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PANDROL CD200 IQ Operation And Maintenance Manual

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CD200 IQ
OPERATION AND MAINTENANCE
MANUAL
ENG_OMM_CD200IQ_P03
11 February 2022
Partners in excellence

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Table of Contents
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Summary of Contents for PANDROL CD200 IQ

  • Page 1 CD200 IQ OPERATION AND MAINTENANCE MANUAL ENG_OMM_CD200IQ_P03 11 February 2022 Partners in excellence...

  • Page 2: Table Of Contents

    Table of contents Review of maintenance plan ................6 Introduction ......................7 General .............................7 New version/manual .........................8 Safety Actions Prior to Working on the CD200 IQ ..............9 2.3.1 Safety Equipment ........................10 2.3.2 Control System ..........................10 Safety warnings ........................11 2.4.1 Moving Parts ..........................11 2.4.2 Pressurised Hydraulic Oil ......................11...
  • Page 3 Clipping ..........................55 8.1.1 Settings Before Clipping ......................55 Clipping Operation ........................56 Sleeper Lifting Operation ......................57 De-clipping ..........................58 8.4.1 Settings Before De-clipping .......................58 8.4.2 De-clipping Operation ........................61 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 3 av 118...
  • Page 4 CH06C Tighten bolts – Check .......................78 CH07L Lubrication, tool .........................79 REMARK: e-Clip too has no lubrication points/grease nipples............79 CH08C FE/FC tool – Check ........................80 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 4 av 118 @Pandrol 2022...
  • Page 5 MI03C Function check – Check ......................112 MI04W Washing ..........................113 A – exam check list ..........................114 B – exam check list ..........................115 C–exam check list ..........................116 C–exam check list ..........................117 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 5 av 118...

  • Page 6: Review Of Maintenance Plan

    The users of the maintenance plan are encouraged to contribute to the review process. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 6 av 118 @Pandrol 2022...

  • Page 7: Introduction

    It is recommended that maintenance/overhaul is performed by qualified personnel from Pandrol AB or personnel that have been trained by Pandrol AB. The manual referrers to a fully equipped CD200 IQ, some of the tools are optional and this particular machine may miss a few of the features.

  • Page 8: New Version/Manual

    DATE COMMENTS REVIEWED 05-11-20 Lena Sohlin New manual 02-12-20 Lena Sohlin Updated to Pandrol graphic 11-02-22 Lena Sohlin Uppdated with offset workhead FC Authored by: Lena Sohlin, Technical Communications Officer, Equipment & Control. Reviewed by: Approved by: OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022...

  • Page 9: Safety Actions Prior To Working On The Cd200 Iq

    • Make sure that no unauthorized persons are located within the operating area during installation, use or maintenance. • Safety regulations regarding authorized personnel within the operating area of the CD200 IQ are valid for this attachment. • Improper operation and maintenance of this equipment can be dangerous and could result in personnel injury.

  • Page 10: Safety Equipment

    Emergency stop button 2.3.2 Control System The control system of the CD200 IQ is configured to avoid simultaneous operations that could cause damage to the vehicle or equipment or injury of personnel. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022...

  • Page 11: Safety Warnings

    In an emergency the machine could be manhandled off the track as a whole unit (poerpack/tool) by 8 people. In the event of lifting equipment failure ONLY it can be broken down into modules. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 11 av 118...

  • Page 12: Safety Conditions

    2.6 Personal Protective Equipment (PPE) Items of PPE provided for maintenance tasks must be worn as appropriate. These include: • Safety Boots • Hard Hats • Safety Glasses OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 12 av 118 @Pandrol 2022...

  • Page 13: Battery Precautions

    • If any components on the following systems have been disturbed, a functional test MUST be carried out on the relevant system AFTER ALL work is completed and BEFORE the unit is returned to service: Braking Equipment Rail Guidance OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 13 av 118...

  • Page 14: Minimum Facilities

    2.10 Competence Staff competence Work on the CD200 IQ 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 and only on specified rail types.

  • Page 15: General Description

    The Clip Driver CD200 IQ is rapid and easy to use and it is ergonomically operated by one single operator. The Clip Driver CD200 IQ can clip on both rails by sliding the unit from one side to the other. The clipping capacity is up to 30 sleepers per minute.

