanders and use the tool until able to fully operate the tool under the conditions for the work area. Warning and Caution statements have been strategically placed throughout the text prior to operating
.0 INSTALLATION INSTRUCTIONS. Unpacking Instructions Upon receiving your weld shear promptly remove it from the shipping container. Always keep top side of container up. Inspect unit for damage which may have incurred during shipping and report it to carrier for claim.. Tool Preparations No preparation is required; the tool is ready to operate after it is removed from the shipping packaging..3 Testing WARNING: NEVER STICK FOREIGN OBJECTS, FINGERS, OR OTHER EXTRMITIES INTO MOVING MECHANISMS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY LEAD TO SEVERE PERSONAL INJURY OR TOOL DAMAGE. Before operating the weld shear it is important to inspect the shear blades for excessive wear or damage. Replace the shear blades if required before operating the shear. Follow all safety precautions and procedures when inspecting tool. CAUTION: THE PRESSURE TESTING PROCEDURE MUST BE CONDUCTED BY A QUALIFIED HYDRAULIC TECHNICIAN. To test the pressure exerted at the shear blades, remove the shear blades from the frame. Insert a pressure testing system between the frame and the ram end frame of the shear. PortaCo's Model TS-00-X-O Tester Shear, is recommended for this procedure. (see figure.3a) The model TS-00-X-O tester is capable of testing most shears. It features a pressure gauge with and arrow indicating the optimum force applied. Position tester while closing the shearing mechanism, aligning the pins in the frames with the holes in the tester; pump the handle to advance the cylinders until the needle, on the pressure gauge, of the tester stops climbing. The needle should be within 500 psi of the red arrow. (figure.3b) When testing follow the instructions provided with the test equipment. Testers other than PortaCo. Inc.'s model TS-00-XX-O may instruct the technician to perform the test in a manor slightly different than the procedure just described. Figure.3A 5
- Do not allow others to be near the tool when starting it or while operating. Keep bystanders and animals out of the work area. - Always wear safety goggles, ear, leg, and head protection devices, safety footwear, and snug fitting clothes. Figure.3B CAUTION: WHEN TESTING THE RAIL SHEAR, BE SURE TO FOLLOW ALL SAFETY GUIDELINES.. Hydraulic Fluid Recommendation Type Hydraulic fluid Chevron Clarity AW 503 Exxon Univis J 3 Mobil D.T.E. 3 M Gulf Harmony AW-HVI-50-3 Shell Tellus T 3 Texaco Rando HDZ 3 Union Unax AW-WR-3 Amsoil AWH 503 Sunvis Low Pour H/03-product code 9300.5 Work Area Safety Precautions - Never operate the tool when you are tired, angry, emotionally disturbed, or under the influence of alcohol, drugs, medications, or anything that could affect your vision, alertness, coordination or judgement. - Establish a training program for all operators to ensure safe operation. - Do not operate the tool near energized transmission lines. - Do not overreach. Maintain proper footing and balance at all times. - Be sure to keep hands and other parts clear and free from all moving parts. - Keep all body parts away from moving jaws. - Keep handles clean and dry. - Only a properly trained person should perform any maintenance, service, and or repairs to a tool. - Never operate a tool that is damaged, improperly adjusted, or not completely and securely assembled. - Do not operate the tool until you have a clear work area and a secure balance. - Do no operate the tool unless thoroughly trained or under the supervision of an instructor. 6
SAFETY REGULATION Enter below any local or other safety regulations required for the operator to follow. Make sure the operator and maintenance personnel have knowledge of these regulations. 7
