PANDROL CD200 IQ User manual

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

Table of contents
1. Review of maintenance plan ..............................................................................6
2. Introduction..............................................................................................................7
2.1 General.....................................................................................................................................7
2.2 New version/manual.................................................................................................................8
2.3 Safety Actions Prior to Working on the CD200 IQ....................................................................9
2.3.1 Safety Equipment ......................................................................................................................10
2.3.2 Control System ..........................................................................................................................10
2.4 Safety warnings......................................................................................................................11
2.4.1 Moving Parts..............................................................................................................................11
2.4.2 Pressurised Hydraulic Oil ..........................................................................................................11
2.4.3 Live Current ...............................................................................................................................11
2.4.4 Vehicle in Operation...................................................................................................................11
2.4.5 Danger due to unergonomic operation ......................................................................................11
2.4.6 Danger due to manual handling.................................................................................................11
2.5 Safety Conditions ...................................................................................................................12
2.6 Personal Protective Equipment (PPE) ...................................................................................12
2.4.7 Danger due to noise ..................................................................................................................12
2.4.8 Danger due to vibration .............................................................................................................12
2.7 Battery Precautions................................................................................................................13
2.8 Remedial Work.......................................................................................................................13
2.9 Minimum Facilities..................................................................................................................14
2.10 Competence ..........................................................................................................................14
2.11 Technical Data .......................................................................................................................14
3. General Description ...........................................................................................15
3.1 Intended Use..........................................................................................................................15
3.2 Main Components ..................................................................................................................15
3.3 TechnicalSpecications .........................................................................................................16
3.4 Drawings Fastclip...................................................................................................................17
3.5 Plant gauge Fastclip...............................................................................................................18
3.6 W6a gauge Fastclip................................................................................................................18
3.7 Drawings e-CLIP ....................................................................................................................19
3.8 Plant gauge e-CLIP................................................................................................................20
3.9 W6a gauge e-CLIP.................................................................................................................20
4. Machine Component..........................................................................................21
4.1 Main Unit ...............................................................................................................................21
4.2 Trolley.....................................................................................................................................22
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4.3 Workhead...............................................................................................................................23
4.2.1 Workhead FC/FE ......................................................................................................................23
4.3.1 Workhead OFFSET FC/FE .......................................................................................................23
4.4 Sleeper Lifter FC/FE...............................................................................................................24
4.5 Workhead e-CLIPS ................................................................................................................25
4.5.1 Indicator.....................................................................................................................................26
4.5.2 Work Head Lifting Mechanism e-CLIPS ....................................................................................26
4.6 Brake......................................................................................................................................27
4.6.1 Brake Trolley..............................................................................................................................27
5. Controls ...................................................................................................................28
5.1 Control panel..........................................................................................................................29
5.2 Electrical System....................................................................................................................32
5.3 Hydraulic System FC/FE........................................................................................................33
5.3.1 Hydraulic System e-CLIPS ........................................................................................................34
6. Transport and Parking .......................................................................................35
6.1 Preparing for Transport or Storage.........................................................................................35
6.2 Parking on the Track ..............................................................................................................36
6.3 Parking Off-Track ...................................................................................................................36
6.4 Storage...................................................................................................................................36
7. Installation on Track............................................................................................39
7.1 General...................................................................................................................................39
7.2 On/Off Tracking ......................................................................................................................40
7.3 EMERGENCY OPERATION - Off-tracking using handles .....................................................43
7.3.1 Lifting device not available.........................................................................................................43
7.3.2 Lifting equipment breakes down................................................................................................44
7.4 Weight distribution..................................................................................................................45
7.5 CoG Center of gravity.............................................................................................................48
7.6 Changing the Inclination.........................................................................................................49
7.7 Changing Direction of Operation............................................................................................50
7.8 Changing Rail Side of Operation............................................................................................52
8. Operation (FASTCLIP- Machine)...................................................................... 55
8.1 Clipping ..................................................................................................................................55
8.1.1 Settings Before Clipping ............................................................................................................55
8.2 Clipping Operation..................................................................................................................56
8.3 Sleeper Lifting Operation........................................................................................................57
8.4 De-clipping .............................................................................................................................58
8.4.1 Settings Before De-clipping .......................................................................................................58
8.4.2 De-clipping Operation................................................................................................................61
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8.5 Storing the shoes when not being used .................................................................................61
9. Workhead Fastclip Oset.................................................................................. 62