  • Page 16: Technical Specifications

    3.3 Technical Specifications Fastclip 5014300 Fastclip 5014853 (Briggs & Stratton) CD200 IQ e-Clip 5014699 (Honda) Measurements Length 2202 mm Height fastclip 1142 mm / e-CLIP 1103 mm Width 2111 mm Weight Power pack 103 kg Weight Trolley 54 kg Weight Tool, Fastclip...

  • Page 17: Drawings Fastclip

    3.4 Drawings Fastclip Figure 5. 1410 mm (gauge 1435) 2111 mm Figure 6. Figure 7. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 17 av 118...

  • Page 18: Plant Gauge Fastclip

    3.5 Plant gauge Fastclip Figure 9. Figure 8. 3.6 W6a gauge Fastclip Figure 11. Figure 10. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 18 av 118 @Pandrol 2022...

  • Page 19: Drawings E-Clip

    3.7 Drawings e-CLIP Figure 12. 2111 mm 1410 mm (gauge 1435) Figure 13. Figure 14. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 19 av 118...

  • Page 20: Plant Gauge E-Clip

    3.8 Plant gauge e-CLIP Figure 16. Figure 15. 3.9 W6a gauge e-CLIP Figure 18. Figure 17. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 20 av 118 @Pandrol 2022...

  • Page 21: Machine Component

    4.1 Main Unit The Main Unit is the heart of CD200 IQ. It contains the engine, all central hydraulic components such as pump, block and valves and almost all electronics. The handle bar with the operator controls is also mounted on the Main Unit.

  • Page 22: Trolley

    4.2 Trolley The trolley for the CD200 IQ supports the machine and guides it along the track. The Trolley also enables the operator to switch direction as well as slide the main unit across to the opposite rail in a convenient manner. When setup correctly, the trolley gives the machine the right inclination independent of direction of travel or chosen rail for operation.

  • Page 23: Workhead

    4.3 Workhead 4.2.1 Workhead FC/FE The work head is designed to be able to both clip up and de-clip PANDROL FASTCLIP and FASTCLIP FE. Table 5 Item Description Item Description Clipping shoe Adjustable datum part Datum arm Double pin for...

  • Page 24: Sleeper Lifter Fc/Fe

    When the dead-mans-handle/sleeper lifter control is pressed in towards the handlebar, the cylinder takes its fully extended position, which is the normal operation position. Table 6 Item Description Height adjustment mechanism Sleeper lift cylinder Jockey wheel Figure 24. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 24 av 118 @Pandrol 2022...

  • Page 25: Workhead E-Clips

    5.7. Figure 25. Table 7 Item Description Item Description Parallel adjustment knob Double hook Tower Datum piece Frame Quick locking mechanism Indicator Height adjustment knob OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 25 av 118...

  • Page 26: Indicator

    (2) will extract to its full length and the work head will rise above the clips. In this position CD200 IQ can easily be pushed towards the next sleeper. 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.

  • Page 27: Brake

    When removing the machine from the trolley there is a possibility that the trolley can run along the track. For that reason the CD200 IQ is equipped with brakes that will automatically stop the trolley from running away when removing the machine. The brake is activated as long as the handle (1) is not pressed down.

  • Page 28: Controls

    5. Controls The CD200 IQ is operated by the operator by a control panel, a dead-mans-handle, and two buttons all located handy on the adjustable handlebar. The CD200 IQ has four different work modes as will be explained below. WARNING! Do not operate the machine before performing the setup procedure.

  • Page 29: Control Panel

    5.1 Control panel Start control system The CD200 IQ is operated by the operator by a control panel. NOTE that the choices in this chapter are made through pressing a button below the display, not on the display/screen itself. Figure 31.
  • Page 30 Lift the tool and release the button when the clip is Figure 45. installed. The tool retracts to origin position when the button is released. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 30 av 118 @Pandrol 2022...
  • Page 31 NOTE that the choices in this chapter are made through pressing a button below the display, not on the display/screen itself. Figure 46. Figure 47. Figure 48. Figure 50. Figure 49. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 31 av 118...

  • Page 32: Electrical System

    5.2 Electrical System The electrical system on the CD200 IQ is robust and built with high quality components. It requires a minimum of maintenance and is well protected from wear and climate impact. Figure 51. Item Description Item Description Controls...

