PANDROL CD100 B Operating instructions

Partners in excellence
ENG_OMM_CD100B_P09
2023-06-14
USER AND MAINTENANCE MANUAL
CD100 B

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The pictures in the manual are for illustration only, the appearance of the machine may vary
This manual aims to help you get to know your new CD100, to use it in the best way and
to maintain it properly for a long lifetime. It also presents important safety regulations and
warnings.
The manual is intended for people who handle and operate the machine. It is originally written in
Swedish and then translated into the local language by Pandrol AB.
Pandrol AB reserves the right to change specications, equipment, instructions and
maintenance guidelines without prior notice.
The manual contains instructions about the following topics:
1. Installation
2. Operation
3. Safety features and warnings
4. Maintenance and troubleshooting
(1) refers to a component in a gure/illustration.
IMPORTANT!
This manual contains ordered actions, e.g.
1. Do this
2. ...and then this...
3 and nally this
These actions must be done in the numerical order presented.
Revision Datum Kommentarer
P04 2021-03-18 New layout
P05 2021-04-13 Added Drive unit/battery Power pack
P06 2022-02-21 Updated manual
P07 2022-05-19 New solution for handlebar and buttons CD100B
Thank you for choosing CD100!
You are now the owner of a quality product from Pandrol.

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Table of contents
1. Safety Information 6
1.1. General 6
1.2. Safety Regulations 6
1.1. Warning Labels 7
1.2. Qualied Personnel 8
2. General Description 9
3. Technical Information 10
2.1. Technical Information CD100B 10
3.1. Technical Data - Battery Drive unit 6000617 11
4. Tools 12
4.1. Clipping Tool 1100201 12
4.2. De-clipping Tool - FE / FCX 5012730 13
4.3. De-clipping Tool - FC 1100058 14
5. Transport And Packaging 15
4.4. Unpacking The Drive unit 15
5.1. Unpacking The Clipping Tool 17
5.2. Recommended storage conditions: 17
5.3. Electrical/Battery Storage 17
5.4. Transportation And Storage Of CD100B 18
6. Setup/Installation 19
6.1. Drive unit 19
6.2. Clipping Tool 20
6.3. De-clipping Tool 21
7. Adjustments 22
7.1. Adjustments of the Handle Bar Unit 22
7.2. Rail Height Adjustments 22
7.3. Lift the workhead 23
7.4. Lower the workhead 23
7.5. Clipping Tool Adjustments 24
7.6. FC De-clipping Tool Adjustments 26
7.7. FE/FCX De-clipping Tool Adjustments 27

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8. Operation CD100B 29
8.1. Mounting Drive unit/Battery 29
8.2. Clipping And Declipping - Connect Rail To Sleeper 30
8.3. De-Clipping - Disconnect Rail From Sleeper 31
8.4. Change of tools 31
8.5. After Operation 31
9. Emergency operation 32
10. Maintenance 33
10.1. Drive unit 33
10.2. Clipping And De-clipping Tools 34
10.3. Lubrication points 34
11. Mounting Torques 36
12. Warranty And Service 37
12.1. Warranty 37
12.2. Service 37
12.3. Disclaimer 37
12.4. Contact 37
12.5. Declaration Of Conformity 37
12.6. Recycling and Environment 37
12.7. Disposal Of Battery 37

