PANDROL Rosenqvist SL400 User manual

Pandrol AB, Hyggesvägen 4, 824 34 Hudiksvall, SWEDEN
Phone + 46 (0)650-16505, www.rosenqvistrail.com, [email protected]
Operation &
Maintenance Manual
Rosenqvist
SL400/SL450
Issue date: 2019-06-28
Dokument ID: ENG_OMM_SL400_SL450
Revision: P01
Original instructions

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Preface
Thank you for choosing a quality product from
Pandrol 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 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:
• 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
2019-06-28 01 New layout, revised manual for SL400, SL450.

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Table of contents
1. Safety 6
1.1 Safety actions 7
1.2 Safety equipment 8
1.3 Control system 8
1.4 Moving parts 8
1.5 Pressurized hydraulic oil 8
1.6 Live current 9
1.7 Machine in operation 9
1.8 Operator leaves the machine unattended 9
2. Risks 10
2.1 Introduction 10
2.2 Operating risk 10
2.3 Overturning 11
2.4 Repair and maintenance 12
2.5 Qualied personnel 12
2.6 Warning labels and information symbols 13
3. Description 14
3.1 The basis for a sleeper layer 14
3.2 Additional equipment 15
4. Technical data 16
5. Installation 17
5.1 Attach the sleeper layer 17
5.2 Connect the hydraulics 18
5.3 Connect the hydraulics with rotator (SL400 only) 18
5.4 Function test 19
6. Setting up the sleeper layer 20
6.1 Preparation before use 20
6.2 Adjustment for different sleepers 21
6.3 Actual sleeper length adjustment SL400 21
6.4 Actual sleeper length adjustment SL450 22
6.5 Actual sleeper height SL400 23
6.6 Actual sleeper width 24
6.7 Actual spreading width 25

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7 Operating the sleeper layer 26
7.1 Operating modes 26
7.2 Loading 26
7.3 Unloading 27
7.4 Positioning of sleepers on track bed 27
7.5 Preparation of railroad bed 28
9. Hydraulic system 29
9.1 Overview 29
9.2 Speed adjustment 30
9.3 Pressure adjustment 31
10. Maintenance 32
10.1 Daily inspection 32
10.2 Lubrication chart 33
10.3 Overhaul 34
10.4 Cleaning 34
11. Warranty and service 35
12. Contact 35
13. Declaration of Conformity 35

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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 Pandrol AB.

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1.1 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 carriermachine 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 Pandrol AB.
• The machine shall not be used as a transport vehicle for personnel or equipment. Only
sleepers are allowed to be carried with the machine.
• Make sure that no unqualied/unauthorized persons are in the operating area during
installation, use or maintenance.
• Safety regulations regarding personnel in operating area for the sleeper layer are valid
for this attachment.
• Improper operation of this equipment can be dangerous and result in personnel injury
or death. Personal eye protection and clothing must be worn when undertaking work.
• Improper maintenance of this equipment can be dangerous and result in personnel
injury or death.
• Before maintenance work on the machine, disconnect hydraulics and electrics to the
carrier machine.
• Use and follow 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.

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1.2 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 machine 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 sleeper layer.
WARNING! Moving parts - risk of crushing, injury or death
WARNING! Pressurized hydraulic oil – risk of personal injuries
1.3 Control system
The machine is to be equipped with safety equipment according to national
requirements.
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 off the engine and drain the hydraulic system.

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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 off the vehicle’s engine.
2. Disconnect the battery terminals.
WARNING! Live current
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.
WARNING! Machine in operation
WARNING! Machine must always be parked safely on the ground
1.8 Operator leaves the machine unattended
When the operator leaves the machine unattended, the machine must always be parked
horizontally on the ground. This is to ensure that the sleeper layer do not fall down on
personnel or on infrastructure at any technical difculties.

