PANDROL CD200 IQ User manual
Partners in excellence
ENG_OMM_CD200IQ_P03
2023-03-16
CD200 IQ
OPERATION AND MAINTENANCE
MANUAL
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Table Of Content
1. Preface 6
2. Introduction 7
2.1. General 7
2.2. Safety Actions Prior to Working on the CD200 IQ 8
2.3. Safety Equipment 10
2.4. Safety warnings 11
2.5. Service and Repairs 14
2.6. Warning Signs and Decals 15
2.7. Minimum Facilities 16
3. Generell Description 17
3.1. Intended Use 17
3.2. Main Components 17
3.4. Drawings Fastclip 19
3.5. Drawings e-CLIP 20
4. Machine Components 21
4.1. Main Unit - Power Pack 21
4.2. Trolley 21
4.3. Brake (option) 22
4.4. Workhead 23
5. Control System 26
5.1. Controls 26
5.2. Control panel 27
5.3. Operation 30
5.4. Electrical System 32
5.5. Hydraulic system FC/FE 33
5.6. Hydraulic System e-clip 34
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6. Transport And Parking 35
6.1. Preparing for Transport or Storage 35
6.2. Parking On The track 36
6.4. Storage 36
6.5. Disassemble CD200IQ 37
7. Installation On Track 39
7.1. General 39
7.4. Lift Weights Manual Handling 44
7.5. Changing The Inclination 49
7.6. Changing Direction Of Operation 50
7.7. Changing Rail Side of Operation 51
8. Operation (FASTCLIP- Machine) 54
8.1. Clipping 54
8.2. Sleeper Lifting Operation 57
8.3. De-clipping 58
8.4. Storing clip/de-clipping plates 62
9. Operation (E-Clip- Machine) 63
9.1. Adjustments before start 63
9.2. Clipping 65
9.3. De-clipping 66
10. Troubleshooting 67
10.1. Clips are being installed before sleeper is fully lifted 67
10.2. Clips are not being fully installed 67
10.3. Clips are being over driven 67
10.4. Clipping shoe rides over clip on one side 67
11.2. The tools are stuck to the rail 68
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11. Maintenance 68
11.1. General 68
11.3. Maintenance schedule 69
11.4. Lubrication points on Fastclip 70
11.5. Engine 70
11.10. Brake pads 73
11.12. Examination of clipping pads 77
11.13. Examination of de-clipping pads 77
12. Nominal mounting torque, Nm 78
13. Warranty and Service 79
13.1. Warranty 79
13.2. Service 79
13.3. Disclaimer 79
13.4. Contact 79
13.6. Recycling and Environment 79
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1. Preface
Revision Date Comment
P01 2020-11-27 New manual
P02 2022-05-02 Updating hydraulics
P03 2022-09-23 General update
This manual aims to help you get to know your new CD200IQ, 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.
without prior notice.
The manual contains instructions about the following topics:
1. Installation
2. Operation
3. Safety features and warnings
4. Maintenance and troubleshooting
IMPORTANT
This manual contains ordered actions, e.g.
1. Do this
2. ...and then this...
These actions must be done in the numerical order presented.
Thank you for choosing CD200IQ! You are now
the owner of a quality product from Pandrol.
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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.
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.
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.
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
warranty of the machine.
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”.
© Pandrol AB
All rights reserved
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2.2. 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.
• Ensure that a risk assessment has been carried out and that the following aspects with
• 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.
•
• 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
• It is of great importance that all service, component replacements or other operations in the
original spare parts are being used
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• 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
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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1
Fig 1. Emergecy Stop button
2.3. Safety Equipment
The machine is to be equipped with safety equipment according to national requirements. The
CD200IQ control system is designed to supervise the machine in a safe way to avoid damage or
injury to the machine or a person.
The machine is equipped with one emergency stop button (1).
1.1.1 Control System
cause damage to the vehicle or equipment or injury of personnel.
Pos. Description
1Emergecy Stop
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2.4. Safety warnings
1.1.2 Moving Parts
WARNING! – Risk of crushing.
During operation, parts of the machine are moving. Moving parts can cause serious personal
injury. To avoid accidents, follow the guideline below:
• Keep away from the machine and moving parts when operating the machine.
