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Related Manuals for PANDROL Rosenqvist CD200
Summary of Contents for PANDROL Rosenqvist CD200
- Page 1 Operation & Maintenance Manual Rosenqvist CD200 Issue date:2016-11-11 Dokument ID:ENG_OMM_CD200 Revision:P05 Original instructions Pandrol AB, Hyggesvägen 4, 824 34 Hudiksvall, Sweden Phone +46 650-16505, www.rosenqvistrail.com, info.rosenqvistrail@pandrol.com...
- Page 2 2. …and then this… 3. …and finally this These actions must be done in the numerical order presented. REVISION NOTES Date Revision Notes 2016-06-23 New layout, updated information, new pictures, added E-CLIPS work head 2016-11-11 Added CD200 Electric © Pandrol AB 2/52...
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Page 3: Table Of Contents
Work Head Lifting Mechanism e-CLIPS 3.7.4 Hydraulic System e-CLIPS Transport and Parking Preparing for Transport or Storage Parking on the Track Parking Off-Track Installation on Track General On/Off Tracking 5.2.1 Off-tracking Using Emergency Handles Changing the Inclination © Pandrol AB 3/52... - Page 4 Clipping shoe rides over clip on one side The tools are stuck to the rail Maintenance General Maintenance Schedule Grease Points 9.3.1 FASTCLIP-equipped Machine 9.3.2 E-CLIPS-equipped Machine 10 Mounting Torque for Screws & Nuts Warranty and Service 11.1 Warranty 11.2 Service 11.3 Contact © Pandrol AB 4/52...
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Page 5: Safety Information
• The rail wheels are shorting the rails and the machine could therefore affect railway signals, e.g. crossings can be affected. National and local regulations are to be followed. © Pandrol AB 5/52... -
Page 6: Safety Equipment
• All personnel should be made aware of the contents of the product data sheets relating to the hydraulic oil used. • Pandrol AB recommends the use of biodegradable oils and greases, in order to minimize the environmental impact in case of an oil leakage. -
Page 7: General Warnings
• If electricity needs to be connected for testing purposes: keep hands, tools etc. away from all electrical parts. In any other case: 1. Shut off the vehicle engine 2. Disconnect the battery terminals © Pandrol AB 7/52... -
Page 8: Machine In Operation
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 AB. In order to avoid personal injury and/or material damage, everyone involved with assembling, starting-up or overhaul must possess relevant knowledge of the following •... -
Page 9: 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 AB. Read manual before use... -
Page 10: General Description
The Clip Driver CD200 is designed and manufactured for clipping and de-clipping PANDROL FASTCLIP and FASTCLIP FE, or PANDROL E-CLIP (depending on how the machine is equipped). Switching from clipping to de-clipping is easy since the Clip Driver CD200 uses the same head for both clipping and de-clipping and it is also easy to setup for different rail gauges and inclinations. -
Page 11: Technical Specifications
Double gear pump Max flow 27 l/min Max pressure 235 bar Hydraulic tank 8-9 litre volume Noise data Noise level, idle 71 dB(A) running Noise level, full 92 dB(A) speed Vibration data Clipping 4,3 m/s² De-clipping 3,15 m/s² © Pandrol AB 11/52... -
Page 12: Machine Components
The handle bar with the operator controls is also mounted on the Main Unit. Fig. 2 Fig. 3 Table 3 Item Description Item Description Working light Support leg Handle bar Control box Hydraulic tank Motor Engine Emergency stop button Accessory box © Pandrol AB 12/52... -
Page 13: Trolley
Fig. 4 Table 4 Item Description Item Description Wheel bracket Latch for slide carriage / Handle Slide bar Setting bolt for slide carriage locking Connection tray Slide carriage Lock pin for rotation © Pandrol AB 13/52... -
Page 14: Controls
WARNING! Do not operate the machine before performing the setup procedure. Fig. 5 Fig. 6 Table 5 Item Description Item Description Push button 1 Light switch Push button 2 Manual/auto switch Dead-mans-handle/sleeper lift function (7) Emergency stop button Extract/Install switch © Pandrol AB 14/52... -
Page 15: Controls Cd200 Electric
The electric cable connected to the machine must be assembled by an electrician and not be damaged in any way. The cable must be checked on a daily basis to ensure no damage is done. © Pandrol AB 15/52... - Page 16 (see chapter 6.1.3 for sleeper lifting procedure). The battery switch shall always be turned off when leaving the machine (see Fig. 8). Battery switch Fig. 8 © Pandrol AB 16/52...