3.0 Operating Instructions 3. Description of Power Tool PortaCo s model WS-00-60- Weld Shear is intended to be used to shear Thermit and Buta type welds. It's light-weight construction and auto cycle valve reduces operator fatigue. The PortaCo Weld Shear secures to the rail at four points. Adjustable roller hold downs provide a smooth shearing operation and guide the shear on worn rail. Hold down assemblies have been designed to be easily serviced in the field. Fully guarded hydraulic plumbing protects the operator from accidental leakage of oil onto the welded area, reducing the potential for a fire. A double acting hand pump extends and retracts the cylinders for faster travel rate. The cylinder direction is controlled with a direction selector valve. Follow the instructions "DO NOT OPERATE SHEAR WITHOUT SHIELD IN PLACE" and "DO NOT STRIKE HOLD DOWNS" printed on this decal. (figure 3.A) (figure 3.G arrow A). Figure 3.A The mounting instructions decal is also located on the guard cover. It states the correct procedure for adjusting the hold down rollers. It tells the operator to "ADJUST ROLLER CLEARANCE TO /8" BELOW BALL OF RAIL". (figure 3.B)(figure 3.G arrow B) 3. Controls and Graphics The following decals are placed on the tool to aid in its operation and maintenance. The operator should locate and understand them before using this power tool. The weld shear has five instructional decals located on the tool. The "WARNING' decal indicates a practice which if conducted could result in injury to the operator or bystander, or damage to the tool. Figure 3.B On the inside of the far side of the frame, is a serial # decal. This decal has the serial number as well as the model number of the unit. Each unit has it s own unique serial number. It 8
is important to keep this decal protected and kept legible. The serial number is needed when ordering replacement parts. (figure 3.C)(figure 3.H arrow C) Figure 3.E The open-close decal indicates weather the jaws will open or close when the pump is being operated. (Figure 3.F) (Figure 3.G arrow E) Figure 3.C The caution decal is located on the guard attached to the frame. (Figure 3.D) (Figure 3.G arrow D) F E G A B D Figure 3.G 3.3 Before Operating Figure 3.D The hydraulic oil decal highlights the oil reservoir. (Figure 3.E) (Figure 3.G arrow E) Check that the guard is in position and securely fastened, and in good condition. Inspect the weld shear for any hydraulic oil leaks and repair as required, Do Not operate the shear if a leak is present, hydraulic oil on the weld area is flammable. Inspect the hold down assemblies, make sure they all operate properly. Replace any damaged or severely worn components before operation. 9
Hold downs which aren't operating correctly may result in an inferior sheared weld. reservoir fill cap is located on top of the tool next to the hand pump. (Figure 3.G arrow G) Inspect the shear blades and replace if severely worn or damaged. CAUTION: WHEN FILLING THE OIL RESERVOIR BE SURE THE JAWS ARE IN THE FULL OPEN POSITION. OVER FILLING OF THE RESERVOIR COULD RESULT IN THE TOOL NOT OPERATING PROPERLY AND OIL BEING FORCE OUT CAP/PLUG. 3. Positioning on Rail BAD "REPLACE" Place the shear over the weld, centering the weld between the shearing blades. Turn the handle on all four rollers to position each roller under the rail. GOOD WARNING: NEVER INSPECT PRESSURIZED HOSES, COUPLERS, OR FITTINGS WITH HANDS OR AT CLOSE DISTANCES. PRESSURIZED FLUID CAN PUNCTURE THE SKIN AND INJECT OIL INTO THE BODY RESULTING IN DEATH. Adjust the roller clearance to /8" below the ball of the rail using the nut to maintain the clearance. Check the oil level in the reservoir, the oil should be just below the bottom of the plug/cap. Always check the level when the jaws are in the full open position. The oil 0
- Set the directional valve to the open position. (Figure 3.5A arrow B) ADJUSTMENT NUT - Pump the handle until the jaws are full open. - Turn the hold down handles to release the rail and remove the shear from the rail. /8" CLEARANCE B A 3.5 Operating Instructions - Set the directional valve to the close position. - Insert the jack handle into the pump receiver tube. (Figure 3.5A arrow A) - Pump the handle until the jaws are closed and the weld is sheared. 3.6 Storage Preparation Store the weld shear on a smooth level surface. The tool should be stored in a cool, dry environment which is not subjected to rapid temperature changes.
