PANDROL Rosenqvist SB60 Manual

Operation &
Maintenance Manual
Rosenqvist SB60
Issue date: 2018-02-19
Dokument ID: SWE_OMM_SB60
Revision: 14
Original instructions
Rosenqvist Rail AB, Hyggesvägen 4, 824 34 Hudiksvall, SWEDEN
Phone + 46 (0)650-16505, www Rosenqvistrail.com, [email protected]
The SB60 in the picture is equipped with Automaster (option).

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Thank you for choosing SB60!
You are now owner of a quality product from
Rosenqvist Rail AB
This manual is intended for people who handle and operate this machine.
This manual is originally written in Swedish and then translated into the local language
by Rosenqvist Rail AB. Rosenqvist Rail AB reserves the right to change specications,
equipment, instructions and maintenance guidelines without prior notice.
The manual contains instructions about the following topics:
• Installation
• Operation
• Safety features and warnings
• Maintenance and troubleshooting
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.
(1) refers to a component in a gure/illustration.
REVISION NOTES
Date Revision Note
2018-02-19 14 New layout, revised manual
Preface

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Table of contents
Preface 2
1. Safety 4
1.2 Safety actions 4
1.3 Safety equipment 5
1.4 Moving parts 5
1.5 Pressurized hydraulic oil 5
1.6 Live current 6
1.7 Machine in operation 6
1.8 Operator leaves the machine unattended 6
2. Risks 7
2.1 Introduction 7
2.2 Operating risk 7
2.3 Infrastructure risk assessment 8
2.4 Repair and maintenance 9
2.5 Qualiedpersonnel  9
2.6 Warning Labels and Information Symbols 10
3. Description 11
3.1 Functions 11
3.2 Congurations 12
4. Technical data 13
5. Installation 14
5.1 Main functions 14
5.2 Manoeuvring buttons and cables 14
5.3 Installation to carrier 16
5.4 Connection of electricity 17
5.5 Function test controlsystem 18
5.6 Adjustment of oil pressure 19
5.7 Adjustment of pit depth 20
5.8 Use 21
6. Maintenance 22
6.1 Ocular inspection, before and after use 22
6.2 Annual overhaul 22
6.3 Lubrication 23
7. Worm gear rotator (option) 24
7.1 Lubrication 24
8. Guarantee and service 25
9. Contact 25

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1. Safety
Incorrect installation, operation and maintenance of this equipment may be dangerous
and result in severe personal injuries.
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.
Workwiththemachineisonlytobecarriedoutbyqualiedpersonnel,well-informedand
educatedingeneralrailway workmanshipandspecicallyinthe conditions,standards
andregulationsonspecicrailtrack.
The machine may only be used for its specied purpose. Any adjustments or service
on the machine is only allowed to be done by qualied personnel that have read and
understood this manual and have had training and information from Rosenqvist Rail AB.
1.2 Safety actions
• Read and understand all safety regulations and warnings before installation, operating
or performing maintenance on this machine.
• Locateemergencystopbuttonsandreextinguisheronthecarrierbeforeinstallation,
operating or performing maintenance on this machine.
• It is essential that all use, maintenance and service is implemented by qualied
personnel, trained by Rosenqvist Rail AB.
• The machine shall not be used as a transport vehicle for personnel or equipment.
• Makesurethatunqualiedpersonsarenotintheoperatingareaduringinstallation,
use or maintenance.
• Safety regulations regarding personnel in operating area for the SB60 are valid for this
attachment.
• Improper operation of this equipment can be dangerous and result in personnel injury
or death.
• Improper maintenance of this equipment can be dangerous and result in personnel
injury or death.
• 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.
• 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.
• The use of an air jet, which must be less than 8 bar (116 psi), to blow parts clean or
to blow them dry after being cleaned with a solvent will cause particles of dirt and/or
droplets of the cleaning solvent to be airborne. These conditions may cause skin and/
or eye irritation.
• When using an air jet do not direct it toward another person. Improper use of air jet
could result in bodily injury.
• Personal eye protection must be worn when undertaking work.

