The Matweld Hand Pump Weld Shear is a self-contained hydraulic weld shear designed for cutting welds. It features adjustable, self-locking hold-downs that ensure a clean and safe cut. The average cycle time to shear a weld is between 30 and 45 seconds. This hand pump model can be converted to operate with a Matweld Power Unit with only minor modifications.
Technical Specifications:
- Model No.: 05000
- Pressure: 3000 psi (206 bar) for the hand pump, 2000 PSI (140 BAR) for operation.
- Dimensions: A - 29", B - 20", C - 13"
- Weight: 111 lbs (50.35 kg)
Accessories:
- 00965 - 115# Long Shear Blade
- 00999 - Hand Pump to Power Conversion Kit
- Other blades are available by special order; consult the factory.
General Safety Precautions:
Operators and maintenance personnel must always comply with the safety precautions outlined in the manual and on all stickers and tags attached to the tool and hose. It is crucial to read, understand, and follow all safety, maintenance, and operation instructions before using or maintaining the tool. The manual should be reviewed daily before use. Additionally, all safety guidelines provided by a supervisor must be followed. Failure to adhere to these instructions can result in personal injury or equipment damage.
Matweld emphasizes that it has no control over tool use or operation once it leaves the plant, nor over operator or maintainer selection. The customer is responsible for determining the tool's suitability for a particular function and for ensuring that anyone using or maintaining the tool is fit for the task, understands the operation and safety/maintenance manual, and possesses the intelligence to use good judgment to work safely and efficiently without endangering themselves or bystanders.
Key safety rules include:
- Do not operate the tool without thorough and proper training or supervision.
- Check the power source daily to ensure correct flow and pressure. Never exceed recommended flows or pressures to avoid personal injury or tool damage.
- Operators must clear the work area of non-essential personnel, as flying debris can cause serious injury.
- Familiarize yourself with all prohibited work areas, such as unsafe grades, poor footing, and overhead hazards.
- Maintain balance and proper footing at all times; avoid overreaching to prevent falls or injury from sudden tool movement or broken parts.
- When working near electrical conductors, assume they are energized and that hoses and clothing can conduct electricity. Use nonconductive hoses.
- Avoid operating the tool at excessive fluid temperatures, which can cause operator discomfort and burns.
- Never wear loose clothing that could get entangled in the tool's working parts. Hydraulic tools exert high torque and force, which can cause serious injury or death if improperly used.
- All tool repair, maintenance, or service must be performed only by authorized and properly trained personnel.
- Always wear appropriate safety equipment, including oil injection-resistant work gloves, safety glasses, safety boots, ear protection, and other apparel dictated by the job and supervisor.
- Never clean, inspect, or repair the tool while it is connected to the power source to prevent accidental engagement and serious personal injury.
- Be aware of oil injection hazards, where hydraulic oil can be injected under the skin from pressure. Always wear gloves and immediately repair any leaks. Never carry the tool by its hoses.
- Do not use damaged equipment. Immediately replace damaged hoses, fittings, or components showing wire braid, nicks, cuts, damage, or abrasions, as failure to do so can result in equipment damage, personal injury, or death.
- Clean up any oil or fluid spills immediately.
- Supervisors should add any additional precautions relevant to the specific work area and local safety regulations.
Specific Safety Precautions for 05000 Hand Pump Weld Shear:
- Always wear safety equipment such as gloves, safety glasses, ear protection, safety shoes, and other required safety equipment.
- Do not wear clothing that may become entangled in the tool.
- Keep hands clear of the work area at all times.
- Always keep the work area free of tools or any other objects that may impair sound footing.
- Due to 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 approximately 400°F. A leak directed into the weld area (1900°F) will cause a fire and possible serious injury or death.
- Always check the work area for any trash that might ignite from sparks, weld splatter, or slag.
- Always check the work area for smoldering ties or trash before leaving the site.
- Never strike hold-downs with any object to loosen the shear from the rail.
Operation:
- Place the shear on the rail before setting up the weld to adjust the hold-down legs. After adjusting the hold-down legs, remove the shear from the rail to prepare the weld.
- When the weld is ready to be cut, two people (one on each side of the shear) should carefully place the shear over the weld and lock it into place with the hold-down legs.
- To shear, rotate the valve handle clockwise to the stop position. With only one person operating the pump handle, pump the handle back and forth to close the blades. Immediately retract the blades after the cut to prolong blade life.
- To retract the blades, rotate the valve handle counterclockwise to the stop position and activate the handle back and forth. After the cut is made and the blades are retracted, return the valve to the center or "neutral" position.
- To remove the shear from the rail, loosen the hold-downs. Two people (one on each side of the shear) should carefully remove it from the rail.