9.1 Offset workhead .....................................................................................................................62
9.2 Adjustment for clipping/de-clippingtool (offset).......................................................................62
10. Troubleshooting...................................................................................................63
10.1 Clips are being installed before sleeper is fully lifted .............................................................63
10.2 Clips are not being fully installed............................................................................................63
10.3 Clips are being over driven.....................................................................................................63
10.4 Clipping shoe rides over clip on one side ..............................................................................63
10.5 The tools are stuck to the rail .................................................................................................63
11. Warranty and Service ......................................................................................... 64
11.1 Warranty.................................................................................................................................64
11.2 Service ...................................................................................................................................64
12. Contact ....................................................................................................................64
13. Maintenance.......................................................................................................... 65
13.1 DenitionofMaintenanceTerms ...........................................................................................65
13.2 Categories of Work ................................................................................................................66
13.2.1 Scheduled Work .......................................................................................................................66
13.2.2 Arising Work .............................................................................................................................66
13.3 Remounting/Assembling ........................................................................................................66
13.4 Fasteners ...............................................................................................................................66
13.5 Maintenance and service .......................................................................................................68
13.5.1 Maintenance Supplies ...............................................................................................................68
13.5.2 Maintenance intervals................................................................................................................68
13.5.3 Job letter allocation....................................................................................................................68
13.5.4 Function code ............................................................................................................................69
13.5.5 Job code example......................................................................................................................69
13.5.6 Safety code................................................................................................................................69
13.5.7 Maintenance Schedule ..............................................................................................................70
13.6 Maintenance Job List .............................................................................................................72
CH01V Safety labels and warnings signs – Visual check .....................................................................72
CH02V Paint work – Visual check.........................................................................................................74
CH03V Frame – Visual check ...............................................................................................................75
CH04V Sign of leakage – Visual check.................................................................................................76
CH05C Abnormal sounds – Check........................................................................................................77
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
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CH09C e-Clip tool – Check ...................................................................................................................81
CH10C Retention pins...........................................................................................................................82
CH11C Centre Lifting Point complete machine .....................................................................................83
CH12C Power unit Lifting Point.............................................................................................................84
CH13C Tool Lifting Point .......................................................................................................................85
CH14C Trolley Lifting Point ...................................................................................................................86
CH15L Trolley surface on slide bar .......................................................................................................87
EL01V Control panel .............................................................................................................................88
EL02V Light – Visual check...................................................................................................................89
EL03V Emergency stop button – Visual check .....................................................................................90
EL04T Emergency stop button – Test ...................................................................................................91
EL05V Electric cables – Visual check ...................................................................................................92
EL06E Battery – Examine .....................................................................................................................93
HY01V Hydraulic oil level – Visual check..............................................................................................94
HY02C Hydraulic cylinders and hoses – Check....................................................................................95
HY03V Hydraulic pump – Visual check.................................................................................................96
HY04RHydrauliclters–Check...........................................................................................................97
HY05C Hydraulic oil change ................................................................................................................98
HY06THydraulicowandpressure–Test. ........................................................................................99
EN01C Engine.....................................................................................................................................100
EN02V Engine mountings ...................................................................................................................101
WH01C Wheels – Check.....................................................................................................................102
WH02E Wheels – Examine.................................................................................................................103
Wheel examination record form ..........................................................................................................106
BR01T Brake function test .................................................................................................................107
BR02E Brake pads – Examine............................................................................................................108
Rail brake test form .............................................................................................................................109
MI01V Emergency equipment – Visual check.....................................................................................110
MI02CLogbook,Manuals,Certicates–Visualcheck ...................................................................... 111
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
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1. Review of maintenance plan
A nominated competent engineer identied by the owner should review the maintenance plan in this manual and its
logs (Exam list check list A-C), as a minimum, every 12 months and the records retained for audit purposes.
The review shall include assessment of frequency and content of each job description and of component failure in
this manual.
The review should be documented in written format and include decided actions upon the maintenance of the
vehicle in question. The “Exam check list” A-C at the end of this document is to be used.
Regular reviews of the performance of the vehicle, reviews of maintenance activities, changes of use or frequency
of use of the vehicle, and external information could all lead to changes in the plan.
Each change of the plan should be authorised by log a nominated competent engineer and where reasonably
practical the change should be agreed by the OEM. The amended plan needs to be re-certicated. It is
recommended that the plan is kept as a live document, with each change authorised by the competent engineer,
who should decide if the amendment is serious (and requires re-certication immediately) or whether several
changes can be bundled together and re-certicated at an annual review.
The users of the maintenance plan are encouraged to contribute to the review process.
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2. Introduction
2.1 General
The purpose of this manual is to provide the owner and its users with the essential knowledge for carrying out
routine maintenance procedures necessary for the proper working of the machine and for the purposes for which
it is intended. All the information contained in this manual must be READ and UNDERSTOOD before undertaking
any attempt to maintain the machine.
