PANDROL CD100 Operating instructions

Partners in excellence
ENG_OMM_CD100_P07
2022-10-19
USER AND MAINTENANCE MANUAL
CD100 / CD100 B

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The pictures in the manual are for illustration only, the appearance of the machine may vary
This manual aims to help you get to know your new CD100, 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.
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:
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.
Revision Datum Kommentarer
P04 2021-03-18 New layout
P05 2021-04-13 Added Drive unit/battery Power pack
P06 2022-02-21 Updated manual
P07 2022-05-19 New solution for handlebar and buttons CD100B
Thank you for choosing CD100!
You are now the owner of a quality product from Pandrol.

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Table of contents
1. Safety Information 5
1.1. General 5
1.2. Safety Regulations 5
1.3. Warning Labels 6
1.4. Qualied Personnel 7
2. General Description 8
3. Technical Information CD100/CD100B 9
3.1. Technical Information CD100 9
3.2. Technical Data - Engine Power Unit 5014188 10
3.3. Technical Information CD100B 11
3.4. Technical Data - Battery Power Unit 6000617 12
4. Tools 13
4.1. Clipping Tool 1100201 13
4.2. De-clipping Tool 1100058 - FE/FCX 5012730 14
5. Transport And Packaging 15
5.1. Unpacking The Power Unit 15
5.2. Unpacking The Clipping Tool 17
5.3. Transportation And Storage Of CD100B 18
6. Setup/Installation 19
6.1. Power Unit 19
6.2. Clipping Tool 20
6.3. De-clipping Tool 21
7. Adjustments 22
7.1. Adjustments for di󰀨erent rail heights 22
7.2. Adjustments of the Handle Bar Unit 22
7.3. Adjustments For Di󰀨erent Types Of Rail Using Shims 23
7.4. Change Of Arms On The De-Clipping Tool 24
7.5. Adjustments Of Claws 24

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8. Operation CD100 25
8.1. Clipping – Connect Rail To Sleeper 25
8.2. De-Clipping - Disconnect Rail From Sleeper 26
8.3. After Operation 26
9. Operation CD100B 27
8.4. Mounting Drive Unit/Battery 27
9.1. Clipping And Declipping - Connect Rail To Sleeper 28
9.2. De-Clipping - Disconnect Rail From Sleeper 29
9.3. After Operation 29
10. Maintenance 30
10.1. Power Unit 30
10.2. Clipping And De-clipping Tools 31
10.3. Lubrication points 31
11. Mounting Torque For Screws And Nuts 33
12. Warranty And Service 34
12.1. Warranty 34
12.2. Service 34
12.3. Disclaimer 34
12.4. Contact 34
12.5. Declaration Of Conformity 34
12.6. Recycling and Environment 34
12.7. Disposal Of Battery 34

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1. Safety Information
1.1. General
• Read and understand all safety regulations and warnings before installation, operating or
performing maintenance on this machine.
• Make sure that no unauthorized personnel are in the operating area during installation, use
or maintenance.
• Improper installation of this unit can be dangerous and may lead to mishaps or accidents
and could result in personal injury.
• Improper operation of this unit can be dangerous and could result in personal injury or
death.
• Improper maintenance of this unit can be dangerous and may lead to mishaps or accidents
and could result in personal injury.
• Do not operate this unit until you have read and understood the safety instructions in this
manual and the enclosed manual from Honda.
• Do not perform any maintenance on this unit until you have read and understood the
instructions in this manual.
• The power unit is only permitted to be used as a power source for Pandrol manufactured
original tools.
1.2. Safety Regulations
• Do not make any alterations to your CD100. Doing that, you could compromise your own
safety and expose yourself to a serious accident or injury risk.
• Before each start, perform a general inspection of all parts and make sure that they are not
worn, damaged or loose. Also make sure that the tool is dry everywhere and that there is no
oil leakage.
• Regular maintenance is required to ensure a safe operation. Keep all nuts and bolts securely
tightened.
• The engine must be switched o󰀨 when performing cleaning, control, adjustments,
reparations, refueling and when the unit is being left unattended.
• Attention! Risk for clamping. Be careful with bodily parts around the unit. Risk for injuries.
• Do not use the unit with damaged or worn parts. If parts must be replaced use original parts,
please contact Pandrol AB for consultation.
• When the CD100 is used the operator must wear protecting clothes, i.e. long trousers, boots,
gloves, ear defenders and goggles or a protective visor.
• Make sure to run the engine in ventilated areas and spaces, otherwise the exhaust fumes
that contains poisoned carbon monoxide can be gathered and this can make you faint and
even death.
• Petrol is extremely ammable and shall be treated with great care. Refueling shall be done
outdoors with the engine switched o󰀨. Do not smoke during refueling or while handling fuel.
• If the fuel tank shall be drained, it should be performed outdoors and when the engine is
cold.