  • Page 33: Hydraulic System Fc/Fe

    Item Description Item Description Clipping/De-clipping cylinder Return filter Sleeper lifter cylinder Valve block assembly Hydraulic fluid reservoir Drain plug Breather filter/ filler cap Table 12 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 33 av 118...

  • Page 34: Hydraulic System E-Clips

    Schematic picture of the hydraulic system on an e-CLIPS equipped machine. The difference between FC/FE is four horizontal cylinders coupled in parallel that work in pairs. Figure 53. Figure 54. Clipping/de-clipping cylinder OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 34 av 118 @Pandrol 2022...

  • Page 35: Transport And Parking

    6. Transport and Parking 6.1 Preparing for Transport or Storage When CD200 IQ is to be transported or stored off-track,ensure that the machine is safely rested on surface. CD200 IQ should only be lifted mechanically. Use appropriate slings/chains and lifting accessories when lifting...

  • Page 36: Parking On The Track

    6.2 Parking on the Track When the CD200 IQ is to be parked on track, the work head 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.
  • Page 37 5. Unlock the powerpack from the working tool by turning/pulling the hatch and then slide the powepack backwards. Figure 59. Open 6. Slide out of position ”Figure 60.” Figure 60. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 37 av 118...
  • Page 38 ”Figure 59” 2. Use a mechanical tool to lift the workhead out of it’s position. Place on steady surface. Figure 61. Figure 62. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 38 av 118 @Pandrol 2022...

  • Page 39: Installation On Track

    7.1 General The CD200 IQ must be adjusted for the type of rail and clip assembly it is to be used on before operation on track. The interaction between the clips on the track and the steel shoes on the de-clipping and the clipping arms must be checked in order not to damage the clips and insulators.

  • Page 40: On/Off Tracking

    3. Release the hatches on the trolley, figure 64 Handle Handle Figure 64. Figure 63. Manually handling Figure 65. Mechanically handling Figure 66. Mechanically handling OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 40 av 118 @Pandrol 2022...
  • Page 41 5. Place carefully on connection tray on trolley, figure 67, 68, 69, 70, 71. The powerpack with tool is well balanced and easy to guide into position. Figure 70. Figure 69. Figure 71. Figure 72. Lock the hatches on the trolley, figure 71. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 41 av 118...
  • Page 42 11. To move the CD200IQ and release the brake, push down the red handle (1). As soon as the handle is released, the machine is braked, release = locked. Figure 75. Figure 76. Figure 77. Figure 78. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 42 av 118 @Pandrol 2022...

  • Page 43: Emergency Operation - Off-Tracking Using Handles

    Figure 79. Handle overwiew WARNING! Heavy lift. 8 persons needed for lift. Lifting handles see ”Figure 76.” Weight FASTCLIP 254 kg. Weight e-CLIP 272 kg. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 43 av 118...

  • Page 44: Lifting Equipment Breakes Down

    For instructions how to separate the CD200 IQ into three parts see chapter 6.4 Storage. Lift the powerpack, tool, trolley in the handles straight up and carry to safe location, maximum 5 meters. Put the powerpack, tool , trolley on the ground.

  • Page 45: Weight Distribution

    Weight 103 kg. Lifting load, figure 79. Point 1, 22 kg Point 2, 27 kg Figure 81. Point 3, 27,5 kg Point 4, 26,5 kg Figure 82. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 45 av 118...
  • Page 46 Weight 115 kg. Lifting load, figure 83: Point 1, 24 kg Point 2, 24 kg Point 3, 33,5 kg Point 4, 33,5 kg Figure 86. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 46 av 118 @Pandrol 2022...
  • Page 47 2 persons needed for lift. Lifting handles see ”Figure 84.” Weight 54 kg. Lifting load, figure 85. Point 1, 32,5 kg Point 2, 21,5 kg Figure 87. Trolley Figure 88. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 47 av 118...

  • Page 48: Cog Center Of Gravity

    7.5 CoG Center of gravity Complete machine Figure 89. Figure 90. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 48 av 118 @Pandrol 2022...