1.1.3 Pressurised Hydraulic Oil
WARNING! – Pressurised hydraulic oil
Hydraulic oil under high pressure is present in the hydraulic system. Fluids under high pressure
are dangerous and can cause serious personal.
To avoid accidents, follow the guidelines below:
1.
and stop” in the operator´s manual.
2. Always wear appropriate personal-protection according to chapter 2.6 in this manual.
1.1.4 Live Current
DANGER! – Live current
High voltage live current is very dangerous and can cause serious injury or death of a person.
Contact with electric parts can damage the equipment if live current is present.
Always ensure that there is no live current present in the power lines or the third rail!
1.1.5 Vehicle in Operation
DANGER! – Machine in operation
Special precautions must be taken to ensure that operation of the machine will not result in
severe personal injury and/or damage to the equipment.
To avoid accidents, make sure that no unauthorized personnel are within 5 meters of the
machine when operation is started.
1.1.6 Danger due to unergonomic operation
WARNING!
With some activities there is a risk of injuring muscles, tendons, joints or bones if the necessary
caution is not exercised with the controls. Avoid adverse movements and poor posture. Avoid
static postures of the thumb and hand when using the controls.
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1.1.7 Danger due to manual handling
WARNING!
To decrease the footprint of the machine on the transportation vehicle the trolley can be
manually handled and then put on track and the rest of the machine put on top of it using
a crane/hoist. This is the only permitted manual handling in the normal course of events.
Alternatively it can be left on the machine and it can all be mechanically handled.
tool) by 8 people. In the event of lifting equipment failure ONLY it can be broken down into
modules.
1.1.8 Danger due to noise
WARNING!
Risk of permanent damage, particularly to hearing, if the user does not continuously wear
suitable hearing protection. Wear hearing protection. See noice data in section 3.3.
1.1.9 Danger due to vibration
WARNING!
The transmission of vibrations to the human body is harmful to health. Wear padded gloves.
Include other vibration-free activities with mainly vigorous use of the muscles during the
work process. See vibration data in section 3.3.
2.4.1. Operator leaving the machine unattended
When the operator leave the machine unattended, the machine must always be parked
horizontal on the ground. If the machine is placed on the rail the clipping tool shall rest on
the ballast or sleeper. This is to avoid the risk of the machine to tip over or uncontrolled
movement along the track.
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1.1 Battery Precautions
• Maintenance tasks or repairs on batteries must NOT be carried out when the battery is on
charge or being discharged. Before commencing any work on the batteries, ensure that the
power has been switched OFF and that the battery is ISOLATED and not being charged.
•
from batteries. Do not smoke in the vicinity of batteries. Where a battery is found to be or is
suspected to be overheated, extreme caution should be taken to prevent ignition and ample
time must be allowed for the dispersal of the gases.
• Metal parts of a battery are LIVE. Use insulated spanners on battery connections. Never
place tools or metal objects on the batteries.
• To avoid short circuits when removing the battery, cables in the battery box should be tied
back and insulated after being disconnected.
• Take care to keep electrolyte away from eyes, skin and clothing. Protective clothing and
goggles must be worn during ALL battery repairs.
•
battery electrolyte is concerned.
• Clothing soaked with electrolyte must be removed immediately.
• Only pure distilled or de-ionised water may be used for topping up battery cells.
• Ensure that all cables used for battery charging are maintained in good condition. When in
use, they MUST be positioned so that they do not present a danger to personnel or damage
cables and equipment.
• Disposal of electrolyte must be strictly in accordance with the Local arrangements made
between the Depot concerned and the Local Government Authority.
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2.5. Service and Repairs
•
vehicle.
• All work shall be carried out in accordance with the job descriptions in this schedule,
supplemented by the base machine manuals.
•
repairing machines. Where equipment is to be tested following repair, this shall be carried out
using the authorized test equipment provided.
• Equipment removed for repair must be protected against damage and handled with care.
• Following any reportable incident or accident involving the machine a detailed examination
must be carried out around the damaged or suspected damaged area. Testing of brakes,
and lifting of vehicles, together with gauging of axles and wheels shall be carried out as
appropriate or called for by the specialist engineer appointed to investigate the incident. Any
tests/checks called for shall be carried out in accordance with the appropriate job description
in this schedule and all details recorded.
