PANDROL CD300 EC User manual
Partners in excellence
ENG_OMM_CD300_EC_P03
2023-08-17
OPERATION AND MAINTENANCE
MANUAL
CD300 EC
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Thank you for choosing CD300 EC!
You are now the owner of a quality
product from Pandrol.
This manual aims to help you get to know your new CD300 EC, 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 CD300 EC. It is originally written in Swedish and then
translated into the local language by Pandrol AB.
Pandrol AB reserves the right to change specications, 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.
1. Preface
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Revision Date Note
P01 2021-12-16 New manual
P02 2023-03-30 Updated work modes
2. Revision
© Pandrol
All Rights Reserved
No part of this publication may be reproduced or copied in any form or by any means without written
permission from Pandrol.
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Table of Contents
1. Preface 2
2. Revision 3
3. Contents 4
4. Safety Information and Warnings 6
4.1. Safety instructions 6
4.2. General 7
4.3. Warnings 7
4.4. General warnings 8
4.5. Warning labels 9
4.6. QualiedPersonnel 10
5. Risks 11
5.1. Introduction 11
5.2. Operation and Handling 11
5.3. Lifting and Handling 13
5.4. Repair and Maintenance 14
5.5. QualiedPersonnel 14
6. Transport 15
6.1. Lifting and Transportation On Flatbed 15
6.2. Transport 16
6.3. Securing The Machine Onto A Flatbed 16
7. Installation 17
7.1. Hydraulics 17
7.2. Hydraulic Diagram CD300IQ E-clip 18
7.3. Electric Cable 19
8. Description 20
8.1. Generel description 20
8.2. Overview 21
3. Contents
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9. Technical data 22
9.1. Technical Information 22
10. Operation 23
10.1. Preparations 23
11. e-clips 24
11.1. Adjustment of e-clips tool 25
11.2. Obsticles on track 27
11.3. De-clipping tool e-clips 28
11.4. Rail type UC60, BV50 or similar 29
11.5. Replacing de-clipping pad 30
11.6. Protection for e-clips clipping tool (option) 30
11.7. Work in clipping mode 31
11.8. Work in de-clipping mode 31
12. Care and Maintenance 32
12.1. Daily Inspection 32
12.2. Maintenace Schedule 33
12.3. Lubrication points 34
14. Warranty and Service 36
14.1. Warranty 36
14.2. Service 36
14.3. Disclaimer 36
14.4. Contact 36
14.5. Declaration Of Conformity 36
14.6. Recycling and Environment 36
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4. Safety Information and Warnings
4.1. Safety instructions
• Read through all the safety instructions and warnings before installing, using or carrying out
maintenance on this machine.
• Ensure that the carrier machine has the requirements to lift and to operate the CD300EC.
• Itisessentialthatallkindofuse,maintenanceandservicework,iscarriedoutbyqualied
personnel, trained by Pandrol AB.
• The CD300EC is can operate with automatic machine cycles that entail a risk of crushing
injuries. Only the operator may be in the vicinity of the machine when in use. Track
personnel must be at a distance of minimum 3 meters from the machine.
• The machine shall not be used as a transport vehicle for personnel or equipment.
• Improper operation of this equipment can be dangerous and could result in personnel injury.
• The safety instructions that apply when working on railroad vehicles in the track area shall
also be applied to work using this equipment.
• Use standards and regulations, accident prevention regulations and regulations concerning
special ambient conditions (e.g. areas potentially endangered by explosive materials, heavy
pollutionorcorrosiveinuences).
• Personnelworkingwithorclosetothemachinemustwearsucientprotectionclothingsuch
as helmet, ear protectors, googles, protection- shoes, gloves, and clothes.
• Beforecarryingoutanymaintenanceorserviceworkonthemachine;switchothecarrier
machine engine, release the hydraulic pressure by moving the levers.
• The carrier machine should only be used under normal conditions and overloading must not
occur.
• If the CD300EC is pressed to much towards the rail, derailment can occur. Make sure that
all carrier machine rail wheels are in full contact with the rail.
• Keep the machine clean and free from dirt to ensure safe work environment.
• Makesurethatunqualiedpersonsarenotwithintheoperatingareaduringinstallation,use
or maintenance.
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4.2. General
• The machine has been developed and manufactured to be used on railway lines with aerial
power lines or lines used by diesel-powered vehicles.