  • Page 49: Changing The Inclination

    Inclination is preset depending on rail inclination. To be changed, the inclination pieces (4) needs to be replaced. To check the inclination setting, see inscription on the inclination piece. There are three different options: 1:20, 1:30 and 1:40, see spare parts manual or consult Pandrol AB for more information To change the inclination pieces: 1.

  • Page 50: Changing Direction Of Operation

    OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 50 av 118 @Pandrol 2022...
  • Page 51 Check that the machine is Figure 95. firmly secured in the correct position before starting to operate the machine Figure 96. Figure 97. Figure 98. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 51 av 118...

  • Page 52: Changing Rail Side Of Operation

    1. Make sure the latch, figure 96, for the slide carriage is open on the unoccupied side of the trolley. 2. Open the latch on the occupied side of the trolley. Figure 99. Figure 100. Figure 101. Setting bolt Lock nut OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 52 av 118 @Pandrol 2022...
  • Page 53 3. Disconnect the brake wire, figure 99. Figure 102. Figure 103. Figure 104. Figure 105. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 53 av 118...
  • Page 54 8. Tighten the locking nut. 9. Connect the brake wire. Figure 108. Figure 109. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 54 av 118 @Pandrol 2022...

  • Page 55: Operation (Fastclip- Machine)

    3. Activate the dead-mans-handle and check that the clipping shoes are in the right height relative the clip. This depends on the type and dimension of the actual rail. If necessary, adjust the height of the work head with the Figure 111. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 55 av 118...

  • Page 56: Clipping Operation

    Figure 112. Figure 113. 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 57: 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 OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022...

  • Page 58: Clipping

    (2). Figure 116. 2. Make sure the mechanical stops (3) for de-clipping are active, i.e. bolt pointing inwards on both sides Figure 117. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 58 av 118 @Pandrol 2022...
  • Page 59 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. Figure 120. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 59 av 118...
  • Page 60 Repeat the procedure on the other side of the work head. Figure 122. : Rubber stop set up for FASTCLIP FC Figure 121. : Rubber stop set up for FASTCLIP FE OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 60 av 118 @Pandrol 2022...

  • Page 61: 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. Figure 123. : Storing shoes not being used OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 61 av 118...

  • Page 62: Workhead Fastclip Offset

    Loosen the cam lever (1) and replace the heelplates (2) Figure 127. De-clipping set-up to (3), fasten the heelplate by locking the cam lever. Figure 128. Clipping set-up OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 62 av 118 @Pandrol 2022...

  • Page 63: Troubleshooting

    • Lift only free laying sleepers • Pressure switch for clipping function may need to be adjusted. This adjustment should only be done after consulting a retailer or Pandrol AB. 10.2 Clips are not being fully installed Possible causes: •...

  • Page 64: Warranty And Service

    11.2 Service Service is offered after the expiration of the warranty as well. Please contact Pandrol AB. 12. Contact Address Telephone...

  • Page 65: Maintenance

    Restore an original part to the required condition by hand tooling, machining, build-up, welding, patching, bending, setting, heat-treating, re-securing etc. NOTE! Any type of repair work must be carried out by Pandrol own personnel. Strip Remove covering, i.e. paint, polish, fabric...

  • Page 66: Categories Of Work

    ”Tightening patterns, multi holes fixing” This second tightening is necessary since bolts may lose tension when adjacent bolts are tightened. Figure 130. Tightening patterns, multi holes fixing OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 66 av 118 @Pandrol 2022...
  • Page 67 5 and Class 80 Dimension Metric Lbft lbft 12.5 125.5 243.5 1130 Dimension UNC Lbft lbft 1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 3/4” 7/8” 1” OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 67 av 118...

  • Page 68: Maintenance And Service

    Weekly / Every 40 hours Yearly / Every 500 hours 13.5.3 Job letter allocation Code Area Chassis and tools Electrics Fuel Hydraulics Engine Wheels Brakes Miscellaneous OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 68 av 118 @Pandrol 2022...

  • Page 69: Function Code

    Function 13.5.6 Safety code Safety code for each job is one of the four identified safety conditions. Code Safety condition Isolated Engine Running Moving Braked OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 69 av 118...