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1.3 Safety equipment
The machine is to be equipped with safety equipment according to national requirements.
1.4 Moving parts
When operated, some parts of the SB60 are moving. Moving parts can cause personal
injury or death.
To avoid accidents, follow the guidelines below:
• Keep hands etc. away from moving parts when operating the machine.
• Make sure no unauthorized personnel are in the working area when working the
machine, particularly when sleepers are carried by the S60.
1.5 Pressurized hydraulic oil
Highpressureuidispresentinoperationalhydraulicsystems.Fluidsunderhighpressure
are dangerous and can cause serious injury or death.
To avoid accidents, follow the guidelines below:
• Onlyqualiedtechniciansorengineersareallowedtomakemodications,repairsor
adjustments to the hydraulic system.
• Alwayswearappropriatepersonal-protectionequipment.
• Shuto󰀨theengineanddrainthehydraulicsystem.
WARNING! Moving parts - risk of crushing, injury or death
WARNING! Pressurized hydraulic oil – risk of personal injuries

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1.6 Live current
Contact with electric parts can damage the equipment if live current is present. To avoid
accidents, follow the guidelines below:
If electricity needs to be connected for testing purposes. Keep hands, tools etc. away
from all electrical parts.
In any other case:
1. Shuto󰀨thevehicle’sengine.
2. Disconnect the battery terminals.
1.7 Machine in operation
Special precautions must be taken to ensure that operation of the machine will not result
in severe injury or death and/or damage to the equipment.
To avoid accidents, make sure no one is in the vicinity of the machine before operation
is started.
1.8 Operator leaves the machine unattended
When the operator leaves the machine unattended, the machine must always be parked
safely on the ground. This is to ensure that the machine don´t fall on personnel or on
infrastructureatanytechnicaldi󰀩culties.
WARNING! Live current
WARNING! Machine in operation
WARNING! Machine must always be parked safely on the ground

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2. Risks
2.1 Introduction
An analysis shows that there are three distinct risk areas for this equipment:
• Operation, lift and handling
• Repair
• Maintenace
Foreachriskidentied,thereisashortexplanationandthemeansoflimitingthisrisk
described. Most of the operating risks are also highlighted in other chapters in this manual.
Great emphasis is placed on the operators training to reduce the risk associated with the
operation of this equipment.
It should be stressed that, whilst the risk assessment laid out in this chapter include some
considerationoftheriskofworkingthemachineunderon-siteconditions,thisshouldnot
be taken as a thorough risk assessment of the site operations, as other equipment and
processes,notconsideredherein,maya󰀨ecttheoverallriskproleoftheoperation.
2.2 Operating risk
Drop of sleepers
During transport of sleepers there is a possibility that the operator unintentionally
presses button for opening of grapple arms and thereby drops the sleepers.
• Operators of the SB60 should get thorough training in how to operate the equipment.
• All personnel are to be kept at least 5 meters from machine when operating the
equipment.
• Both hydraulic cylinders are equipped with hydraulic locks which prevents the cylinders
to open in case a hose should break in the hydraulic system.
• Personnel working with handtools or with Automaster shall always wear protective
helmet and shoes. Personnel shall not aproach the SB60 until the operator gives
visually and/or sound clear.
Clamping force is set too low and the sleepers drop down.
• Clamping force should be checked and adjusted if needed, before start, see chapter
5.6
Hydraulic leakage (personal injury)
High pressure hydraulic systems are used on this equipment. Damage or failure
of hoses and ttings may cause a high pressure jet of oil to be emitted from the
system. This could be hazardous to eyes, skin etc. Pools of leaked oil could lead to
an increased risk of slips, trips or falls. Connecting and disconnecting the supply
and return hoses to the hydraulic systems of the carrier machine carries a risk
that oil may be spilled. Hydraulic oil is frequently very hot and may cause burns
and scalds.
• Allhosesttedtothesleeperlifterhaveaburstpressureinexcessoffourtimesthe
speciedworkingpressure.Regularmonitoringofthedimensionsoftheferrulestted
tothehoses,andcarefultrainingofthesta󰀨employedtomakeuphosesensuresthat
hosespecicationsareconsistent.
• All components used in the hydraulic system are CE marked.