• 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.
• Workwiththemachineisonlytobecarriedoutbyqualiedpersonnel,well-informedand
educatedingeneralrailwayworkmanshipandspecicallyintheconditions,standardsand
regulationsonspecicrailtrack.
• Themachinemayonlybeusedforitsspeciedpurpose.
• Make sure that the working area is free from obstacles that could cause a risk of stumble
and fall.
• It is not allowed to climb on or step on the machine due to the risk of injury.
• Any adjustments, service or maintenance work on the machine is only allowed to be carried
outbyqualiedpersonnelwhohavereadandfullyunderstoodthismanual,themaintenance
manual and have had training and information for this particular model from Pandrol AB.
Instructions and maintenance schedule is given in the maintenance manual. If there is a
situation where a trained and skilled person is not available, contact your local Pandrol
service person, or Pandrol aftersales technical support. Contact information is available at
the end of this manual.
4.3. Warnings
This section describes safety related information that needs to be taken into consideration
before, during and after using the equipment.
DANGER, WARNING, CAUTION and Note statements are used throughout this manual to
emphasize important and critical information. You must read these statements to help ensure
safetyandtopreventdamagetotheproduct.Thestatementsaredenedbelow.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited to the most extreme situations.
WARNING indicates a potentially hazardous situation which, if not avoided, could resultin death
or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury. It may also be used to alert against unsafe practices.
Note: A note statement is used to notify people of installation, operation or maintenance
information that is important, but not hazard-related.
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4.4. General warnings
Incorrect installation, usage or maintenance of this equipment can be dangerous and can result in personal injury,
or in worst case death of a person.
Do never install, use or carry out any maintenance on this equipment before you have read through and fully
understood the instructions in this manual´and the carriermachine.
ÌWARNING! Moving Parts
Risk of crushing. During operation, some parts of the CD300EC are moving. Moving parts can cause
personal injury.
To avoid accidents, follow the guidelines below:
• Keep away from moving parts when operating the machine.
• Make sure that no unauthorized personnel are within the working area (3m) when operating the
machine.
ÌWARNING! Pressurised hydraulic oil
Highpressureuidispresentinthehydraulicsystem.Fluidsunderhighpressurearedangerousandcan
cause serious injury. To avoid accidents, follow the guidelines below:
• Onlyqualiedtechniciansorengineersareallowedtomakemodications,serviceoradjustmentsto
the hydraulic system.
• Always wear appropriate personal-protection equipment.
• Shutotheengineanddrainthehydraulicsystembeforecarryoutanyworkonthehydraulicsystem.
ÌWARNING! Live current
Contact with electric parts can cause serious injury or death, and/or serious damage on 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. Shutotheengine.
2. Disconnect the battery cables from the battery terminals.
ÌDANGER! – Machine in operation
Special precautions must be taken to ensure that operation of the machine will not result in injury of a
person and/or serious damage to the equipment.
To avoid accidents, make sure no unauthorized persons are in the vicinity of the machine before
operation is started.
ÌWARNING! – Operator leaves the machine unattended
When the operator leaves the machine unattended, the machine must always be parked horizontally
on the ground or on the rail with the brakes activated. This is to ensure that the machine does not move
unintentionally that could result in serious injury of a person and/or serious damage to other equipment.
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4.5. Warning labels
There are a number av labels intended to inform and warn the operator of the machine. If any label become
damaged or lost, they are to be replaced with new original warning labels that are available from Pandrol AB.
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4.6. Qualied Personnel
The CD300EC is only to be used by trained personnel, thoroughly familiar with, and trained in general railway
workmanship.
The CD300EC shall be operated according to the conditions and standard regulations applying to the track of
where the machine is being operated.
Theequipmentmustbeserviced,maintained,orinanywaymodiedonlybytrainedpersonnel,whohavereceived
training and information from Pandrol AB.
The components of this unit and other components in the vicinity are powered by dangerous contact high voltage.
Touching any parts, connected to such voltage, can cause serious injury or death of a person.
In order to avoid personal injury or death and/or material damage, everyone involved with assembling, starting-up
or overhaul must possess relevant 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.areaspotentiallyendangeredbyexplosivematerials,heavypollutionorcorrosiveinuences).
ÌWARNING!
Touching parts that are subject to high voltage may cause personal injury or death of a
person.