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1.3. Warning Labels
The warning labels present on the machine are presented below. If any of these warning labels
become damaged or lost, they are to be replaced with new original warning labels that are
available from Pandrol AB.
Read manual before use
(art. 710016)
Wear safety googles
(art. 710017)
Wear safety helmet
(art. 710018)
Wear hearing
protection
(art. 710019)
WARNING! Oil
pressure
(art. 710216)
WARNING! Risk
of crushing
(art. 710217)
High voltage
(art. 710018)
(only CD100 B)
• To protect the environment, do not dispose old oil or fuel by pouring it down the drain, in the gutter or on the
ground.
• Let the engine cool down before putting the unit away in its storage.
• All handling of the battery must be done according to the manual for the battery and battery charger.

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1.4. Qualied Personnel
The CD100 with its working tools is only to be used by qualied personnel, thoroughly familiar
with and trained in general railway workmanship and operated 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 repaired only by qualied personnel
who are familiar with both this Operation & Maintenance Manual and the Honda manual and
have received training and information from Pandrol AB.
In order to avoid personal injury or death and/or material damage, everyone involved with
assembling, starting-up or overhaul must possess pertinent knowledge according to the Honda
manual.
ÌWARNING! All maintenance and service or other operations on the hydraulic
system is to be carried out by qualied personnel.

Fig 1. Identication plate
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2. General Description
CD100 is patented and delivered CE-certied. A machine
identication plate is fastened on the Power Unit, refer to Fig.
1. In case the identication plate becomes damaged or lost,
please contact Pandrol AB to obtain a new one
CD100 is available in two variants Petrol engine and
Battery powered.
• CD100 consists of a motor unit, a handlebar, a fastening tool
and a declipping tool according to (2), (4), (5) and (6) in the
table below.
• CD100 B consists of a drive unit, a handlebar, a fastening
tool and a declipping tool according to (1), (3), (5) och (6) in
the table below.
Nr Dercription Item No
1 Handle bars CD100B 6000618
2 Handle bars CD100 1100058
3 Drive unit CD100 B 6000617 (incl. handlebar)
4 Motor unit CD100 5014188 (incl. handlebar)
5 Clipping tool FC / FCX 1100201
6 Declipping unit FC / FE&FCX 1100058 / 5012730
Fig 2. Handlebar CD100 B Fig 3. Handlebar CD100 Fig 4. Drive unit
Fig 5. Motor unit Fig 6. Clipping tool Fig 7. Declipping tool
1
4
2
5 6
3

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3. Technical Information CD100/CD100B
3.1. Technical Information CD100
The Power Unit is designed as an easy moveable, ergonomically friendly hydraulic power source. It is designed
with a quick connect interface which enables fast and easy connection to the working tools.
The engine of the Power Unit is based on Honda original parts and the working tools are based on well-known
Pandrol technology. The Power Unit is supported by a steel wheel to the rail, which relieves the operator
from the weight and thus prevents the operator from wearing injuries. The components of the Power Unit are
presented in Fig 8. och and the components of the handle bar in Fig 9.
Nr Description
1Engine
2Hydraulic connectors
3Wheel adjustment screw
4Hydraulic tank
5Accelerator
6Handle
7Steering bar
8Change of direction control
Fig 8. motor unit
Fig 9. Handlebar
(2)
(3)
(1)
(4)
(5)
(8)
(7)
(6)