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2. Risks
2.2 Operating risk
Drop of sleepers
Risk: During transport of sleepers there is a possibility that the operator unintentionally
activate the function for opening of grapple arms and thereby drops the sleepers.
• Operators of the sleeper layer should always get training in how to operate the
equipment.
• All personnel are to be kept at least 10 meters from machine when operating the
equipment.
Loss of hydraulic pressure
Risk: If the machine loses the hydraulic pressure there is risk for drop of sleepers.
All hydraulic cylinders are equipped with hydraulic locks which prevents the cylinders
to open in case a hose should break in the hydraulic system. All hoses tted to the
machine have a burst pressure in excess of four times the specied working pressure.
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 affect the
overall risk prole of the operation.

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Hydraulic leakage (personal injury)
Risk: 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 layer 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 staff employed to make up hoses ensures that
hose specications are consistent.
• All components used in the hydraulic system are CE marked.
• Quick couplers 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.
• Pandrol AB recommends the use of biodegradable oils and greases, in order to
minimize the environmental impact in case of an oil leakage.
2.3 Overturning
Risk: Operating the sleeper layer with a machine of insufcient capacity or if jibbed out
too great a radius, there is a risk for overturning.
• Only trained personnel should operate the equipment.
• Safe load indicators must be used at all times.
• Ground conditions, rail cant etc should be considered before lifting.
• Keep all personnel clear of working area when operating the equipment.

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2.4 Repair and maintenance
Damage to the equipment
Damage to the machine during repair or overhaul may cause the equipment to
malfunction and may increase risk for personnel when in service.
Only competent staff should perform any repair or maintenance. For advice on maintenance
or repair on the machine, please contact Pandrol 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 staff should perform any repair or maintenance. For advice on
maintenance or repair on the machine, please contact Pandrol 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 sleeper layer
• Machine must only be lifted in the machine bracket or rotator. 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 layer 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 Pandrol 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 or death.
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 Pandrol AB.
710016 -Read manual 710048 -Wear safety goggles 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 layer is designed and manufactured for efcient positioning of concrete
sleepers. It utilise standard couplings on heavy excavators and loaders.
Rotator is provided as option. The rotator is hydraulically rotating, allowing perfect sleeper
positioning regardless of the position or level of the carrier machine.
Up to four adjacent sleepers can be laid simultaneously from an accompanying supply.
Lifted into position, their correct placement are ensured by a precision gauging hydraulic
system that spreads the sleepers to the desired distance up to maximum 750 mm (29.5
in).
The sleeper layer has been rigorously developed, extensively tested and utilised with
excellent results and high productivity. The sleeper layer can also be used to gather
sleepers for storage.
SL400/SL450 is delivered CE-certied.
3.1 The basis for a sleeper layer
Without additional equipment (options) the sleeper layer consists of the following units:
Fig 1. Identication plate
Fig 2. The gure shows SL450, the principle is the same for SL400.
This is the machine identication plate with
CE-marking and serial number.
Installation plate
Fixed frame
Telescopic frame
Grapple arms

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3.2 Additional equipment
Machine bracket
With the machine bracket attached to the machine it is possible to lift and handle the sleeper
lifter with a carrier. There are many different types of brackets available. Mounting of the
machine bracket is normally done at the factory. Mounting of the machine bracket is to be done
by qualied personnel only in accordance with the carrier manufacturer’s recommendations.
Fig 3. Machine bracket

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4. Technical data
Type SL400- 1430 0001 SL450 - 5008200
Length 1 000 – 2 500 mm
(39.7 – 98.5 in)
1 120 – 2 500 mm
(6’7” – 14’8” ft-in)
Height -
Standard
exclusive rotator and
tilt rotator
655 mm (25.8 in) 762 mm (30 in)
Width
2 578 mm (101.5 in) Min: 2 905 mm (114.1 in)
Weight
(exclusive rotator/
tilt rotator) 814 kg (1795 lb) 1050 kg (2315 Ib)
Lifting capacity Maximum 1250 kg (2756 lb) Maximum 1800 kg (3968 lb)
Number of sleepers 4 pcs
Sleeper length
Per request
STANDARD 2490 mm - 2800 mm
OPTION 2220 mm - 2530 mm
Sleeper distances
750 mm (29.5 in)
Performance
Any suitably
excavator or truck
with crane.
Up to 60m/h (197 ft/h) Up to 60m/h (197 ft/h)
Hydraulics
Two-way hydraulic
function, 2 hoses.
Recommended oil ow:
30-50 L/min (7.9-13.2 gal/min)
Recommended oil pressure:
180-200 bar (2611-2900 psi) Maximum
Attention!
Exeeding the maximum oilpressure can cause damage to the equipment.