ÌWARNING!
All maintenance and service on the electric or hydraulic system shall be carried out by
qualied personnel.
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5. Risks
5.1. Introduction
An analysis shows that there are three distinct risk areas for this equipment:
• Operation and handling
• Repair and Maintenace
• Transport
For each risk identied, 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
siteoperations,asotherequipmentandprocesses,notconsideredherein,mayaecttheoverallriskproleofthe
operation.
5.2. Operation and Handling
Machine rolls away
If the Clip Driver is left on the rail and not attached to a carrier macine, the Clip Driver could roll away. The Clip
Driver can be equipped with a parking brake that activates as son as the pressure from the carrier machine drops.
If the Clip Driver is not equipped with parking brake, wheel stops are to be placed at all of the four wheels when
parked on a rail.
Flying objects
If a sleeper is not correctly aligned during clipping, there is a risk that the toe insulalator brakes and parts of the it
goesoathighspeedcausingpersonalinjury.
Make sure that no personnel are within the working area (3m) when operating the machine.
Hydraulic uid under pressure
Pressurizedhydraulicsystemsinuseonthisequipment.Damageorfailureofhosesandttingsmaycauseahigh
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 power unit carries a risk that oil may be spilled. Hydraulic oil is frequently very hot and
may cause burns and scalds.
All components used in the power unit hydraulic system are CE marked.
Quick couplers used minimizes oil being spilled during connection or disconnection.
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 Inc recommends the use of biodegradable oils and greases, in order to minimize the environmental impact
in case of an oil leakage.
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Risk of crushing
The CD300EC is can operate with automatic machine cycles that entail a risk of crushing injuries.
Track personnel must be at a distance of minimum 3 meters from the machine.
Damaged clip
Incorrect angle between sleeper and rail the toe insulator touches the edge of the rail. If the clip is forced to fasten,
the the toe insulator could be damaged. Too high pressure when clipping could cause damage to the equipment.
Pandrol(UK)Ltdspeciesamaximalclampingforceof35kNtopreventdamagetothetoeinsulators.The
clamping force is limitied by a pressure valve set at factory assembly.
The clipping tool design prevents the clipping pads to move too far causing damage to the equipment.
Insucient clipping
If the clip is not properly installed, the functionality of the e-clip is impaired. The clips connect the sleeper with the
rail, which makes it a key factor of the railway infrastructure. Failed installatons och clips could result in catastrophic
results such as derailment of train.
Operators and inspection personnel must be observant and make sure that the operators always make controls to
ensure correct installation of clips.
Damage to shoulder
Incorrect adjustment of the clipping tool may lead to damage on the shoulder or the attachment betwen sleeper
and shoulder. Sleepers made of concreete need extra attention due to risk from water penetrating the damaged
area. This could lead to frost damage and crackilation.
Operators and inspection personnel must consider the importance of correct adjustments of the clipping tools
described in this manual.
Technical information about Pandrol FASTCLIP can be ordered from:
Pandrol UK Ltd
Gateford Road, Worksop
Nottinghamshire, S81 7AX
England
Tel. +44 (0)1909 476 101
Fax. +44 (0)1909 500 004
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5.3. Lifting and Handling
Personal injury
Risk of machine or equipment drop. Risk of death or serious injury. The machine must on ly be lifted at designated
liftingpoints at the machine bracket or support legs.
Lifting chains and slings must be approved for lifting the machinen and be in good condition.
Only trained personnel are allowed to handle lifting equipment.
Do not lift the machine if there are any loose objects laying onto the machine.
No person are allowed within the working are during lifting.
Tipping
Thereisagreatriskoftippingoverifthecarriermachineliftingcapacityisbelowspecication,orloadingarm
extensions are outside given lifting safety area.
Ensure that the carrier machine has the lifting capacity required for lifting the Clip Driver.
Only trained personnel are allowed to carry out lifting.
Lifting and load indicators on the carrier machine must at all time be used when lifting.
Always take the cant and ground strength into consderation before lifting.
No person are allowed within the working are during lifting.
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5.4. 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.
Onlycompetentstashouldperformanyrepairormaintenance.Foradviceonmaintenanceorrepaironthemachine,
please contact Pandrol Inc.
Personnel injury
Hydraulic system may have stored pressure even with the tool disconnected.