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3.2. Technical Data - Engine Power Unit 5014188
Technical data for the Power Unit (part no. 5014188)
Description Specication
Engine Refer to the enclosed manual from Honda
Noise level Measuring point :
Operating condition:
Measured vibration emission value:
In operating position
Full operation
98 dB (A)
Measuring point :
Operating condition:
Measured vibration emission value:
In operating position
Idle running
74 dB (A)
Vibration emission Measuring point :
Operating condition:
Measured vibration emission value:
Handle bar
Idle running
0,53 m/s2
Measuring point :
Operating condition:
Measured vibration emission value:
Handle bar
Full operation
1,28 m/s2
Measurement
Length 480 mm
Width 260 mm
Height 400 mm
Weight 16 kg
Packaging measurements
Length 371 mm
Width 671 mm
Height 450 mm
Weight 26 kg
Hydraulics
Pump Vivolo XV-OP/0.45
Max. oil pressure 190 bar
Deplacement 0,45 cm3/rev
Max. engine speed 6000 rpm
Hydraulic tank volume 1,1 L (1,16 Quarts)
Hydraulic oil quality ISO VG 46 or similar
Hydraulic connectors Quick coupling (adaptable)
Above specications may be changed without notice according to Pandrol AB´s requirements.

(1)
(2)
(3)
(4)
Fig 10.
Fig 11.
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3.3. Technical Information CD100B
The Drive Unit is designed as an easy moveable, ergonomically battery driven hydraulic power
source. It is designed with a quick connect interface which enables fast and easy connection to
the working tools.
The Drive Unit is supported by a steel wheel to the rail, which relieves the operator from the
weight and thus prevents the operator from wearing injuries. The components of the Drive Unit
are presented in Fig 43 and the components of the Handle Bar Unit are presented in Fig 10.
Nr Dercription
1Battery
2Hydraulic connections
3Wheel adjustment screw
4Hydraulic tank
5Direction control
6Handlebar
7Handle rod
8Throttle and locking controls
(5) (6)
(7)
(8)

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Technical data for the Drive Unit (part no. 6000617)
Description Specication
Noise level Measuring point :
Operating condition:
Measured vibration emission value:
In operating position
Normal operation
79.2 dB (A)
Vibration emission Measuring point :
Operating condition:
Measured vibration emission value:
Handle bar
Normal operation
1,28 m/s2
Measurement
Length 480 mm
Width 260 mm
Height 400 mm
Weight 19 kg
Packaging dimensions
Length 390 mm
Width 580 mm
Height 450 mm
Weight 29 kg
Battery
Battery capacity 432 Wh - 6 Ah - 72 V
Work capacity 300 clips / charge cycle
Charge time 45 min (use 82C2/82C1G charger)
Hydraulics
Pump Vivolo XV-OP/0.45
Max. oil pressure 190 bar
Deplacement 0,45 cm3/rev
Max. engine speed 6000 rpm
Hydraulic tank volume 1,1 L (1,16 Quarts)
Hydraulic oil quality ISO VG 46 or similar
Hydraulic connectors Quick coupling (adjustable)
3.4. Technical Data - Battery Power Unit 6000617
Above specications may be changed without notice according to Pandrol AB´s requirements.

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4. Tools
4.1. Clipping Tool 1100201
The Clipping Tool is an attachment to the Power Unit, ergonomically friendly designed and easy
to lift manually. It is based on well-known Pandrol technology and has a quick connect interface
which enables fast and easy connection to the Power Unit.
The components of the Clipping Tool are presented in Fig 12.
Nr Description
1Locking mechanism
2Arm
3Hydraulic connectors
4Bracket
5Claws
Fig 12. Clipping tool
Technical data for the Clipping Tool (part no. 1100201).
Decription Specication
Attachment to Power Unit, part no. 5014188, or Battery Drive Unit, art nr 6000617
Capacity Approx. 10 installations/min
Clips Pandrol Fastclip
Measurements
Length 580 mm
Width 210 mm
Height 390 mm
Weight 24 kg
Packaging measurements
Length 590 mm
Width 240 mm
Height 450 mm
Weight 32 kg
Hydraulics
Max. working force 33,8 kN
Max. oil pressure 190 bar
Hydraulic cylinder Double-acting, with spring return
Hydraulic connectors Quick coupling
Cycle time 6,5 sek
Above specications may be changed without notice according Pandrol AB´s requirements.
(3)
(1)
(5)
(2)
(4)