  • Page 70: Maintenance Schedule

    Hydraulic cylinder and hoses Check HY02C Hydraulic pump Visual check HY03V Hydraulic filters Check HY04R Hydraulic oil change Check HY05C Hydraulic oil pressure and flow Test HY06T OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 70 av 118 @Pandrol 2022...
  • Page 71 Examine BR02E Brakes test Test BR03T Miscellaneous Emergency equipment Visual check MI01V Log book, Manuals, Certificates Check MI04C Function check Check MI05C Washing Washing MI06W OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 71 av 118...

  • Page 72: Maintenance Job List

    To improve safety, warning labels are attached on the vehicle where there is an increased risk. If any of these labels are damage or lost, they must be replaced with new original warning labels that can be ordered from Pandrol AB. Labels depending on configuration. Figure 131.
  • Page 73 UK CD200IQ 710176 710175 Complete machine Fastclip 710062 710178 710177 Complete machine e-clip Do not manually handle CD200IQ Data panel CD200 IQ Blå 5014338 Lyftkrok OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 73 av 118...

  • Page 74: Ch02V Paint Work - Visual Check

    2. The red paint must not due to safety be worn out or discoloured. Arising work 1. Clean the red painted areas. 2. Repaint areas affected by corrosion or discolouration. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 74 av 118 @Pandrol 2022...

  • Page 75: Ch03V Frame - Visual Check

    Job no. CH03V Safety condition: SCB Scheduled work 1. Visually check vehicle frame for cracks. Arising work 1. Contact Pandrol technical support team for repairs. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 75 av 118...

  • Page 76: Ch04V Sign Of Leakage - Visual Check

    2. Visually check the area underneath the machine for leakage after standing still for a period of time. Arising work 1. Identify leaks and rectify. 2. Clean the affected area. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 76 av 118 @Pandrol 2022...

  • Page 77: Ch05C Abnormal Sounds - Check

    Safety condition: SCM Scheduled work Check for abnormal sounds while operating all hydraulic functions of the machine. Arising work 1. Investigate what is causing the sound. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 77 av 118...

  • Page 78: Ch06C Tighten Bolts - Check

    1. Tighten loose bolts according to section 3.4 Fasteners in chapter 3. Maintenance. Arising work 1. Tighten loose bolts according to section 3.4 Fasteners in chapter 3. Maintenance. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 78 av 118 @Pandrol 2022...

  • Page 79: Ch07L Lubrication, Tool

    Wipe off excess grease. Arising work 1. Replace damaged grease nipples with new nipples. Figure 135. Figure 136. Figure 137. REMARK: e-Clip too has no lubrication points/grease nipples. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 79 av 118...

  • Page 80: Ch08C Fe/Fc Tool - Check

    1. Check that the clipping pads they are free from damages if in use. Arising work 1. Replace if necessary. Figure 138. Inspection FE/FC tool OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 80 av 118 @Pandrol 2022...

  • Page 81: Ch09C E-Clip Tool - Check

    Job no. CH09C Safety condition: SCB Scheduled work 1. Check that the installation pads are free from damages if in use. Arising work 1. Replace if necessary. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 81 av 118...

  • Page 82: Ch10C Retention Pins

    Ensure that all elements on the exterior of the vehicle are secured Arising work 1. Replace retention pins if damaged or broken. 2. Fit retention pin if there is no retention pin. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 82 av 118 @Pandrol 2022...

  • Page 83: Ch11C Centre Lifting Point Complete Machine

    Scheduled work 1. Check that the centre lifting yoke and brackets are free from damages Arising work 1. Replace damaged parts. Figure 139. Centre lifting point OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 83 av 118...

  • Page 84: Ch12C Power Unit Lifting Point

    Scheduled work 1. Check that the lifting yoke and brackets are free from damages Arising work 1. Replace damaged parts. Figure 140. Motor lifting point OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 84 av 118 @Pandrol 2022...

  • Page 85: Ch13C Tool Lifting Point

    1. Check that the tool lifting handles and brackets are free from damages Arising work 1. Replace damaged parts. Figure 141. Tool lifting point Figure 142. Tool lifting point OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 85 av 118...

  • Page 86: Ch14C Trolley Lifting Point

    Scheduled work 1. Check that the trollety lifting handles and brackets are free from damages Arising work 1. Replace damaged parts. Figure 143. Trolley lifting points OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 86 av 118 @Pandrol 2022...