Maintenance:
- As blades wear or when replacing them, the clearance gap between blade tips may require adjustment. This is done by removing the cylinder rod jam nuts at the rear of the shear. Loosen the cylinder rod adjusting nuts, and with the cylinder rods completely extended, set the gap at 1/32". Retighten the cylinder rod adjusting nuts, cycle the shear to check the gap dimension, and then reinstall and tighten the cylinder rod jam nuts.
- Inspect hoses daily. Replace any cut, burned, or otherwise damaged hoses.
- Keep quick disconnect couplers clean and lubricated.
- Use hydraulic fluids that comply with HTMA Specification 5.7. The hydraulic fluid should have a viscosity 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 a viscosity index over 140 are suitable for a wide range of operating conditions.
Recommended Oils (meeting HTMA Specification 5.7):
- AMOCO RYKON MV
- SUNVIS 706
- CHEVRON EP-MV
- CITGO A/W ALL TEMP
- MOBIL D.T.E. 13
- TEXACO "RANDO" HDAZ
Other fluids that meet or exceed this specification can be used.
- Have the tool inspected at least annually by Matweld or a Matweld-qualified service representative to determine if it needs safety changes or worn part replacement.
- Contact Matweld periodically, at least annually, for service bulletins, safety notices, or other important information regarding this tool.
Cold Weather Operation:
Hydraulic system performance is affected when the temperature drops below 50°F. Measures should be taken to pre-warm tools and fluids before operating.
Hydraulic Principles:
- Hydraulic Formulas:
- GPM = (CID x RPM) / 231
- HP = (GPM x PSI) / 1714 (0.85)
- Example: HP required to deliver 10 GPM at 1500 PSI = (10 GPM x 1500 PSI) / 1456.9 = 10.3 HP (subtract back pressure for tool HP).
- Back Pressure:
Back pressure measured at the tool return port must not exceed the manufacturer's back pressure rating (typically 250 PSI for most hydraulic tools). Back pressure is the force required to return oil to the tank. Lower back pressure generally improves tool performance. Back pressure is subtracted from the maximum tool pressure to determine the actual operating pressure. For instance, a 2000 PSI tool on a system with 250 PSI back pressure will operate at 1750 PSI. High back pressure (e.g., 500 PSI) would reduce the operating pressure to 1500 PSI, affecting performance and potentially blowing seals. It is critical to direct flow into the tool correctly; reversing hoses can blow seals, damage the tool, and cause personal injury.
Decal Legend:
- DCL-1007 (Matweld, Inc. PADUCAH, KY logo)
- DCL-1002 (WARNING - HIGH-PRESSURE FLUID HAZARD): To prevent serious injury or death: Relieve pressure on the system before repairing, adjusting, or disconnecting. Wear proper hand and eye protection when searching for leaks; use wood or cardboard instead of hands. Keep all components in good repair.
- DCL-1001 (WARNING): To prevent serious injury or death: Avoid unsafe operation or maintenance. Do not operate or work on this machine without reading and understanding the operator's manual. If the manual is lost, contact MATWELD INC. for a new manual.
- DCL-1027 (DANGER - KEEP HANDS AWAY)
- DCL-1078 (PROUDLY MADE IN USA)
Warranty:
Matweld, Inc. warrants to the original purchaser that this product will be free from defects in material and workmanship for one (1) year after delivery. Other equipment and parts not manufactured by Matweld Inc. are covered by their respective manufacturers' warranties. Proof of purchase, including the serial number, is required. The purchaser's sole remedies are repair, replacement, or refund of the purchase price of defective products, at Matweld's option. These remedies require timely notification of the defect and substantiation that the product was properly stored, maintained, and used. Matweld's obligations extend only to the purchaser.
Exclusions to Warranty:
The warranty is exclusive and in lieu of all other warranties, expressed or implied, including merchantability or fitness for a particular purpose. It does not cover normal wear and tear items such as filters, hoses, couplers, bits, sockets, augers, and batteries. The warranty is void if the product has been altered, modified without written approval, subjected to deliberate damage, shipping damage, neglect, tampering by unauthorized personnel, or damage from improper use, storage, or maintenance. Altered or defaced serial numbers also void the warranty.
Limitation of Liability:
Matweld is not liable for any injury, loss, or damage (direct, incidental, or consequential) arising from the use or misuse of the product, regardless of the cause or theory of liability (including breach of contract, tort, negligence, or strict liability), even if Matweld was aware of the possibility of such damage. Matweld's limited warranty will not be enlarged, diminished, or affected by technical advice or service from Matweld or its agents. The remedies stated are exclusive and cannot be changed except by written agreement signed by an authorized Matweld officer.
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