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1.1. General
• Read and understand all safety regulations and warnings before installation, operating or
performing maintenance on this machine.
• Make sure that no unauthorized personnel are in the operating area during installation, use
or maintenance.
• Improper installation of this unit can be dangerous and may lead to mishaps or accidents
and could result in personal injury.
• Improper operation of this unit can be dangerous and could result in personal injury or
death.
• Improper maintenance of this unit can be dangerous and may lead to mishaps or accidents
and could result in personal injury.
• Do not operate this unit until you have read and understood the safety instructions in this
manual.
• Do not perform any maintenance on this unit until you have read and understood the
instructions in this manual.
• The drive unit is only permitted to be used as a power source for Pandrol manufactured
original tools.
1.2. Safety Regulations
• Do not make any alterations to your CD100. Doing that, you could compromise your own
safety and expose yourself to a serious accident or injury risk.
• Before each start, perform a general inspection of all parts and make sure that they are not
worn, damaged or loose. Also make sure that the tool is dry everywhere and that there is no
oil leakage.
• Regular maintenance is required to ensure a safe operation. Keep all nuts and bolts securely
tightened.
• The drive unit must be switched o󰀨 when performing cleaning, control, adjustments,
reparations, oil lling and when the unit is being left unattended.
• Attention! Risk for clamping. Be careful with bodily parts around the unit. Risk for injuries.
• Do not use the unit with damaged or worn parts. If parts must be replaced use original parts,
please contact Pandrol AB for consultation.
• When the CD100 is used the operator must wear protecting clothes, i.e. long trousers,
boots, gloves, ear defenders and goggles or a protective visor.
• To protect the environment, do not dispose oil by pouring it down the drain, in the gutter or
on the ground.
• All handling of the battery must be done according to the manual for the battery and battery
charger.
1. Safety Information

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1.1. Warning Labels
The warning labels present on the machine are presented below. If any of these warning 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
(art. 710016)
Wear safety googles
(art. 710017)
Wear safety helmet
(art. 710018)
Wear hearing
protection
(art. 710019)
WARNING! Oil
pressure
(art. 710216)
WARNING! Risk
of crushing
(art. 710217)
High voltage
(art. 710018)

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1.2. Qualied Personnel
The CD100B with its working tools is only to be used by qualied personnel, thoroughly familiar
with and trained in general railway workmanship and 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 repaired only by qualied personnel
who are familiar with both this Operation & Maintenance Manual and have received training and
information from Pandrol AB.
In order to avoid personal injury or death and/or material damage, everyone involved with
assembling, starting-up or overhaul must possess pertinent knowledge.
ÌWARNING! All maintenance and service or other operations on the hydraulic
system is to be carried out by qualied personnel.

Fig 1. Identication plate
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Nr Dercription Item No
1 Drive unit CD100 B 6000617 (incl. handlebar)
2 Handle bars CD100B 6000618
3 Clipping tool FC / FCX 1100201
4 Declipping tool FC 1100058
5 Declipping tool FE / FCX 5012730
Fig 2. Drive unit CD100 B Fig 3. Handlebar Fig 4. Clipping tool
Fig 5. Declipping tool FC Fig 6. Declipping tool FE / FCX
1
4
2
5
3
2. General Description
CD100B is a single person walk behind tool used to install and uninstall Fastclip FE and FCX
clips on railway worksites.
The CD100B is designed for installing and uninstalling two clips per cycle and is not able to lift
any sleeper or rail. Due to design, the tool is not able to be used on insulated rail joints.
CD100B is patented and delivered CE-certied. A machine identication plate is fastened on
the Drive unit, refer to Fig. 1. In case the identication plate becomes damaged or lost, please
contact Pandrol AB to obtain a new identication plate.
The CD100 B consists of a drive unit (1), a handlebar (2), a fastening tool (3) and a declipping
tools (4,5) according to the table below.

Fig 7.
Fig 8.
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2.1. Technical Information CD100B
The Drive unit is designed as an easy moveable, ergonomically battery driven hydraulic power
source. It is designed with a quick connect interface which enables fast and easy connection to
the working tools.
The Drive unit is supported by a steel wheel to the rail, which relieves the operator from the
weight and thus prevents the operator from wearing injuries. The components of the Drive unit
are presented in Fig 7 and the components of the Handle Bar are presented in Fig 8.
Nr Description
1Battery
2Hydraulic connections
3Wheel adjustment screw
4Hydraulic tank
5Direction control
6Handlebar
7Handle rod
8Throttle and locking controls
(5)
(6)
(7)
(8)
3. Technical Information
(4)
(1)
(3)
(2)