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WARNING! Bracket must be welded on the sleeper layer installation
  platebyqualiedpersonnelandinaccordancewiththecarrier
manufacturer’s recommendations.
Fig 4. Machine bracket
5. Installation
5.1 Attach the sleeper layer
1. Make sure that the Sleeper layer is equipped with a machine bracket suitable for
the actual carrier. The bracket can be either welded or bolted onto the bracket
installation plate.
2. Connect the Sleeper Layer to the excavator arm, or to the crane on the carrier.
Make sure that it is correctly connected and secured.
3. Stop the engine and release the remaining hydraulic pressure.
4. Connect the two hydraulic hoses from the sleeper layer to the carrier machine
auxilliary hydraulic functions.
Pre-drilled holes for rotator
attachment.

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5.3 Connect the hydraulics with rotator (SL400 only)
Connect the hydraulics to the carrier machines auxiliary hydraulic functions according to
the picture below.
IMPORTANT!
The hydraulic pressure from the carrier machine should never exceed 180-200 bar
(2611-2900 psi)
NOTE!
Deviation in the hydraulic ow will result in inaccurate functionality of the sleeper
layer.Recommended oil ow from the carrier machine: 30-50 L/min (7.9-13.2 gal/
min)
Adjustment of the hydraulic oil pressure and ow settings on the sleeper layer are
normally not necessary. The adjustment is done at the factory. If minor adjustments
are necessary for correct functionality, please contact Pandrol AB for more
information.
Fig 5. Connecting the hydraulics
5.2 Connect the hydraulics
Connect the hydraulics to the carrier machines auxiliary hydraulic function quick
couplers.

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5.4 Function test
1. Set the sleeper layer to ”work mode”.
2. Operate the hydraulic function to close the grapples and spread the arms.
3. Operate the hydraulic function to open the grapples and retract the arms.
4. Set the sleeper layer to loading mode.
5. Operate the hydraulic funtion to close the grapples. The spreading function should
not move the arms.
6. Operate the rotating function if applicable.
7. Check for leakage and tighten leaking couplings if necessary.
WARNING! The operator of the equipment must take necessary precautions to ensure
safe operation of the equipment. The operator is responsible that nobody interferes with
the machine and/or equipment when it is in use.
Safety regulations for the carrier regarding personnel in the operating area must also be
considered during operation.

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6. Setting up the sleeper layer
The sleeper layer must be tested and adjusted to t:
• The actual type of concrete sleeper.
• The applicable sleeper distance.
All movements on lifting arms, rotator and spread functions must if tted be checked
and correctly adjusted before use to ensure no damage to the sleepers or injury of a
person
6.1 Preparation before use
Before operation, the sleeper layer has to be adjusted for the current track condition. In
this chapter will guide you through the necessary adjustments.
• Measure the dimensions on actual sleepers: length, height, width.
• Check the sleeper distance on the track and set the same sleeper distance for the
sleeper layer.
• All movements on grapple arms and spread functions must be checked before use to
prevent damage to the sleepers when handling.
WARNING! The sleeper layer is only to be used on a railway by qualied and
experienced personnel.
WARNING! Set up of the sleeper layer is only to be done by qualied personnel with
experienced workmanship.
WARNING! The carrier must adhere to the standards, terms and general conditions
laid out by the track owner or railway administrators. The user of the equipment must
observe and comply with the appropriate safety precautions.
WARNING! The sleeper layer must always be handled with the utmost care in all
aspects during operation or maintenance. Failure to do so entails risk of mishaps that
could result in serious or even fatal injuries.
WARNING! The user of the equipment must take the necessary precautions to ensure
safe operation of the equipment. The operator is responsible for ensuring that nobody
interferes with the machine and/or equipment whilst it is in use.