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• Fast connections are used, which minimizes oil being spilled during connection or
disconnection to the carrier machine.
• Operators and service personnel should wear appropriate protective equipment, such
as gloves, goggles and overalls. Skin exposed to hydraulic oils should be washed
immediately.
• All personnel should be made aware of the contents of the product data sheets relating
to the oil used.
• Rosenqvist Rail AB recommends the use of biodegradable oils and greases, in order
to minimize the environmental impact in case of an oil leakage.
Noise (personal injury)
Hearing loss may occur due to the high noise level that can occur when SB60 is
excavating ballast.
• All personnel who work with or near the SB60 must use hearing protection.
Installing clips (personal injury)
During installation of clips the operator can make a wrong movement of the S60 and harm
the personnel.
• TheoperatoroftheSB60shouldexerciseextracautionwhiletheclipsareinstalledon
to the sleepers. All personnel must have good knowledge of how the S60 is used and
have a good communication with the operator. Safety helmets must be used at all time.
The personnel on hand to fasten the sleeper should remain at a safe distance from the
SleeperReplacerSB60untiltheoperatorgivestheall-clearsign.
2.3 Infrastructure risk assessment
Damage to sleepers
The sleeper grips presses too hard on the sleepers so that the sleepers are damaged.
• Clamping force can be adjusted on the sleeper lifting tool, see chapter 5.6.
Damagetoshplates,weldedjointse.g.
Operator strikes in to obstacles
• WhentheSB60isbeingoperatedonthetrack,thedrivermustexercisetheutmost
caretoavoidtheunitcomingintocontactwithshplates,weldedjointsorotherrelated
ttings.SuchobstaclescanseriouslydamagetheSB60andvice-versaanditisvital
that the drivers acquaint themselves with the relevant stretch of track and if necessary
takethemachineo󰀨thetracktoavoidthem.

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2.4 Repair and maintenance
Damage to the equipment
Damage to the Sleeper Replacer during repair or overhaul may cause the equipment
to malfunction and may increase risk for personnel when in service.
Onlycompetentsta󰀨shouldperformanyrepairormaintenance.Foradviceonmaintenance
or repair on the machine, please contact Rosenqvist Rail AB.
Personnel injury
High pressure hydraulic system may have stored pressure even when disconnected
from the rail/road machine. Some parts of the machine are heavy and may cause
personal injury if dropped.
• Only competent sta󰀨 should perform any repair or maintenance. For advice on
maintenance or repair on the machine, please contact Rosenqvist Rail AB.
• Appropriate protective equipment should be used at all times.
• Careful consideration should be given to the handling of all parts before commencing
repair operations.
Operator drops the SB60 or tools that are on the SB60
• Machine must only be lifted in the machine bracket. Only properly trained personnel
should attach and detach the equipment. Do not lift the machine with loose items lying
on the machine. Keep all personnel clear of working area when lifting machine.
2.5 Qualiedpersonnel
TheSleeperReplacerSB60isonlytobeusedbyqualiedpersonnel,thoroughlyfamiliar
with and trained in general railway workmanship and operation 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modiedonlybyqualied
personnel who are familiar with the Operation & Maintenance Manual and have received
training and information from Rosenqvist Rail AB.
The components in this unit and other components in the vicinity are powered by
dangerous contact voltage.
Touching any parts, connected to such voltage, can cause serious injury.
In order to avoid personal injury or death and/or material damage, everyone involved with
assembling,starting-uporoverhaulmustpossesspertinentknowledgeofthefollowing:
• The automation technology sector
• Dealing with dangerous voltages
• Using 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)
WARNING! All maintenance and service, or other operations on the electronic
or hydraulic systems are to be carried out by qualied personnel.