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Technical data for the Drive unit (part no. 6000617)
Description Specication
Noise level Measuring point :
Operating condition:
Measured vibration emission value:
In operating position
Normal operation
79.2 dB (A)
Vibration emission Measuring point :
Operating condition:
Measured vibration emission value:
Handle bar
Normal operation
1,28 m/s2
Measurement
Length 480 mm
Width 260 mm
Height 400 mm
Weight 19 kg
Packaging dimensions
Length 580 mm
Width 390 mm
Height 450 mm
Weight 29 kg
Battery
Battery capacity 72V DC 6 Ah, 432 Wh, 82V max
Work capacity 300 clips / charge cycle
Charge time 45 min (use 82C2/82C1G charger)
Hydraulics
Pump Vivolo XV-OP/0.45
Max. oil pressure 190 bar
Deplacement 0,45 cm3/rev
Max. engine speed 6000 rpm
Hydraulic tank volume 1,1 L (1,16 Quarts)
Hydraulic oil quality ISO VG 46 or similar
Hydraulic connectors Quick coupling (adjustable)
3.1. Technical Data - Battery Drive unit 6000617
Above specications may be changed without notice according to Pandrol AB´s requirements.

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4. Tools
Nr Description
1Locking mechanism
2Arm
3Hydraulic connectors
4Bracket
5Claws
Fig 9. Clipping tool
Technical data for the Clipping Tool (part no. 1100201).
Decription Specication
Attachment to Drive unit, part no. 5014188, or Battery Drive unit, art nr 6000617
Capacity Approx. 10 installations/min
Clips Pandrol Fastclip
Measurements
Length 580 mm
Width 210 mm
Height 390 mm
Weight 24 kg
Packaging measurements
Length 590 mm
Width 240 mm
Height 450 mm
Weight 32 kg
Hydraulics
Max. working force 33,8 kN
Max. oil pressure 190 bar
Hydraulic cylinder Double-acting, with spring return
Hydraulic connectors Quick coupling
Cycle time 6,5 sek
Above specications may be changed without notice according Pandrol AB´s requirements.
4.1. Clipping Tool 1100201
The Clipping Tool is an attachment to the Drive unit, ergonomically friendly designed and easy
to lift manually. It is based on well-known Pandrol technology and has a quick connect interface
which enables fast and easy connection to the Drive unit.
The components of the Clipping Tool are presented in Fig 9.
(3)
(1)
(5)
(2)
(4)

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4.2. De-clipping Tool - FE / FCX 5012730
The De-clipping Tool is an attachment to the Drive unit, ergonomically friendly designed and
easy to lift manually. It is based on well-known Pandrol technology and has a quick connect
interface which enables fast and easy connection to the Drive unit. The components of the De-
clipping Tool are presented in Fig 10.
Nr Dercription
1Hydraulic connectors
2Clip catcher
3Arm
4Locking mechanism
5Bracket
6Claw
7Adjustment screws torsional sti󰀨ness
Above specications may be changed without notice according to Pandrol AB´s requirements.
Fig 10. Declipping tool FE / FCX
Technical data for the De-clipping Tool (part no. FE/FCX 5012730).
Decription Specication
Attachment to Drive unit, part no. 5014188, or Battery Drive unit, art nr 6000617
Capacity Approx. 10 installations/min
Clips Pandrol Fastclip
Tool Measurements
Length 560 mm
Width 338 mm
Height 408 mm
Weight 29 kg
Transport packaging
measurement
Length 621 mm
Width 371 mm
Height 450 mm
Weight 40 kg
Hydraulics
Max. working force 23,9 kN
Max. oil pressure 190 bar
Hydraulic cylinder Double-acting
Hydraulic connectors Quick coupling
Cycle time 6,5 sek
(4)
(1)
(2)
(5)
(3)
(6)
(7)