• 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
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CD200 IQ Blue
5014338710143
710044
710048 710051 710017 710052
710135 710062710063
710187 710019 710020 710021
2.6. Warning Signs and Decals
The images below describe the valid signs that apply to this machine. The signs must remain visible to guide and
to inform about risks. If a sign is damaged or missing, new signs can be ordered from your service provider or
Pandrol AB.
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2.7. Minimum Facilities
Clean, dry, covered accommodation for dealing with wheel set, bearings, mechanical hydraulic
and electrical components etc.
• Adequate illumination for inspection of components and under frames.
• Cleaning facilities which will not cause damage to the components.
• Jacking facilities for raising the machine.
•
• Protection from the weather of vulnerable areas of the vehicles and its components.
•
description.
• A suitable length of straight level rail track for carrying out brake tests.
2.8. Qualied personnel
In order to carry out this maintenance plan in a manner that will achieve the required safety and
quality, the following minimum level of competence required is:
• For all activities the person leading the task must be able to follow and carry out the
instruction detailed in this document.
• All Safety Critical Work must be carried out by persons competent in accordance with:
1.
2 0 07.
2. Duty holders safety critical work competence management system
3. The railways and other guided transport system (safety) Regulations
4.
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(1)
(2)
(3) (4)
(5)
Fig 2.
Fig 3.
(6)
(7)
3. General Description
3.1. Intended Use
The Clip Driver CD200 IQ 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 IQ uses
gauges and inclinations. Choose the type of tool in the control panel (2).
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. The CD200 IQ can be
separated into 3 pieces.
3.2. Main Components
Fig 4.
Pos Description Pos Description
(1) Height adjustable handlebar (5) Main unit
(2) Control panel (6)
(3) Work head FC/FE (7 Work head e-clip
(4) Trolley unit
change any technical details without prior notice.
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3.3. Technical Specications
CD200 IQ
Fastclip 5014300
e-Clip 5014699
(Honda)
Fastclip 5014853
e-clip 5016448
(Briggs & Stratton)
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 97 kg
Weight Tool, e-CLIP 115 kg
Performance Track gauge 1067-1600 mm
No of clips being installed/extracted at the same time, 2 clips per cycle
Capacity: Fastclip (up to) 30 sleepers/min / e-CLIP (up to) 10 sleepers/min
Engine Manufacturer Honda Briggs & Stratton
Model GX 270 XR1450 / 19N1
Type Air-cooled 4-stroke OHV Air-cooled 4-stroke OHV
Power 8,5 HP (6,3 kW) @ 3600 rpm 10 HP (7,5 kW) @ 3600 rpm
Net torque 14.1 lb-ft (19.1 Nm) @ 2,500 rpm 19,77 Nm @2600 rpm
Fuel Unleaded 86 octane or higher Automotive gasoline (unleaded)
Fuel tank capacity 5,3 litre 5,3 litre
Electronics Voltage 12 volt DC
Ground Negative
Hydraulics Pump Gear pump
17 l/min
Max pressure 120 bar / Boost 215 bar
Hydraulic tank volume 8-9 litre
Noise data Noise level, LpA 86 dB (A)
Noise level, LwA 88,5 dB (A)
Vibration data Clipping 4,31 m/s²
De-clipping 4,65 m/s²
Electrical protection index IP64
Maximum travelling speed 3 mph
Maximum working speed 0,5 mph
Maximum travelling speed through S&C 3 mph
Maximum travelling speed through raised check rails 3 mph
Maximum working cant 150 mm
Maximum working gradient 1:25
Minimum radius 80 m
Maximum ON/OFF track gradient 1:25
Maximum ON/OFF track cant 100 mm
May be used under LIVE overhead lines Yes
May travel on LIVE 3 or 4 rail lines No
May be used on isolated 4/4 rail lines See ECC
May be used adjacent to running line Yes
Not permitted outside of a possession
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1142 mm2202 mm
2111 mm
1410 mm (gauge 1435)
3.4. Drawings Fastclip
Fig 5.
Fig 6.
Fig 7.
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1103 mm
2111 mm
1410 mm (gauge 1435)
2202 mm
3.5. Drawings e-CLIP
Fig 8.
Fig 9.
Fig 10.
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