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Page 17: Electrical System
The electrical system on the CD200 is robust and built with high quality components. It requires a minimum of maintenance and is well protected from wear and climate impact. Fig. 9 Table 7 Item Description Item Description Controls Valve connectors Work light Pressure sensor connectors Relay box Battery Battery switch Fuse 10A © Pandrol AB 17/52... -
Page 18: Fastclip-Equipped Machine
Work Head FC/FE The work head is designed to be able to both clip up and de-clip PANDROL FASTCLIP and FASTCLIP FE. It is adjustable to facilitate different rail sections (from S49 all the way up to 141 RE, rail heights from 149-189 mm). -
Page 19: Sleeper Lifter Fc/Fe
Fig. 11 Table 9 Item Description Item Description Height adjustment mechanism Jockey wheel Sleeper lift cylinder © Pandrol AB 19/52... -
Page 20: Hydraulic System Fc/Fe
Fig. 12 Table 10 Item Description Item Description Clipping/De-clipping cylinder Return filter Sleeper lifter cylinder Pump assembly Hydraulic fluid reservoir Valve block assembly Breather filter/ filler cap Drain plug © Pandrol AB 20/52... -
Page 21: E-Clips-Equipped Machine
The work head is designed to be able to both clip up and de-clip e-CLIPS. It is also designed to be able to work on rails with different rail heights. Fig. 13 Table 11 Item Description Item Description Parallel adjustment knob Double hook Tower Datum piece Frame Quick locking mechanism Indicator Height adjustment knob © Pandrol AB 21/52... -
Page 22: Indicator
It will then move back to the starting position and the cycle is complete. Fig. 14 Table 12 Item Description Item Description Indicator Install Mode Zone Extract Mode Zone Center mark © Pandrol AB 22/52... -
Page 23: Work Head Lifting Mechanism E-Clips
This mechanism is also used to adjust the machine to different rail heights and also to make sure the work head is parallel to the rail. Fig. 15 Table 13 Item Description Item Description Height adjustment knob Support wheel Lifting cylinder Parallelity adjustment knob © Pandrol AB 23/52... -
Page 24: Hydraulic System E-Clips
Hydraulic System e-CLIPS Schematic picture of the hydraulic system on an e-CLIPS equipped machine. The difference between FC/FE (see chapter 3.5.3) is four horizontal cylinders coupled in parallel that work in pairs. Clipping/de-clipping cylinder Fig. 16 © Pandrol AB 24/52... -
Page 25: Transport And Parking
When the CD200 is to be parked on track, the work head (see Fig. 18 for FC/FE and Fig. 19 for e-CLIP) has to rest with the shoes onto a sleeper or the ballast. This is to ensure that the machine does not fall over or run away along the track. Fig. 18 Fig. 19: © Pandrol AB 25/52... -
Page 26: Parking Off-Track
The support legs are secured with the locking pin in the lower position. Fig. 20: Parked off track (FC/FE work head) Fig. 21: Parked off track (E-CLIPS work head) Fig. 22: Support leg © Pandrol AB 26/52... -
Page 27: Installation On Track
2. Lift the trolley by the handles/latches and put the trolley on track and make sure it cannot run away. Secure the handle/latch to the slide carriage on the side that is to be worked on first. Handle Handle Fig. 23 © Pandrol AB 27/52... - Page 28 Only qualified personnel are allowed to operate the lifting machinery. • The lifting zone has to be clear when lifting is taking place. • Ground conditions, inclination etc. should be evaluated prior to lifting the machine to reduce the risk of rolling over. © Pandrol AB 28/52...
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Page 29: Off-Tracking Using Emergency Handles
1. Pull the locking pin up. 2. Pull the handle out until the locking pin lands in the next hole on the handle. 3. Lift the machine to a spot on a safe distance from the track. Fig. 27 Fig. 28 © Pandrol AB 29/52... -
Page 30: Changing The Inclination
2. Unscrew the four vertical bolts (3) and replace the inclination pieces on both sides (4). 3. Tighten the four vertical bolts (3), put the latch (2) back and tighten the horizontal bolt (1). Fig. 29 © Pandrol AB 30/52... -
Page 31: Changing Direction Of Operation
Consider this and make sure the change of direction is carried out within the safety zone, e.g. between the rails or on the side that is in the safety zone. © Pandrol AB 31/52... -
Page 32: Changing Rail Side Of Operation
2. Adjust the setting bolt until the desired latch locking force is obtained and there's no gap in between the setting bolt and the slide carriage. 3. Tighten the lock nut. Setting bolt Lock nut Fig. 33 © Pandrol AB 32/52... -
Page 33: Operation (Fastclip-Equipped Machine)
NOTE! The machine is NOT limited to the combinations stated in this table. These combinations are only examples. 2. Make sure the mechanical stops (3) for de-clipping are inactive, i.e. bolt pointing outwards on both sides. Fig. 35 © Pandrol AB 33/52... -
Page 34: Clipping Operation
Fig. 36 Fig. 37 After clipping the FASTCLIP shall be in the position recommended by Pandrol. Measure its position and check with prescription documentation from Pandrol Rail Fastenings Ltd. WARNING! To avoid injury, ensure the engine is turned off before adjusting anything on the machine. -
Page 35: Sleeper Lifting Operation
• check that the installed clips have not been damaged during installation and that they have been properly installed in accordance to recommendations from Pandrol UK Ltd © Pandrol AB 35/52... -
Page 36: Clipping
(2). Fig. 40 2. Make sure the mechanical stops (3) for de-clipping are active, i.e. bolt pointing inwards on both sides Fig. 41 © Pandrol AB 36/52... - Page 37 Open the arms by pushing the button on the right hand side. Adjust the four datum pieces by first opening the cam lever and then positioning the datum pieces for the current rail type. Fig. 44 © Pandrol AB 37/52...