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4.3. De-clipping Tool - FC 1100058
The De-clipping Tool is an attachment to the Drive unit, ergonomically friendly designed and
easy to lift manually. It is based on well-known Pandrol technology and has a quick connect
interface which enables fast and easy connection to the Drive unit. The components of the De-
clipping Tool are presented in Fig 11.
Nr Dercription
1Hydraulic connectors
2Clip catcher
3Arm
4Locking mechanism
5Bracket
6Claw
7Adjustment screws torsional sti󰀨ness
Technical data for the De-clipping Tool (part no. FC 1100058).
Decription Specication
Attachment to Drive unit, part no. 5014188, or Battery Drive unit, art nr 6000617
Capacity Approx. 10 installations/min
Clips Pandrol Fastclip
Measurements
Length 560 mm
Width 270 mm
Height 400 mm
Weight 24 kg (29 kg for 5012730)
Packaging measurement
Length 580 mm
Width 330 mm
Height 450 mm
Weight 35 kg (40 kg for 5012730)
Hydraulics
Max. working force 23,9 kN
Max. oil pressure 190 bar
Hydraulic cylinder Double-acting
Hydraulic connectors Quick coupling
Cycle time 6,5 sek
Above specications may be changed without notice according to Pandrol AB´s requirements.
Fig 11. Declipping tool FC
(1)
(4)
(2)
(5)
(3)
(6)
(7)

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The CD100B are delivered in a suitable, environmentally friendly wooden boxes. When the
machine is not being used or transported, the components shall be stored in their suitable
boxes. The boxes are designed as a system easy and safe to transport, store and carry. Follow
the instructions in the reversed order when storing the components.
The pictures are for illustration only, the appearance of the machine may vary
4.4. Unpacking The Drive unit
1. Lift the drive unit and the handle out of the box and place it on the ground.
2. Mount and attach the Handle Bar Unit to the Drive unit using the locking mechanism.
3. Attach the Handle to the Handle Bar.
4. Adjust the handles
5. Attach the required tools according to section ”6. Setup/Installation”.
Fig 12. Fig 13.
Fig 14. Fig 15.
5. Transport And Packaging

Figur 19.
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Fig 16. Fig 17.
Fig 18.
Fig 19.

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5.1. Unpacking The Clipping Tool
Fig 20. Clipping Tool in its storage box
Fig 21. Easy to lift up and to store when not being used.
5.2. Recommended storage conditions:
Store in a dry environment between -25°C and +40°C.
5.3. Electrical/Battery Storage
See battery and charger manual. Do not place the battery in direct sunlight or in a hot or cold
environment. Keep it at normal room temperature in a dry environment. When not using the
battery for an extended period of at least 2 months, store it in a room temperature environment.
Half charge the battery before storing and charge it for 2 hours every 2 months.

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5.4. Transportation And Storage Of CD100B
The Drive unit contain a Lithium Ion battery and shall be handled according to local legislations
of handling and transporting batteries.
The battery is classied according to UN 3481 standard, meaning that the capacity is greater
than 100 Wh. Find detailed battery information in section ”9.2. Battery Technical Specication”
on page 17.
On-ground transport for private use or transport carried out by an employee or an inhouse
company transport service from company site to working site does not require lithium battery
mark and ADR.
All transports with a forwarder requires Lithium battery mark and ADR. Always consult your
forwarder before the transport is to be carried out. Special terms for air transport of the Drive
unit applies. Always contact your forwarder for information.
Remove the battery pack from the tool before storing.
Store and charge your batteries in a cool area. Temperatures above or below normal room
temperature will shorten battery pack life.
Fig 22. Fig 23.

Figur 24.
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6. Setup/Installation
ÌWARNING!
Check that the hydraulic hoses are clean each time prior to connection.
Fig 24.
Dipstick
6.1. Drive unit
Be aware that the Drive unit is delivered without Hydraulic oil
ÌWARNING! Fill up the Drive unit with hydraulic oil according to the manual
before starting.
6.1.1. Hydraulic oil (CD100/CD100B)
Fill with new hydraulic oil, quality ISO VG 46 or similar, approximately. 1,1 litres until the oil level
is 10 mm up on the oil dipstick. Check the oil level with the oil dipstick.

(1)
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6.2. Clipping Tool
• Place the Clipping Tool with the arms on each side of the rail.
• Disconnect the Handle Bar Unit from the Drive unit).
• Fasten steering bar to the Clipping Tool using the locking mechanism.
• Fasten the Drive unit to the Clipping Tool. Connect the hydraulic hoses, making sure they are clean
before connecting.
Fig 25. Fig 26.
Fig 27. Fig 28.