  • Page 87: Ch15L Trolley Surface On Slide Bar

    1. Inspect the surface on slide bar and check that it is free from damage.. Arising work 1. Replace if damaged or broken. 2. Clean and lubricate with oil spray (CRC6-56 or similar). OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 87 av 118...

  • Page 88: El01V Control Panel

    2. Check that the control panel are working correctly. Arising work 1. Replace defective parts or whole panel assembly if needed. 2. Investigate fault, correct and retest. Figure 144. Control panel OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 88 av 118 @Pandrol 2022...

  • Page 89: El02V Light - Visual Check

    2. Check that the light are working correctly. Arising work 1. Replace defective parts or whole lamp assembly if needed. 2. Investigate fault, correct and retest. Figure 145. Light OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 89 av 118...

  • Page 90: El03V Emergency Stop Button - Visual Check

    1. Replace defective parts. Test replaced emergency stop buttons according to job EL04T. Location No. of Emergency stop buttons Handle bar Figure 146. Emergency stops OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 90 av 118 @Pandrol 2022...

  • Page 91: El04T Emergency Stop Button - Test

    1. Test emergency stop button and ensure that the engine is stopped. Work lights shall remain lit. Arising work 1. Report any faults to the supervisor rectify and retest Location No of E-stops Handle bar Figure 147. Emergency stops OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 91 av 118...

  • Page 92: El05V Electric Cables - Visual Check

    1. Replace any broken or damaged components and re-tighten loose fixings. Apply protection wax or grease on terminations and contact surfaces. Carry out job EL06E after renewing any cable or fixing. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 92 av 118 @Pandrol 2022...

  • Page 93: El06E Battery - Examine

    2. Clean corroded terminals and grease with vaseline or similar product. Tighten loose connections. 3. Replace battery if showing signs of leakage or overheating. Weight battery 7 kg. Figure 148. Battery position OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 93 av 118...

  • Page 94: Hy01V Hydraulic Oil Level - Visual Check

    1. Check the hydraulic oil level with the oil dipstick. Arising work 1. Clean the area around the filler cap and fill it up with hydraulic oil Figure 149. Hydraulic tank OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 94 av 118 @Pandrol 2022...

  • Page 95: Hy02C Hydraulic Cylinders And Hoses - Check

    Replace defective items. 3. Replace damaged seals and re-secure loose items. 4. Tighten loose fittings and check that leaks have been repaired. 5. Replace any defective hose. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 95 av 118...

  • Page 96: Hy03V Hydraulic Pump - Visual Check

    2. Run the engine to check there are no leaks. 3. Re-secure loose fittings. 4. Replace damaged hoses and connections. Figure 150. Location of the hydraulic pump OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 96 av 118 @Pandrol 2022...

  • Page 97: Hy04R Hydraulic Filters - Check

    1. Breather filter 2. Return line filter Arising work 1. 1-2 Replace the filter. Figure 152. Return line filter positions Figure 151. Breather filter position OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 97 av 118...

  • Page 98: Hy05C Hydraulic Oil Change

    The oil used for filling must be clean. Do not mix different The viscosity of the oil is of great oils. Hydraulic oil that is approved for Pandrol products must importance to achieve high efficiency of comply with one of the following standards or equivalents: the hydraulic system.

  • Page 99: Hy06T Hydraulic Flow And Pressure - Test

    The pump can be considered in good condition if maximum flow is not less than 90% of nominal. Pump Flow l/m System pressure 215 BAR OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 99 av 118...

  • Page 100: En01C Engine

    EN01C Engine Job no. EN01C Safety condition: SCB Scheduled work Please read the engine user manual for maintenance instructions. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 100 av 118 @Pandrol 2022...

  • Page 101: En02V Engine Mountings

    2. Check bolt connections on the engine fastening brackets. Arising work 1. Replace worn rubber mountings 2. Tighten bolts according to section 3.4 Fasteners in chapter 3. Maintenance. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 101 av 118...

  • Page 102: Wh01C Wheels - Check

    Safety condition: SCB Scheduled work 1. Check the wheels for signs of pitting, scoring, flat spots and other damages. Arising work 2. See job WH02E. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 102 av 118 @Pandrol 2022...