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2.6 Warning labels and information symbols
Below are warning labels and information symbols on the machine.
If any of these labels become damaged or lost, they are to be replaced with new original
warning labels that are available from Rosenqvist Rail AB.
710016-Readmanual 7 1 0 0 4 8  - W e a r  s a f e t y  g o g g l e s  710051-Wearsafety
helmet
710052-Wearear
protection
710020-WarningOil
pressure
710019-WarningRisk
of crushing
710021-Donotrideor
stand on machine

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3. Description
The Sleeper Replacer SB60 is designed and manufactured for use as a hydraulic
attachment on rail-bounded excavators for e󰀩cient replacing of concrete and wooden
sleepers. It is hydraulically rotating and tilting and can replace the sleepers both from the
middle and from the side of the track.
It is also designed for e󰀨ective movement and recessing of the ballast. The high
performance Sleeper Replacer SB60 holds a key function in a versatile high output, cost
e󰀩cientandsafeworkingmethod.
The Sleeper Replacer SB60 has been rigorously developed, extensively tested and
utilisedwithexcellentresultsandhighproductivity.
DeliveredCE-certied.
ThisisthemachineidenticationplatewithCE-markingandserialnumber.
360°
15°
Sleeper grab
Rotation
Tilt function
Excavationblade
Adjustable rollers for
di󰀨erentrailtypes
3.1 Functions
Fig 1.
Fig 2.

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3.2 Congurations
SB60ismodularbuiltanddi󰀨erentoptionsareavailableasbelow.
Support (option Automaster)
Grapple claw
(4x)
Machine bracket plate
Wet-spotbucket
(option)
Excavatorblade
Worm gear rotor with quick hitch
Rotor unit
Rigid grapple holder
Tilt unit
Automaster (option)
Grapple unit
Fig 3.
Quick hitch
bracket

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4. Technical data
Item Standard gauge 1435 mm
Customized gauge 1520 mm
Customized gauge 1067 mm
Customized gauge 1000 mm
5008730
5007246
5007245
5007244
Width Standard gauge 1435 mm
Customized gauge 1520 mm
Customized gauge 1067 mm
Customized gauge 1000 mm
2578 mm
2746 mm
2290 mm
2223 mm
Weight Standard gauge 1435 mm 1050 kg
Rail type Europe standard 60 kg/m, 50 kg/m
Clamping force 6000 kg
Torque 295 dNm (180 bar)
Electrics Standard
Customer adjusted
24 volt DC, negativ ground
12 volt DC, negativ ground
Hydraulics 2outletswithtwo-wayfunction
required (4 hoses) + one drainage
line direct to tank
Rec.owfromhydraulic
pump:
20–50 litres/min
(5,3-13,2gal/min)
Recommended oil pressure:
180 bar (2610 psi)
Min. 160 bar (2320 psi)
Max.220bar(3190psi)
Option Automaster attachment for Pandrol FASTCLIP
Option Buckets
Option Fastening tool for screw fastening

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5. Installation
5.1 Main functions
The Sleeper Replacer SB60 is manoeuvred hydraulically from the carrying vehicle.
Pleaseobservethatthecarryingvehicleshouldincorporatetwo2-wayhydraulicoutlets.
The Sleeper Replacer SB60 performs the following operations:
• Gripping: The unit incorporates a load holding facility, pressure relief valve, as well
as an accumulator to maintain grip on the sleeper.
• Turning: The unit can rotate the sleeper 360 degrees, with the speed adjusted by a
owcontrolvalve.
• Tilting:Withinarangeof+/-15degrees,withthespeedadjustedbyaowcontrol
valve.
• Excavating:Theexcavatingbladeenablesdiggingoperations.
5.2 Manoeuvring buttons and cables
1. Connectthechargerplug,withorwithoutadapter,seegure4and5tothe24-volt
DCchargerplugconnectorindriverscabin,seegure6.
Fig 4. With adapter Fig 5. Without adapter
Fig 6. Examplesofchargerplug 
 connectorindriver’scabin

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2. Mount the manoeuvring buttons on the joystick.
2. Drawinthecableviathecabinoor.Installitalongthediggingarm,orononeof
the lifting arms, and fasten it with plastic ties.
3. Fasten the other end with the electrical contact on the digging arm, close to the
hydraulic outlets or the machine coupling.
4. Connect the electrical contact with the equivalent contact on the SB60.
WARNING! Ensure that the cable is long enough for the excavator arm to be
able to move freely without damaging the cable.
Fig 7. Exampleofplacementofthemaneuverbuttons. Fig 8. Exampleofmaneuveringcables.