CAUTION: USE ONLY GENUINE PORTACO INC PARTS OR EQUIVALENT. THE USE OF REPLACEMENT PARTS WHICH ARE NOT OF EQUIVALENT QUALITY MAY DAMAGE THE HYDRAULIC POWER UNIT..0 Maintenance Instruction. Assembly View and Parts List ITEM 3 5 6 7 8 9 0 3 5 6 7 8 9 0 3 5 6 7 8 9 30 3 3 33 3 35 36 37 38 39 0 PART NO. 00-OOP 0-OOP 0-OOP 06-OSP 06-OOP 065-OOP -OOP 7-OOP 65-OOP 788-OOP 83-OOP 8-OOP 605-OOP 308-OOP 3395-OOP 37-OOP 35-OOP 358-OOP 3595-OOW 37-OOP 3779-OOP 398-OOP 77-OOP 78-OOD 80-OOW 8-OOP 8-OOP 8-OOD 85-OOP 86-OOP 88-OOW 89-OOW 505-OOW 5055-OOD 5056-OOP 5057-OOW 5058-OOW 5059-OOD 5060-OOP 506-OOP 06-OOP 78-OOP DESCRIPTION BOLT #0-3 X 3/ NUT JAM, / BOLT, /nc X 3/ NUT / nc NYLOCK LOCK WASHER / LOCK WASHER 7/6 BOLT,7/6nc X / NUT 0 X 3 WASHER, LOCK 0-3 FITTING #0-- PIN, SPRING.50 X.5 NUT 3/ nc FITTING BOLT /NCX3 FITTING 660-- FITTING #6500-- FITTING #6600-- PIN ROLL 3/8 X -/" PL BLADE COMP. 3 FITTING 90 VALVE HYDRAULIC PLUG / CAP CYLINDER HYDRAULIC RETAINER HYD. CYLINDER GUIDE RAM END BEARING NUT HALF 5/8", FINE THREAD SPACER WASHER FLAT 5/8"SAE WASHER LOCK STOP CYLINDER (R) STOP CYLINDER (L) TANK HYDRAULIC GUARD COVER CLIP HANDL HOLDER FRAME WELD SHEAR HAND PUMP HANDLE HOLD DOWN HP HOLD DOWN BOLT HAND PUMP FITTING -MP -MJ 5 NUT / FITTING QTY 7 7 5
3
. Graphic Set Complete (39-00D) 58-08D 378-0D 39-03D 58-00D 906-00D 39-0D 363-00D
.3 Care Requirements Maintenance CLEANING AND MAINTENANCE RECOMMENDATIONS Wipe all external surfaces after each use with a clean, lint free cloth to remove surface contaminants from the tool. Inspect the hold down assemblies for wear or damage and replace any components as necessary to maintain a good working condition. Hold down service kits: 6-9-OOK Roller bearing replacement kit Daily:. Wipe all tool surfaces, fittings, and coupling free of grease, dirt, and foreign materials. WARNING: DO NOT ATTEMPT TO LOCATE HYDRAULIC LEAKS BY FEELING AROUND HOSES AND FITTINGS WITH HANDS. PINHOLE LEAKS CAN PENETRATE THE SKIN.. Inspect the tool signs of leaks and worn, and/or damage couplers. Replace if necessary. 3. Inspect shear blades every day. Replace as required. 6-95-OOK Hold down bolt replacement kit Annually: Remove the hydraulic system guard and inspect fittings and tubing for damage and replace as required. NOTE: Do not attempt to repair this product. Only properly trained person should perform any maintenance, service, and or repair to a tool. COMPLETE DIASSEMBLY OF THE TOOL IS NOT RECOMMENDED. RETURN TO PORTACO, INC. FOR REPAIRS. Monthly: 5
. Trouble Shooting The following chart can be used as a guide to correct any problem you may experience with the tool. PROBLEM Shear binds or travels jerky. If blades move but not enough power to shear weld. Blades will not move. CAUSE Hold downs are too tight. REMEDY Adjust hold downs so rollers are /8" below the ball of the rail. Hold downs are damaged Check for damage to the hold down bolts or rollers. Replace if required. Air in system Run shear to full close and return to full open position. Inspect shear blades for Replace shear blades if wear or damage. required. Hydraulic system leak. Check system for leaks and repair as required. Leaky cylinder seal Perform test in section.3 of this manual. Control valve not in the Check that the control correct position. valve is in the open or close position. Check valve malfunction. Remove check valve and inspect for contamination. Replace if required. Make sure the control Shift control to the open valve is in the correct or close position until the position. handle hits the stops. Low oil level Check oil level and add as required. Hydraulic system leak. Check system for leaks and repair as required. NOTE: After reviewing trouble shooting chart and still unable to determine problem call the service department at PortaCo Inc. (8-36-03) for assistance. 6
.5 Technical Specifications 8. 57 Weld Shear with blades Max Pressure 96-lbs/3.5 kg 500 psi/7.5 bar Consumable Items List Description Shear Blade Kit Part Number 358-OOK Source PortaCo Inc. Recommend Hydraulic Fluids Type Chevron Exxon Mobil Gulf Shell Texaco Union Amsoil Sunvis Bolt Size #0-3 ¼-0 5/6-8 3/8-6 Hydraulic fluid Clarity AW ISO 3 Univis J 3 D.T.E. 3 M Harmony AW-HVI-50-3 Tellus T 3 Rando HDZ 3 Unax AW-WR-3 AWH ISO 3 Low Pour H/03-product code 93000 Torque 38 in. lbs. 76 in. lbs. 3 ft. lbs. 3 ft. lbs 7
SERVICE AND REPAIR NOTES 8