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4.2. De-clipping Tool 1100058 - FE/FCX 5012730
The De-clipping Tool is an attachment to the Power Unit, ergonomically friendly designed and
easy to lift manually. It is based on well-known Pandrol technology and has a quick connect
interface which enables fast and easy connection to the Power Unit. The components of the
De-clipping Tool are presented in Fig 13.
Nr Dercription
1Hydraulic connectors
2Clip catcher
3Arm
4Locking mechanism
5Bracket
6Claw
Technical data for the De-clipping Tool (part no. FC 1100058 - FE/FCX 5012730).
Decription Specikation
Attachment to Power Unit, part no. 5014188, or Battery Drive Unit, art nr 6000617
Capacity Approx. 10 installations/min
Clips Pandrol Fastclip
Measurements
Length 560 mm
Width 270 mm
Height 400 mm
Weight 24 kg (29 kg for 5012730)
Packaging measurement
Length 580 mm
Width 330 mm
Height 450 mm
Weight 35 kg (40 kg for 5012730)
Hydraulics
Max. working force 23,9 kN
Max. oil pressure 190 bar
Hydraulic cylinder Double-acting
Hydraulic connectors Quick coupling
Cycle time 6,5 sek
Above specications may be changed without notice according to Pandrol AB´s requirements.
Fig 13. Declipping tool
(1)
(4)
(2)
(5)
(3)
(6)

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5. Transport And Packaging
CD100 and CD100B are delivered in a suitable, environmentally friendly wooden boxes. When
the machine is not being used or transported, the components shall be stored in their suitable
boxes. The boxes are designed as a system easy and safe to transport, store and carry. Follow
the instructions in the reversed order when storing the components.
The pictures are for illustration only, the appearance of the machine may vary
5.1. Unpacking The Power Unit
1. Lift the power unit and the handle out of the box and place it on the ground.
2. Mount and attach the Handle Bar Unit to the Power Unit using the locking mechanism.
3. Attach the Handle to the Handle Bar.
4. Adjust the handles
5. Attach the required tools according to section ”6. Setup/Installation”.
Fig 14. Fig 15.
Fig 16. Fig 17.

Figur 19.
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Fig 18. Fig 19.
Fig 20.
Fig 21.

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5.2. Unpacking The Clipping Tool
Fig 22. Clipping Tool in its suitable box
Fig 23. Easy to lift up and to store when not being used.

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5.3. Transportation And Storage Of CD100B
The Power Unit contain a Lithium Ion battery and shall be handled according to local
legislations of handling and transporting batteries.
The battery is classied according to UN 3481 standard, meaning that the capacity is greater
than 100 Wh. Find detailed battery information in section ”9.2. Battery Technical Specication”
on page 17.
On-ground transport for private use or transport carried out by an employee or an inhouse
company transport service from company site to working site does not require lithium battery
mark and ADR.
All transports with a forwarder requires Lithium battery mark and ADR. Always consult your
forwarder before the transport is to be carried out. Special terms for air transport of the Power
Unit applies. Always contact your forwarder for information.
Remove the battery pack from the tool before storing.
Store and charge your batteries in a cool area. Temperatures above or below normal room
temperature will shorten battery pack life.
Fig 24. Fig 25.

Figur 24.
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6. Setup/Installation
6.1. Power Unit
Be aware that the Power Unit is delivered without:
• Engine oil (CD100)
• Hydraulic oil (CD100/CD100B)
• Fuel (CD100)
ÌWARNING! Fill up the Power Unit with engine oil, hydraulic oil and fuel, according to the
manual, before starting the engine.
6.1.1 Engine oil and fuel (CD100)
Read the Honda manual for further information, enclosed with the Power Unit.
6.1.2 Hydraulic oil (CD100/CD100B)
Fill with new hydraulic oil, quality ISO VG 46 or similar, approximately. 1,1 litres until the oil level is 10 mm up
on the oil dipstick. Check the oil level with the oil dipstick
ÌWARNING!
Check that the hydraulic hoses are clean each time prior to connection.
Fig 26.
Dipstick