- Page 38 2. Turn the rubber stop assembly around into the desired position (1). 3. Tighten the screws. Repeat the procedure on the other side of the work head. Fig. 45: Rubber stop set up for FASTCLIP FC Fig. 46: Rubber stop set up for FASTCLIP FE © Pandrol AB 38/52...
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Page 39: Clipping Operation
There are double pins on both sides of the fairing on the main unit. These can be used to store the work shoes not being used to make them easily and quickly accessible for use. Fig. 47: Storing shoes not being used © Pandrol AB 39/52... -
Page 40: Operation (E-Clips-Equipped Machine)
4. Tighten the cam levers (3). 5. Tune the height of the work head using the height adjustment knob (2). It is correctly adjusted when the double hook is 2-3 mm above the shoulder (see Fig. 50). Fig. 49 © Pandrol AB 40/52... -
Page 41: Adjusting The Sliding Plate
4. Tighten the locking nuts (3). 5. Tighten the hex head bolts (1). Repeat the procedure on the other side of the work head. Fig. 51 Table 15 Item Description Item Description Hex Head Bolt Locking Nut Adjustment Screw Sliding Plate © Pandrol AB 41/52... -
Page 42: Clipping
Fig. 53: The double hook installs the clip by pushing it into the correct position. Fig. 54: The clipping sequence finishes and the clip is installed. The double hook will now return to the starting position and the indicator will be back in INSTALL MODE ZONE. © Pandrol AB 42/52... -
Page 43: Clipping
Fig. 56: The double hook extracts the clip by pulling it out of the shoulder. Fig. 57: The de-clipping sequence finishes and the clip has been extracted. The double hook will now return to the starting position and the indicator will be back in EXTRACT MODE ZONE. © Pandrol AB 43/52... -
Page 44: Troubleshooting
Description Pressure switch for de-clipping function Pressure switch for clipping function Pressure reducing valve Pressure switch for sleeper lifting function WARNING! Hydraulic oil can cause dermatitis! Wear protective clothing and gloves when working with hydraulic systems © Pandrol AB 44/52... -
Page 45: Clips Are Being Installed Before Sleeper Is Fully Lifted
Pressure switch for clipping function may need to be adjusted. This adjustment should only be done after consulting a retailer or Rosenqvist Rail AB. 8.5 Clipping shoe rides over clip on one side Possible causes: • Inclination setting is wrong. Solution: • Set inclination according to chapter 5.3. © Pandrol AB 45/52... -
Page 46: The Tools Are Stuck To The Rail
This can and shall only be done with the machine turned off (hydraulics, electricity and engine) e.g. after using the emergency stop button. Emergency valve button Fig. 59 © Pandrol AB 46/52... -
Page 47: Maintenance
All adjustments work, overhaul and service must take place with the engine turned off, cooled down and with working tools disengaged. Failure to do so could lead to fatal injury. • It is of great importance that qualified personnel accomplish all service and overhaul © Pandrol AB 47/52... -
Page 48: Maintenance Schedule
At temperatures below 25 °C is oil of viscosity grade 46 recommended At temperatures above 25 °C is oil of viscosity grade 68 recommended It is very important that the service intervals are thoroughly followed to guarantee the safety and the performance of the machine © Pandrol AB 48/52... -
Page 49: Grease Points
Doc id: ENG_OMM_CD200_P05 9.3 Grease Points 9.3.1 FASTCLIP-equipped Machine Fig. 60: Grease points visible from the backside Fig. 61: Grease points visible from the side 9.3.2 E-CLIPS-equipped Machine The E-CLIPS work head does not have any grease points. © Pandrol AB 49/52... -
Page 50: Mounting Torque For Screws & Nuts
At Pandrol AB we mainly use steel screws and nuts. The table below shows the nominal tightening torque in Nm for the screws and nuts that are used... -
Page 51: Warranty And Service
11.2 Service Service is offered after the expiration of the warranty as well. Please contact Pandrol AB. 11.3 Contact Address... - Page 52 Pandrol AB, Hyggesvägen 4, 824 34 Hudiksvall, Sweden Phone +46 650-16505 www.rosenqvistrail.com info.rosenqvistrail@pandrol.com...
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