Onlycompetentstashouldperformanyrepairormaintenance.Foradviceonmaintenanceorrepaironthemachine,
please contact Pandrol Inc.
• Appropriate protective equipment should be used at all times.
• Careful consideration should be given to the handling of all parts before commencing repair operations.
5.5. Qualied Personnel
Themachineisonlytobeusedbyqualiedpersonnel.
Theequipmentmustbeserviced,maintained,orinanywaymodiedonlybyqualiedpersonnelwhoarefamiliar
with this Operation & Maintenance Manual.
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 operator must be familiar with all prohibited work areas such as unsafe grades, poor footing areas,
overhead hazards and the automation technology sector.
• Dealing with dangerous voltages
• Using standards and regulations, accident prevention regulations and regulations concerning special ambient
conditions(e.g.areaspotentiallyendangeredbyexplosivematerials,heavypollutionorcorrosiveinuences)
ÌWARNING!
All maintenance and service, or other operations on the electronic or hydraulic systems
are to be carried out by qualied personnel.
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Fig 1. Lifting points
6. Transport
6.1. Lifting and Transportation On Flatbed
Before lifting, make sure that the lifting equipment is suitable for its task. Chains or straps must be of an
appropriate strength with a minimum of 3 tonne lifting capacity. See ””9.1. Technical Information” på sida 2227”
for machine weight and dimension. Use a guiding rope to align the machine during lifting. Lifting of the machine is
only allowed at the dedicated lifting eylets ”Fig 1. Lifting points”.
ÌDANGER!
Never stand under a hanging load. If a chain or strap comes o there is a serious risk of
death of a person.
ÌWARNING!
Do not stand within two meters from the machine during lifting. Use a guiding rope to
align the machine during lifting.
Lifting points
No Description
1Lifting point for lifting chain, strap, pallet fork
2Lifting point for lifting chain or strap
1
2
2
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Fig 2. Securing the machine
6.2. Transport
Duringtransportitisessintialthatthemachineissecurilyfastenedontothetransportatbed.
6.3. Securing The Machine Onto A Flatbed
Beforeliftingthemachineontoaatbedtheparkingsupportlegsmustbeloweredtoparkingposition.Liftthe
machine accoding to instructions given in chapter ”6.1 Lifting and Transportation” The machine and parking
supportlegsmustfullyrestontheatbedtoensurefullstabilityduringtransport.
SecuretheCD300EContheatbedwithchainsorstrapsofappropriatestrengthEnsuretousededicated
fastening points according to ”Fig 2. Securing the machine”.
No Description
1 Fastening point for lifting and load securing
2Support legs
1
1
1
1
2
2
2
2
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7. Installation
7.1. Hydraulics
Connect the hydraulics after the CD300 is attached to the machine bracket on the carrier
machine.
Dependingoncarriermachineandconguration,thepressureandreturncouplersmaydier.
In some cases, the quick couplers on the CD300 need to be switched. Check and verify
pressure and return lines on the carrier machine before connecting the CD300.
Connect the hose (1) to the pressure line.
Connect the hose (2) to the return line.
Readsection”9.1.TechnicalInformation”forrecommendedoilpressureandoilow.
Fig 3.
2
1
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AB AB
PT PT
C+
C-
-C-C
C-
C+
C+
C+
2
2
1
PP
TT
@210bar
RightLeft
PT
Presssure switch
GM6D 0,4
7.2. Hydraulic Diagram CD300IQ E-clip
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7.3. Electric Cable
Electric cable on excavator arm
1. Install the rectangulad connection socket on the
loader arm near the machine bracket, Fig 4. Attach
the cable along the excavator arm and fasten with
straps.
Fig 4. Connection socket
Fig 5. Cable
1
Fig 6. Extra connection
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Fig 7. Identicationplate
MachineidenticationplatewithCE-
marking and serial number.
8. Description
8.1. Generel description
Clip Driver CD300EC has been developed and manufactured as a machine held tool for clipping and declipping
Pandrol e-clip.
The CD300EC can be connected to any rail vehicle that can supply the equipment with hydraulic feed.
The machine is equipped with a pressure switch that controls the semi-auto function.
AlltoolscanbepermanentlymountedontheCD300ECanddonotneedtoberemovedtorundierenttypesof
clips.
The CD300EC is CE marked on delivery.
Fig 8.
Table of contents