It is recommended that maintenance/overhaul is performed by qualied 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.
Read the safety instruction in the user manual and shut o󰀨 the machine before performing any maintenance. See
chapter “Start and Stop” in the operator´s manual
Warnings and safety precautions described in this document shall only be considered as a minimum. National
conditions, standards and regulations override conditions, standards and regulations described in this document.
Any adjustments or service on the machine only allowed to be done by qualied personnel that have read and
understood this manual and have had training and information from Pandrol AB.
A copy of this manual must be kept with the machine at all times as it provides essential maintenance and safety
information, and details the mandatory requirements for the general use of the machine.
In case of replacement of spare parts, always use Pandrol original spare parts to ensure that the machine full the
correct safety requirements at all times. Incorrect spare parts will a󰀨ect the warranty of the machine.
To ensure that correct oils and grease are being used, see chapter “Technical Specications” in the operator´s
manual for information of oil and grease specications, volumes and colour coding.
This manual is written according to the RIS-1530-PLT standard.
Training on how to use and work with the CD200IQ can be found on our YouTube channel, ”Training CD200IQ”.
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2.2 New version/manual
ISSUE PR NUMBER DATE BY COMMENTS REVIEWED
P01 N/A 05 -11-2 0 Lena Sohlin New manual
P02 02-12-20 Lena Sohlin Updated to Pandrol graphic
P03 11- 02-22 Lena Sohlin Uppdated with o󰀨set workhead FC
Authored by:
Lena Sohlin, Technical Communications O󰀩cer, Equipment & Control.
Reviewed by:
Approved by:
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2.3 Safety Actions Prior to Working on the CD200 IQ
• Prior to transportation, ensure that the pathway is free of obstructions or trip hazards.
• When lifting or carrying machinery or equipment, adhere to the permissible per-person lifting weight. It is the
responsibility of the operating company to ensure that the national safety regulations and guidelines of the
trade associations in the respective countries are observed. The values stated in the warning notices of these
operating instructions relate to regulations in United Kingdom.
• Ensure that a risk assessment has been carried out and that the following aspects with regard to operators and
the transport task have been considered: – Frequency of transport – Age – Gender – Operator’s state of health
– Uneven ooring – Poorly lit worksites – Bad weather – Working under time pressure – etc.
• Observe the relevant guidelines on lifting and transporting heavy machinery or equipment.
• Mechanical aids to lifting are always the preferred method of handling where possible, e.g. hoists, tail lift, rail
trolleys et
• Your Safety and the persons who work with you are within your responsibility.
• Read and understand all safety regulations and warnings stated both in the operator manual and in this manual
before any installation, operating or performing maintenance on this machine.
• Locate the emergency stop button before installation, operating or performing maintenance on this machine.
• Only qualied personnel are permitted to operate the machine during operation.
• The machine is never to be used as a transport vehicle for personnel or equipment.
• The machine is not to be used to recover other vehicles or equipment.
• 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.
• Use standards and regulations, accident prevention regulations and regulations concerning special ambient
conditions (e.g. areas potentially endangered by explosive materials, heavy pollution or corrosive inuences).
• It is of great importance that all service, component replacements or other operations in the electronic or
hydraulic systems are accomplished by Qualied Personnel only. And that only original spare parts are being
used
• The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards.
The manufacturers of the solvents and lubricants should be contacted for safety data. The recommended
precautions and procedures of the manufacturers should be followed.
• Personal protection clothing and eye protection must be worn when undertaking work. Read chapter 2.6 in this
manual for detailed information of protection clothing.
• When placing CD200IQ on track, choose a suitable place with as little interfering obstacles and with as rm and
at ground as possible. If the permissible per-person lifting weight is exceeded when lifting or carrying, there is
a risk of injuring muscles, tendons, joints or bones.
• Ensure that the road to the workplace is safe and free from interfering obstacles to avoid accidents.
• The modules should only be manually handled in an emergency situation. Always use the handles
to lift the modules. Always use two hands and address the modules symmetrically. Do not twist the spine when
handling. Do not carry any of the modules more than 3 meters without a rest, or without using a mechanical aid.
Contact your Health and Safety Advisor for more information.
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Figure 1. Safety equipment
Item Description
1Emergency stop button
2.3.1 Safety Equipment
The machine is to be equipped with safety equipment according to national requirements.
Text within brackets ( ) refers to number in gure unless otherwise specied.
The machine is equipped with one emergency stop button (1).
2.3.2 Control System
The control system of the CD200 IQ is congured to avoid simultaneous operations that could cause damage to
the vehicle or equipment or injury of personnel.
1
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