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5.3 Installation to carrier
TheSB60shallbeequippedwithamachinebracketappropriatetothespeciccarrier
and welded onto the installation plate placed on the SB60.
WARNING! Bracket must be welded on the B60 installation plate by qualied
personnel and in accordance with the carrier manufacturer’s
recommendations.
1. Connect the SB60 machine bracket to the coupling on the carrier’s digging arm.
MakesuretheSB60ispositionedsothattheexcavationbladeispointingtowards
thedriver’scabin.
2. Close the engine and all hydraulic power outlets.
3. Connect 4 hydraulic hoses from the Sleeper Replacer SB60 to the hydraulic inlet and
outlet on the digging arm. Drain line connected to (L)
WARNING! Machine engine and hydraulics must be turned OFF before
proceeding with the next step.
Fig 9. Machine bracket
Fig 10. Female connection for turning function. L for drain
WARNING! Make sure that the hoses are properly secured and connected
before proceeding with the next step.
Fig 11. Male connection for sleepergrab

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5.4 Connection of electricity
The power to the rotation, tilting and gripping features are connected on to the side where
thefemalettingstohydraulicsislocated.
Fig 12. Power connection to the SB60 Fig 13.

Doc id: ENG_OMM_SB60_P14
18/26 © Rosenqvist Rail AB
5.5 Function test controlsystem
Start the engine and activate the hydraulics for the Sleeper Replacer SB60.
Test functions:
• Sleeper grabber – two way function no. 1.
• Rotation function – two way function no. 2.
• Tiltfunction–twowayfunctionsno1togetherwithextratiltbuttonsonjoystick(see
gure7-8).
2
1
Fig 14. Functions on the SB60

Doc id: ENG_OMM_SB60_P14
19/26
Doc id: ENG_OMM_SB60_P14
© Rosenqvist Rail AB
5.6 Adjustment of oil pressure
Adjustment of clamp force
If reduced clamping force when grabbing sleepers is required, the oil pressure can be
regulated.
1. Loosen the 8 screws (1) with a 6 mm allen key.
2. Loosen (2) then adjust the oil pressure (3) by using a 5 mm allen key and a 17 mm
U-key.
3. The oil pressure can be measured with a manometer at measure point (4).
Correct pressure is 100 Bar.
Fig 15. Adjustment of clamp force
1
1
4
2
3

Doc id: ENG_OMM_SB60_P14
20/26 © Rosenqvist Rail AB
5.7 Adjustment of pit depth
Depending on the variety and amount of ballast the pit depth can be set for a more
e󰀩cientworkprocedure. Therearethreedi󰀨erentsizesofsupport rollers mountedon
totheSB60.Whentheoperatorexcavates,thesupportrollerrollsontherailhead,see
Figure 19.
Dependingonwhichsupportrollerismounted,thebladeexcavatesatdi󰀨erentdepths.
Excavationdepthis adjustedbychangingthebladesupportrolls.Tochangerollsyou
needtwo24mmspanners.Seegbelow.
Dependingonthedriverandhowmuchthesmallerrollersareuseditcouldbedi󰀩cultto
mount the bigger rollers back because of deformation of the smaller used roller.
Dependingonhowwornordeformedthesmallerrollerisitcanbeeasilyxedbygrinding
the deformed surface. New rollers are available and can be ordered from Rosenqvist Rail
AB. See contact information on the last page.
Fig 16.
Fig 17. Support roller on rail head Fig 18. Support roller mounted
Fig 19. There are three support roller mounted on the SB60 Fig 20. Three support rollers