  • Page 103: Wh02E Wheels - Examine

    If flat is >30 mm, remove from service immediately. If flat is 20-30 mm, remove from service on completion of work. Figure 154. Wear limit max 3 mm Figure 155. Profile template OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 103 av 118...
  • Page 104 50 mm of each other and their combined length exceeds 15 mm. Re-profile wheels to remove cavities and cracks, otherwise replace the wheels. Figure 158. Microscopic cracks Figure 159. Cavities OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 104 av 118 @Pandrol 2022...
  • Page 105 These defects are removed when re-profiling becomes necessary to restore the wheel profile Figure 160. Circumferential cracking limit associated with Figure 161. Rollover rollover Figure 162. Migration down the flange OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 105 av 118...

  • Page 106: Wheel Examination Record Form

    Record amount of wear Wear/defect Limit (mm) Axle 1 Axle 2 Left Right Left Right False flange 2 mm Flats 20 mm *Back to back OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 106 av 118 @Pandrol 2022...

  • Page 107: Br01T Brake Function Test

    3. Run the machine backward at transport speed, release the lever to apply the brakes. 4. Make sure that the brakes are operating effectively and that the machine fully stops. Arising work 1. Report any faults to the supervisor. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 107 av 118...

  • Page 108: Br02E Brake Pads - Examine

    1. Use a calibrated measuring device measure the thickness on the brake pads ensuring there is a minimum of 2 mm friction material remaining. Arising work 1. If the pad is worn to less than 2 mm thickness, replace the pad. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 108 av 118 @Pandrol 2022...

  • Page 109: Rail Brake Test Form

    Result no 2 Result no 3 Comment 0,5 kph (working speed) 3 kph (walking speed) Park brake pull test result (done annualy or after repair) Approved OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 109 av 118...

  • Page 110: Mi01V Emergency Equipment - Visual Check

    Scheduled work 1. Check that all required safety items according to national and local regulations are present. Arising work 2. Replace missing or faulty/expired items. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 110 av 118 @Pandrol 2022...

  • Page 111: Mi02C Log Book, Manuals, Certificates - Visual Check

    2. Replace log book, take the old log book to the Supervisor. 3. Clear outstanding faults where possible. Supervisor to endorse remaining faults with intended action Figure 163. Dossier storage OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 111 av 118...

  • Page 112: Mi03C Function Check - Check

    4. Check that all controls operate according to operating instructions and that there are no inappropriate or uncontrolled movements. Arising work 1. 1-4 Rectify and retest OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 112 av 118 @Pandrol 2022...

  • Page 113: Mi04W Washing

    1. Wash with warm water and mildly floating neutral solvents as washing up liquids and soap solutions. Do not wash with high-pressure water. 2. Dry the vehicle. 3. Grease and lubricate after drying. OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 113 av 118...

  • Page 114: A - Exam Check List

    Hydraulic oil level EN01C Main engine EN02V Engine mountings Safety condition “Isolated” SCI Safety condition (Engine ) “Running” SCR Safety condition “Moving” SCM Safety condition “Braked” SCB OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 114 av 118 @Pandrol 2022...

  • Page 115: B - Exam Check List

    Wheels BR01T Brake function test MI04W Washing Safety condition “Isolated” SCI Safety condition (Engine ) “Running” SCR Safety condition “Moving” SCM Safety condition “Braked” SCB OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 115 av 118...

  • Page 116: C-Exam Check List

    Emergency stop buttons EL04T Emergency stop buttons EL05V Electric cables EL06E Battery HY01V Hydraulic oil level Hydraulic cylinders and HY02C hoses The list continue on next page OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 116 av 118 @Pandrol 2022...

  • Page 117: C-Exam Check List

    MI02C certificates MI03C Function test MI04W Washing Safety condition “Isolated” SCI Safety condition (Engine ) “Running” SCR Safety condition “Moving” SCM Safety condition “Braked” SCB OPERATION AND MAINTENANCE MANUAL I ENG_OMM_CD200IQ_P03 I 11 February 2022 @Pandrol 2022 117 av 118...
  • Page 118 Find out more at pandrol.com Pandrol AB Hyggesvagen 4 824 35 Hudiksvall SWEDEN +46 650 16505 info.rosenqvistrail@pandrol.com ©Pandrol Partners in excellence...

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